Mantenimiento Valvulas LVF

Edition 2005
Revision B
Installation, operation and maintenance instructions
Gate, globe, check and ball valves

Doc. DT01e-E
MAIN PLANT & FACTORY:

24060 S.Paolo dArgon (BG) ITALY Via Mazzini, 6 Tel. (++39) 035.4255211 Fax (++39) 035.959210 INTERNET: http://www.lvf.it - e-mail: info@lvf.it
Installation, operation and maintenance instruction

General Summary
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GENERAL ........................................................................................................................................2 INSTALLATION ...............................................................................................................................2 MAINTENANCE ...............................................................................................................................3 PACKING .........................................................................................................................................5 BODY-BONNET BOLTINGS............................................................................................................8 MAINTENANCE ON BOLTED BONNET GATE VALVE TRIM ........................................................9 MAINTENANCE ON BOLTED BONNET GLOBE VALVE TRIM ................................................... 10 MAINTENANCE ON BOLTED BONNET CHECK VALVE TRIM ................................................... 12 GATE, GLOBE AND CHECK VALVES WELDED BONNET ......................................................... 14 MAINTENANCE OF BALL VALVES.............................................................................................. 15 VALVES WITH ELECTRIC/PNEUMATIC ACTUATOR ................................................................. 16 RECOMMENDATIONS FOR FIELD WELDING ............................................................................. 18 THE NAMEPLATE ......................................................................................................................... 21 HOW TO ORDER SPARES PARTS .............................................................................................. 23 SAFETY INSTRUCTIONS .............................................................................................................. 24
ANNEX A VALVES COMONENTS .................................................................................................... A.1 ANNEX B RECOMMENDED TORQUE VALUES FOR BOLTING ...................................................... B.1 ANNEX C MATERIAL CORROSION GUIDE ...................................................................................... C.1 ANNEX D LUBRICATION DATA ........................................................................................................ D.1
Parts and sentences which have been modified in the last revision of this document are written in red colour and a vertical line is placed at the external side of them.
Document DT01-05e- B - Published on: July 2005Page 1.1

General 1 GENERAL
These instructions apply to all standard valves manufactured by LVF (see enclosure A and the catalogue for further details).
2
2.1
INSTALLATION
VALVE CARE BEFORE INSTALLATION
LVF valves are carefully made from selected materials to give long, trouble-free service when properly installed in applications for which they were designed. Proper care and maintenance in the field can contribute significantly to maximum performance. The care the valve receives between the time it is shipped by the manufacturer and installed in the piping system is important. During this period, the valve can be handled many times and can be kept in storage for long periods. Industrial valves are not delicate, but they are mechanical devices which should be treated as such and handled with care. LVF always provides valves with appropriate end covers to protect the end connections and to prevent foreign material from entering the valve. If at all practical, keep the valves in the original boxes with end covers in place until ready to be installed. Storing the valves off the ground and indoors is always preferable. When stored outside, valves should be off the ground and protected by a weatherproof cover. Prior to installation, the valves and nameplates should be checked for proper identification to be sure the valve is the proper type and of a suitable pressure class (see paragraph 2.3). Actuate the valve to check for possible damage from shipping and handling. Also, it is extremely important to inspect the interior of both the valve and the adjoining pipe for cleanliness. By far the major cause of seat leakage and seat damage is foreign material in the line. Also, inspect end connections to be sure that pipe threads and flange faces are free from scratches, nicks, or dents.
2.2
VALVE IDENTIFICATION
All valves have a nameplate attached that include the figure number, size, pressure class and material. The valve nameplate needs to be reviewed in conjunction with the installation, maintenance, and spare parts ordering instruction in this manual (see also paragraph 14).
Page 1.2
Document DT01-05e- B - Published on: July 2005

General
2.3 WORKING CONDITIONS
Valves manufactured by LVF are to be installed and assembled on the plant in the observance of the pressure rating and design temperature and to the test pressure values. Moreover limit in the working temperature of the valves shall be observed according to the rules detailed in paragraph 15.
In order to preserve the packing best performances, LVF valves are, generally, furnished with the gland bolts loosen. Hence special care is to be placed in the tightening of gland nuts during installation, in order to get the proper packing adjustment and functionality (see paragraph 4 for details). In order to avoid valves deformation and consequence of risk of contact with dangerous fluids (toxic, high or low temperature, corrosive...), explosion or fire, the valve must be installed taking care to adequately reduce any vibration which can be transmitted to the valve throughout the pipe line. In order to avoid the ignition of fire or explosion undcer European Directive 94/9/EC ATEX, the valve and/or the system in which the valve is installed has to have a cathodic protection according with clause 6.4.6 of the standard EN 1127-1. The presence of electrostatic charges may result in a risk of fire or explosion under the European Directive 94/9/EC ATEX. The ball valves with soft seat are fitted with antistatic device. Valve and/or the system in which the valve is installed has to have a ground connection. The valves produced by LVF do not need sealants for both the packing and the seating area. In the cases in which a sealant is required, use only sealants the maximum working temperature of which is at least 20 K over the maximum working temperature of the valve.
3
3.1
MAINTENANCE
GENERAL
Replacement of important parts as: bodies, bonnets, stems, seats and wedges. For these pieces is preferable to carry out the replacement in our factory or if possible in an well equipped workshop. Maintenance on other parts, more simple to be replaced or checked, as gland bolts and nuts, body-bonnet bolts and packing can be carried out on site. In any case, please contact our commercial department giving necessary information as described in section 14 to obtain correct pieces to be replaced.
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General
After receiving follow closely instructions given in the applicable point of this manual or contact, for any hesitation, our technical department. We will not be responsible for any damage due to carelessness on following instructions.
3.2
ROUTINE INSPECTION AND MAINTENANCE

Once the right valve is properly installed, field maintenance is of a generally routine nature and can be readily performed by the user.
3.2.1
CHECK OF GASKET AND SEATING AREAS The critical areas of a valve include the stem threads and those locations where leakage will most likely occur: the stem packing, the bonnet joint, the seat and the end connections. It is desirable that a maintenance program be established which will include periodic inspection of the noted critical areas. The most common location of a noticeable leak is at the stem seal. Leakage at the stem can usually be stopped by adjusting the packing. (see paragraph 4.3). If leakage cannot be stopped by packing adjustment, either installation of additional packing rings (see paragraph 4.4) or a complete packing replacement (see paragraphs 4.5) is indicated.
3.2.2
CHECK OF PRESENCE OF FRICTION Friction involves generation of heat and the relevant overheating of surfaces. Surfaces at high temperature may induce danger of fire/explosion. Both during installation and cyclically check any eventual bearing for unexpected friction due to failure (when the valve is operated, take care the any eventual suspicious noise combined with an increment of the effort required to operate the handwheel failure of bearing may be involved). Annex D shows the valves components which may be object of friction and for which cyclic lubrication is required.
3.2.3
CHECK/REMOVAL OF DUSTS The presence of dust on the external surface of the valve may induce danger of fire/explosion: install the valve in place which make easy the cleaning activities clean the surfaces of the valve periodically and when ever the thickness of the dust reach 5mm (special care is to be paid to the moving parts which may be subject to friction: e.g. yoke sleeve, bearings, packing area...). surface temperature depends on the service medium temperature: when necessary preventive measures are to be taken to limit the temperature, to avoid heat accumulation.
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General 4
4.1
PACKING
OVERVIEW
Special care is to be placed in the tightening of gland nuts during installation or after replacement of the packing or during periodic checks (remember that due to natural loss of elasticity of the packing along the time it is possible that tightening is necessary). Note, on this argument, that great interest is placed today in fugitive emissions from piping components (see for example "EPA American regulation, TA-LUFT protocol, etc.) in a way that for some places now is compulsory that valve stem emissions be monitored, being estimated one of the greater causes of atmospheric emissions from oil, petrochemical and chemical industries. Our valves are in accordance to the main of the said regulations; however periodic check for packing adjustment and/or replacement are strongly recommended.
4.2
RECOMMENDATIONS
LVF valves are packed with all-purpose packing sets. This is a combination of packing using braided rings at the top and bottom of the packing chamber and flexible graphite packing in the middle section. Packing glands should be tightened down enough to prevent leakage but not enough to develop excessive operating torque. When the gland has advanced approximately to half way into the packing chamber, it is recommended that additional packing rings be added. To obtain best results, the stem should be thoroughly cleaned. Replacement packing should be the same as that originally furnished. LVF valve packing are inhibited to prevent stem pitting in service. We recommend packing be purchased from LVF to assure packing with the proper density and corrosion inhibitors is always used.
4.3
PACKING ADJUSTING
Packing glands should be tightened down enough to prevent leakage but not enough to develop excessive operating torque. The packing adjusting is the operation by which the proper compromise is set up. It consists in loosening and/or tightening the gland bolting, taking in care some easy tricks: proceed to lock in a alternative way maintaining the stuffing box flange parallel to the lid flange. The stuffing box flange, subject to movements caused by the operator, does not lead to horizontal or rotary shifting with respect to the lid flange. Every now and then stroke the valve, to allow a correct settlement of the packing and, in the meantime, to check the effort to operate the handwheel.
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General
Should the operator be convinced that described operations were carried out well but some leaks arise the packing must be replaced according to the instructions at paragraphs 4.5 o 4.6.
4.4
ADDING RINGS TO THE PACKING

When the gland has advanced approximately to half way into the packing chamber, it is recommended that additional packing rings be added. This shall be carried out in this manner: 1. Remove packing gland bolting and free up packing gland. 2. Remove top ring of packing. This will be a braided graphite packing. Prepare chamber to accept new ring or rings of packing. 3. Split a number of packing rings of flexible graphite as required and place individual ring in packing chamber using the gland to ram the packing into the chamber. Stagger packing rings separations by 90 if more than one ring is required. Replace top ring of braided graphite packing as required. 4. Tighten packing gland bolting evenly (follow instruction given in paragraph 4.3). 5. Open and close valve to insure free operation and to allow packing settlement. Check for an acceptable force to operate the handwheel. 6. Place valve back in service.
4.5
RE-PACKING DURING A SHUT DOWN

Long service life from modern graphitic packing requires that adequate loads be applied when repacking. Special care is to paid for what follows: 1. All parts should be clean and not scored or pitted, especially the stem. 2. The valve internal parts and bonnet should be assembled prior to installing the packing. 3. Position split packing rings with the ends of adjacent rings rotated 90. 4. Install in the original sequence. Standard sequence consist of: Bottom Ring Braided Ring
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General
Middle Rings Die formed expanded graphite Top Ring Braided Ring Clean the gland bolts. Carefully seat each individual packing ring following indication of points 3 and 4. Apply the recommended torque to the gland nuts evenly without cocking the gland. See Annex B for recommended torques. Tighten the nuts being sure that: proceed to lock in a alternative way maintaining the stuffing box flange parallel to the lid flange. The stuffing box flange, subject to movements caused by the operator, does not lead to horizontal or rotary shifting with respect to the lid flange. Stroke the valve, then re-check the gland nut torques.
5. 6. 7. 8.
9.
4.6
RE-PACKING THE VALVE UNDER PRESSURE

Back seating the valve and attempting to repack under pressure is hazardous and is not recommended. Rather than attempting to repack under pressure, it is preferable to use the backseat to control the stem leakage until a shutdown provides safe repacking conditions. When required, re-packing with valve under pressure shall be carried out being sure that: 1. Proceed opening completely the valve taking care that the stem is brought back to backseat position. 2. Only when the stem is in this position, loosen the bolts of the stuffing box flange so to remove pressure from the packing pack. 3. Check that the stem is really in the backseat position ensuring that there are no losses. 4. Only now loose completely nuts and move the flange and the packing gland ring upwards. Remove packing and replace with the new one. 5. Position split packing rings with the ends of adjacent rings rotated 90. 6. Install in the original sequence. Standard sequence consist of: Bottom Ring Braided Ring Middle Rings Die formed expanded graphite Top Ring Braided Ring 7. Carefully seat each individual packing ring following indication of points 5 and 6.
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General
8. Bring the packing gland ring and the flange to the original position. 9. Tighten the nuts being sure that: proceed to lock in a alternative way maintaining the stuffing box flange parallel to the lid flange. The stuffing box flange, subject to movements caused by the operator, does not lead to horizontal or rotary shifting with respect to the lid flange.
BODY-BONNET BOLTINGS
Replacement of these bolts does not require special care. Only proceed to this operation changing one bolt at a time to prevent losses of pressure on the gasket. If this is not possible replace the body-bonnet gasket locking bolts in a crossed way (see figure) till torque are the same of annex B.
Page 1.8

General 6
6.1
MAINTENANCE ON BOLTED BONNET GATE VALVE TRIM

WEDGE
a) Proceed opening completely the valve taking care that the stem is brought back to backseat position. b) loosen body-bonnet bolting. c) Remove bonnet and extract wedge (take note of coupling side with respective seat, see figure) from the special slot of the stem. d) Check that no incisions or marks are on holding planes. If any use fine sand paper or emery cloth to eliminate them, taking care that the original planarity of these surfaces is not modified. e) When removed possible defects as described in point d, proceed replacing the gasket between body and bonnet, insert wedge in the slot of the stem making sure that is in the same previous couplement with surface of seats (see figure here below). f) Proceed tightening body-bonnet bolts as described in section 5.
IMPORTANT: final situation (couplement with faces of seats) will be the same that before disassembling, being this couplement of faces obtained, during first assembling, by expanding the seats with the wedge in the operating position. In case that operator doesn't follow these instructions WE CANNOT GUARANTEE the absence of leakage: the customer is advised about the necessity to perform again the seat test according to the original test specification.
6.2
STEM
a) Proceed opening completely the valve taking care that the stem is brought back to backseat position. b) loosen body-bonnet bolting. c) Remove bonnet-stem group (wedge must remain in his position) and then disassemble the stem turning it in anticlockwise way. d) Make sure that surfaces of the stem (especially the ones in contact with packing) are not damaged. If you are not in this optimal situation contact our commercial department giving information as described later to obtain a new stem and replace screwing it clockwise in the bonnet yoke sleeve. e) Replace body-bonnet gasket. f) Insert the slot of the stem into the wedge, bring the bonnet to his original position and tighten body-bonnet bolts as described in section 5.
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General
6.3 SEATS
No maintenance is possible on seats of gate valves but only replacement with the aid of blunt chisels and hammer after removal of bonnet and wedge (see figure),
and new seats must be assembled by expansion
Note that seats to be used for this operation, if possible, can be greater in external diameter than the original ones (due to original expansion). In this case please advise the housing diameter into the body to our commercial department in order to obtain the proper seats for replacement. Being this replacement very difficult to be performed in non-equipped workshops, it is preferable to be carried out in our factory where this procedure will be completed by a new set of hydrostatic tests.
7
7.1
MAINTENANCE ON BOLTED BONNET GLOBE VALVE TRIM

DISC
LVFs globe valves do not allow the disc to be disassembled from stem. To check seal characteristics between disc and seat we suggest the "BLUEING TEST": a) Proceed opening completely the valve taking care that the stem is brought back to backseat position. b) loosen body-bonnet bolting.
Page 1.10

General
c) Remove bonnet with stem and disc attached and put some prussic-blue on surface of the seat.
d) Place the bonnet-stem-wedge group in the original position and tighten bolts as described in section 5. e) Take the valve in close position, wait 20 seconds min., and repeat points a and b. f) Remove bonnet again and check that blue trace on wedge is uniformly present on contact surface. If this is not happened there are two possibilities: there are incisions or marks on holding planes. Check and, if any, use fine sand paper or emery cloth to eliminate them, taking care that the original planarity of these surfaces is not modified. No repair is possible because of the great damage. Contact our commercial department giving details as described later to receive a new group stem-wedge and replace it removing the handwheel and turning it in clockwise way so that can leave the bonnet. Assemble the new one in anticlockwise way to the bonnet and put again the handwheel in the original position. g) Replace the body-bonnet gasket. h) Reassemble the group bonnet-stem-wedge and close bolts as described in section 5.
7.2
STEM
a) Proceed opening completely the valve taking care that the stem is brought back to backseat position. b) loosen body-bonnet bolting. c) Remove bonnet with stem and wedge attached. d) Make sure that surfaces of the stem (especially the ones in contact with packing) are not damaged. If you are not in this optimal situation contact our commercial department giving information as described later to obtain a new stem-wedge group and replace screwing it anticlockwise in the bonnet yoke sleeve. e) Replace body-bonnet gasket.
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General
Reassemble the group bonnet-stem-wedge and close bolts as described in section 5.
7.3
SEAT
Check the seat in the same way as described in point 8.1 (blueing test, points a to e). f) Then remove bonnet again and check that blue trace on seat is uniformly present on contact surface with the wedge and that no damage has occurred. If you are not in this situation, we suggest to contact our commercial department giving details as described later to receive a new seat and replace removing the old one turning it in anticlockwise way with a proper hexagon ring wrench so that it can leave the body. Assemble the new one in clockwise way to the body . g) Replace the body-bonnet gasket. h) Reassemble the group bonnet-stem-wedge and close bolts as described in section 5.
MAINTENANCE ON BOLTED BONNET CHECK VALVE TRIM

There are three types of check valves: ball, piston and swing type.
8.1
BALL AND PISTON

a) Disassemble the valve. b) Visual check all contact surfaces.
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General
c) No incisions or marks must be on holding planes. If any AND ONLY FOR PISTON use emery cloth to eliminate them, taking care that the original planarity of the surface is not modified. d) Except for pistons as described in point c, if some damage are present contact our commercial department giving details as described later to receive a new wedge and replace it. e) Replace the body-bonnet gasket. f) Reassemble the valve and close bolts as described in section 5.
8.2
SEAT OF BALL OR PISTON VALVES

a) Disassemble the valve. b) Visual check all contact surface of the seat. c) No incisions or marks must be on holding planes. If there are damages, we suggest to contact our commercial department giving details as described later to receive a new seat and replace removing the old one turning it in anticlockwise way with a proper hexagon ring wrench (see figure in point 8.3) so that it can leave the body. Assemble the new one in clockwise way to the body . d) Replace the body-bonnet gasket. Reassemble the group bonnet-wedge and close bolts as described in section 5.
8.3
SWING TYPE VALVE

a) Disassemble the valve. b) Visual check all contact surface of the swing wedge. c) No incisions or marks must be on holding plane. If there are proceed with the aid of a hinge pin extractor to disassemble the swing from the bonnet. If possible use fine sand paper or emery cloth to eliminate them, taking care that the original planarity of the surface is not modified. If result is not satisfactory contact our commercial department giving details as described later to receive a new one. Replace the old loosening the nut and then fix the hinge again to the bonnet using the pin. d) Replace the body-bonnet gasket. e) Reassemble the group bonnet-wedge and close bolts as described in section 5.
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General
8.4 SEAT FOR SWING TYPE VALVES
As per gate valves no maintenance is possible on the seat, but only replacement as described in section 7.3.
GATE, GLOBE AND CHECK VALVES WELDED BONNET

The only one difference with respect to the above mentioned cases is that there is a seal weld between body and bonnet.
So no complete maintenance is for this case programmed. Is only possible a replacement of the packing and tightening of gland bolting as described for bolted bonnet valves. But for special maintenance (not under our responsibility if not performed in our factory) is possible to remove the seal welding with machining and then, unscrewing the bonnet, proceed as per bolted bonnet valves. After maintenance and reassembling a new seal weld is necessary (welding procedures are available).
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General 10
10.1
MAINTENANCE OF BALL VALVES

REPLACEMENT OF MAIN COMPONENTS
Main components consist of: The ball The stem The seats The replacement of the main components is recommended to be carried out at LVF premises or in specialized workshop by personnel very skilled in valves maintenance.
10.2
MAINTENANCE OF OTHER COMPONENTS

The maintenance of the components simpler to be checked and replaced (e.g. packing) may be easily carried out on site. In any case it is recommended to contact our sales department and provide the all the useful information (see clause 14) for getting the spare parts. After receiving the spare parts, follow carefully the instructions in this manual or, if the case, contact our technical department.
10.3
MIANTENANCE OF PACKING
Check periodically the tightening of gland bolting to achieve an optimal compromise between the absence of leaks and the ease of operation of the handwheel. To reduce the effort on the handwheel, gland bolting may be lightly loosen. In any case, check for leakage after any packing regulation. The packing shall be replaced (see clause 4) when no acceptable compromise can be achieved by the regulation of gland bolting.
10.4
MAINTENANCE OF BALL, STEM AND SEATS

a) Remove the body flange b) Check carefully the condition of the seats and the body-to-flange gasket c) Turn the ball into the closure position and pick it out of the body, avoiding any shock as far as possible. Check carefully the surface of the ball for any scratch or damage d) Remove the gland nuts, the packing gland and the packing it self. Pick out the stem and check the surface for any scratch or damage e)In case of damages the component shall be replaced. After the replacement, assemble the valve following the above instructions in the opposite order. Use a new gasket for body-to-flange seal. f) Tighten the bolting according to clause 10.3.
Page 1.15

General 11 VALVES WITH ELECTRIC/PNEUMATIC ACTUATOR

Valves provided or prearranged to be connected to electric and/or pneumatic actuators present the same constructive solutions of the different models (globe, trim), of the valves with manual command. The differences are in fact limited to the presence of an automatic actuator as a substitute of the handwheel.
Therefore this solution allows favourable conditions both about the availability of spare parts, and for the maintenance point of view: it is to be noticed, in fact, than all the maintenance operations described in the above paragraphs cover also the valve with automatic actuator. For installation, maintenance and normal use regarding strictly the actuators, see the installation manuals supplied with them and making integral part of this document.
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General
11.1 COUPLING VALVE ACTUATOR.
Valves supplied with simple predisposition to connection by actuators, are realised for getting an optimal junction between the two elements; the efficiency of this link depends, in any case, on the connection flange mounted on the actuator: make sure to match all the requirements indicated in data sheet supplied with the valve and here below summarised: Actuators run Vertical push Torsion moment The lack of observance of the data sheet requirements relieves LVF S.p.A. for any responsibility on correct behaviour of the valves. In case of valves supplied with actuators, their substitution shall be done only after the LVFs verification; the lack of observance of this indication relieves LVF S.p.A. for any responsibility on correct behaviour of the valves.
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General 12
12.1
RECOMMENDATIONS FOR FIELD WELDING

OVERVIEW
Welding activities are special processes: codes to carry out these activities are usually referenced (see paragraph 12.2) as well as Procedure specifications (WPS) and Qualifications (PQR). The aim of paragraph 12 is, however, to furnish general indication to support the selection of the process to adopt, and to provide auxiliary information to the ones which are stated into a typical WPS.
12.2
EVALUATION OF CODE REQUIREMENTS

Prior to welding, construction code requirements should be reviewed (ASME Section I, VIII, IX, ANSI B31.1, B31.3, etc.). Applicable code requirements may supersede these recommendations. In the absence of specific code requirements, the guidelines of ASME Section IX are recommended for qualification.
12.3
SELECTION OF PROCESS
Based on the size of the valve and the skill of the welder, either the SMAW (stick) or GTAW (Tig) process is recommended. SMAW is generally preferred, although, GTAW offers more control (at the expense of speed) and may be preferred for and smaller valves.
12.4
SELECTION OF WELD FILLER METAL

For SMAW, use 3/32 electrode on the first pass with 1/8 for subsequent passes. 1/8 and 5/32 electrodes may be used effectively on larger valves. 3/32 type is recommended for GTAW. 1/16 and 1/8 may also be used successfully. Care should be taken to use only SMAW electrodes that have been kept essentially free of exposure to moisture. Exposure of coated electrodes to moisture can cause high levels of hydrogen in the weld which can result in delayed cracking, especially with hardenable alloys. To avoid such a risk follow carefully the electrode supplier instructions. When no instruction is available, the following guidelines can help: Electrodes should be kept in heated electrode ovens operating at 120150 C when not being used. Limit atmospheric exposure to 8 hours maximum without reheating. Electrodes may be used immediately following opening of the hermetically sealed containers in which they are normally supplied.
12.5
SELECTING THE WELDER

Most construction codes require a welder to qualify prior to making a production weld.
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General
Welder performance qualification provides some assurance that the production weld will be of good quality since the welder has proven, through testing, that he can make a good weld. Care should be taken in comparing the welders qualification with the code requirements to assure that the welder has qualified with an appropriate test for the intended production weld.
12.6
JOINT CLEANLINESS
The area in-way-of welding should be cleaned to remove, dirt, oil, and protective coatings. This should be done prior to fit-up or residue in the joint overlap will not be removed. Sanding, grinding, or wire brushing is usually adequate. Solvents may be necessary, if oil is to be removed.
12.7
FIT-UP (SOCKET WELD VALVES)

To avoid fracture, bottom out the pipe engagement into the socket and pull it back approximately 1,5 mm to allow for weld shrinkage. Tack welds should be contoured to allow for easy inclusion into the final weld.
12.8
WELDING TECHNIQUE
Prior to welding, the valve should be lightly closed. Where possible, attach the electrical ground to the adjoining pipe on the same side of the valve as the weld being made. Do not attach the ground to the handwheel or upper structure of the valve or arcing across the valve seating surfaces could occur. Where possible, welding should be done in the flat or horizontal position. Where vertical welding is necessary, progression should be upward (vertical down welding is prone to lack-of-fusion). A minimum preheat of 150180 C is recommended for alloy steels A low heat input is preferred as far as allowed by the applicable welding procedure specification. A minimum of two layers should be used for all socket welds. This will decrease the chance of leaking even if one pass contains a weld defect. Due to controls on thickness and chemical composition, post weld heat treatment (PWHT) on LVF steel valves is normally rarely required. However
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General
always refer to applicable governing codes to determine if post weld heat treatment is required. When required, it shall be carried out a localised PWHT. In this manner LVF valves dimensions normally allow the packing to withstand without damage a not extremely high PWHT temperature. In any case check the packing capability to seal after PWHT and, if the case, replace it (see paragraph 4.5).
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General 13
13.1
THE NAMEPLATE
MAIN NAMEPLATE
Each single valve made by LVF is equipped with an identification nameplate, typically placed over the handwheel. Original nameplates are printed up by a customised laser machine to prevent any possibility of counterfeit or imitation. Here below is the typical nameplate and the description of the therein data.
1 2 10
FIGURE BODY
3
0948
4 5 6 7 8 9
STEM DISC SEAT
TYPE PN / CLASS DN / SIZE YEAR LVF REF. T max (C) PS@T max (bar)
11 12 13 14 15 16 17
T min (C) PS@T min (bar)
LV
Sp
A - IT
LY
1. CE marking, for compliance to the European Directive 97/23/EC PED. The Directive allows the CE logo to be applied ONLY for valves OVER ONE INCH. No logo can be shown in the other sizes. 2. TAG or Customers identification code 3. LVF Valves catalogue figure 4. Shell material (body, bonnet, extension) 5. Stem material 6. Closure member material (in case of hard-facing overlay HF will be shown) 7. Seat material (in case of hard-facing overlay HF will be shown) 8. Minimum design temperature (expressed in Celsius degrees) 9. Maximum operative pressure (PS) at minimum design temperature conditions 10. Type of valve (e.g. Gate, globe, check) 11. Valves Pressure rating (e.g. PN or class designation) 12. Nominal diameter (i.e. DN or size in NPS) 13. Year of production 14. LVF job and item number 15. Maximum design temperature (expressed in Celsius degrees) 16. Maximum operative pressure (PS) at maximum design temperature conditions 17. Applicable Design codes
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General
13.2 ATEXS NAMEPLATE
The ATEXs nameplate if fitted, fastened by a metal wire, to the valves which are required to comply with the European Directive 94/9/EC ATEX. The following figure shows an example of the ATEXs nameplate.
LVF S.p.A.
1 3 5
Via G. Mazzini, 6 San Paolo dArgon Italy
Type: Year: Serial / Ref. Tech. File:
2 4 6
7 1. Catalogues figure of the valve 2. Year of production of the valve 3. Reference for traceability of the valve. In the case a serial number is requiested, this will be printed here; in all the other cases the reference traces to the lot of production (internal job + position number) 4. Number of the technical file covering the valve in subject 5. The specific marking for the explosion protection 6. CE Marking indicating compliance with the European Directive 94/9/EC ATEX 7. ATEX classification as follows: symbol of group, category, type of hazard, gas (G) or dust (D) Classification may be added by the temperature class (according to the EN 13463-1) as follows: Temperature class T1 T2 T3 T4 T5 T6 Maximum surface temperature (C) 450 300 200 135 100 85
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General 14 HOW TO ORDER SPARES PARTS

Genuine spare parts and accessories authorized by LVF serve to maintain safety and efficiency. The use of non-authorized parts may lead to personnel injury or damage to parts, and render the warranty void. Genuine replacement parts are available for LVF current standard valves and can usually be shipped from stock. All parts are made with the same careful inspection and laboratory control given original valves and parts. To obtain spare parts please contact our commercial department indicating the LVF job and item number. The LVF job and item number are shown on the identification nameplate set on the handwheel (see paragraph 13) and allow us to provide all the information related both to the valve and to the spare parts.
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General 15
15.1
SAFETY INSTRUCTIONS
REQUIREMENTS UNDER EUROPEAN DIRECTIVE 97/23/EC - PED
This paragraph details the essential safety requirements to be taken in care by the user, according to the Annex 1 of the European Directive 97/23/CE (P.E.D.). Moreover the temperature of the valves in the operating conditions shall be maintained within the limits stated on the nameplate.
15.1.1
REFERENCE DOCUMENTS European Directive 97/23/EC - PED: Pressure Equipment Devices LVF Procedure SQ 27: Particular material appraisal according to 97/23/EC PED
15.1.2
RISK ANALYSIS Each single sentence written in bolt characters refer to a general safety note. Otherwise a reference to the proper page of this manual is provided. RISK PREVENTIVE ACTION
Accidental contact with 1) Check periodically the tightness of the bolted dangerous service medium connections (connection flanges, body bonnet (toxic fluids, high or low flange etc.) see paragraphs 3.2, and 5 temperature fluids, 2) Check periodically the tightness of the packing bolts corrosive fluids, etc.) due to see paragraphs 3.2, and 4.3 a gasket or packing blow 3) Replace periodically gasket and packing see out paragraphs 3.2, 4.4 and 4.5 4) Replace immediately gasket and packing after a blow out- see paragraph 4.6 5) Use always protective clothing (masks, gloves, etc.) during all maintenance operations 6) Predispose supplementary safety protection devices on the bolted connections 7) Use only suitable and approved materials for gaskets and packing 8) Avoid absolutely overpressures in the closed cavities due to the "boiler effect, installing apposite relief devices 1) Depressurise completely the valve before all the Accidental contact with operations dangerous service medium 2) Open and close the valve and check the internal (toxic fluids, high or low pressure that should be equal to external temperature fluids, ambient pressure before to disassembly the corrosive fluids, etc.) during valve. the disassembly or 3) Empty and drain completely the valve before to maintenance operations disassemble it
Page 1.24 Document DT01-05e- B - Published on: July 2005

General
RISK PREVENTIVE ACTION
4) Drain the remaining fluid with suitable devices 5) Vent the valve when disassembled 6) Use always protective clothing (masks, gloves, etc.) during all maintenance operations Accidental contact with 1) Check periodically the valve body for corrosion dangerous service medium damages (pitting holes, corrosion cracks etc.) (toxic fluids, high or low temperature fluids, corrosive fluids, etc.) due to a leakage from valve body Structural yielding of valve 1) Use the valves only in the prescribed pressure / temperature limits see paragraph 2.3, 15.1.5 body with consequent risk of contact with dangerous 2) Consider the suitability of the material in respect with the service Medium see Annex C. fluids (corrosive fluids, high 3) Check periodically the valve body thickness for or low temperature fluids, erosion or corrosion processes etc.) or explosion or fire. 4) Predispose supplementary devices to avoid additional forces on the valve body 5) Avoids absolutely water hammers: install apposite devices if necessary (brakes, anti shock devices, pressure reducing devices, etc.) 6) Avoid to submit the valve to excessive vibrations see clause 2.3 7) Avoid quick pressure and / or temperature changes 8) Avoid absolutely overpressures in the closed cavities due to the "boiler effect" installing (if necessary) apposite relief devices Accidental contact with 1) Use always protective clothes (gloves, etc.) high or low temperature during the manoeuvre and maintenance parts operations 2) Predispose apposite insulation on the valve 3) Predispose apposite warnings about the risks of burns 4) For cryogenic service use only valves provided with cryogenic extension. Fire or explosion in case of 1) Install only EEX proof electrical devices in the service with flammable area fluids 2) Check periodically the tightness of the bolted connections (connection flanges, body bonnet flange etc.) see paragraphs 3.2, and 5 3) Check periodically the tightness of the packing bolts see paragraphs 3.2, and 4.3 4) Replace periodically gasket and packing see paragraphs 3.2, 4.4 and 4.5 5) During maintenance operation shut down all electrical device s in the area. 6) Don't smoke and don't use any portable not EEX-
Page 1.25

General
RISK PREVENTIVE ACTION proof electrical device in the area. 7) Drain and vent completely the valve before to proceed with the maintenance operations 1) Install and use only valves completely degreased 2) Don't grease any component of the valve 3) use valves only made with materials suitable for oxygen services (see EN 1797-1). 4) Install only EEX proof electrical devices in the area 5) Check periodically the tightness of the bolted connections (connection flanges, body bonnet flange etc.) see paragraphs 3.2, and 5 6) Check periodically the tightness of the packing bolts see paragraphs 3.2, and 4.3 7) Replace periodically gasket and packing see paragraphs 3.2, 4.4 and 4.5 8) During maintenance operation shut down all electrical device s in the area. 9) Don't smoke and don't use any portable not EEXproof electrical device in the area.
Explosion in case of oxygen service
15.1.3
OTHER INSTRUCTIONS Here below are provided some further instructions related to the safe use of LVF valves, as outlined by the European Directive 97/23/EC PED. Special consideration is given to the temperature/pressure limits in the working condition as depending by the design code (e.g. ASME, Din, BSI) as well as by the additional safety requirements outlined by 97/23/EC Directive (PED). Moreover additional suggestions are given to provide the end user with a guideline for the selection of the materials depending on the medium/service foreseen.
15.1.4
VALVE CLASSIFICATION ACCORDING TO PED LVF has implemented, operates and maintains a quality system as described in the PED Annex III Module H. When not otherwise stated LVF valves are designed, manufactured and tested to comply with Category III and for fluid groups 1 and 2. According to the requirements in PED Annex II the LVF valves are marked with the CE logo as follow: Valves from up to 1: No CE marking is allowed Valves above 1: CE marking on the nameplates Details regarding the method of CE marking for valves above 1 are given in paragraph 13.
Page 1.26

General
15.1.5 PRECAUTIONS BEFORE INSTALLATION Prior to the installation, the valves and nameplates should be checked for proper identification to be sure the valve is the proper type and of a suitable pressure class. Valves manufactured by LVF are to be installed and assembled on the plant in the observance of the pressure rating and design temperature and to the test pressures. Do not use valve with pressure higher than the working values stated on the nameplate. Additional attention is to be paid to the limits in the working temperature (as referenced by the design standard stated on the nameplate) which is shown on the nameplate when European Directive 97/23C PED does apply.
15.1.6
MATERIAL MECHANICAL REQUIREMENTS In addition to the requirements of each specific design code adopted, according to the PED Appendix I, paragraph 7.5, [] a steel is considered as sufficiently ductile [] if, in a tensile test carried out by a standard procedure, its elongation after rupture is no less than 14 % and its bending rupture energy measured on an ISO V test-piece is no less than 27 J, at a temperature not greater than 20C but not higher than the lowest scheduled operating temperature []. LVF approval, achieved through module H, ensures that each single material used for pressure containing parts (shell and bolting) for valves over 1 in diameter (DN 25) is covered by a PMA (Particular Material Appraisal) by the Notified Body, in which the above mentioned mechanical characteristics, among the others, are defined.
15.1.7
LVF APPROVED MATERIALS The end user is advised that misapplication of the product may result in injuries or property damage. A selection of valve components of the proper material consistent with the particular performance requirement, is important for proper application. Examples of the misapplication or misuse of the valves include use in an application in which the pressure/temperature rating is exceeded or failure to maintain valves as recommended.
15.2
REQUIREMENTS UNDER THE EUROPEAN DIRECTIVE 94/9/EC ATEX

This clause describes the minimum essential requirements which the user shall take in consideration for the safety, under the definition given by the European Directive 94/9/EC (ATEX).
Page 1.27

General
15.2.1 REFERENCE DOCUMENTS European Directive 94/9/EC - ATEX: Equipment and protective systems intended for use in potentially explosive atmospheres Technical file of design n FTP-02 (TV No. EX9 04 05 52830 001) in accordance with the European Directive 94/9/EC ATEX 15.2.2 RISK ANALYSIS The notes in dark background refer to the risks in normal working conditions. The notes in clear background refer to the foreseen failures.
RISK Hot surfaces Hot surfaces may be source of ignition for fire/explosion of suspended dust. Surfaces temperature depends on the temperature of the process medium. The installer/end user is responsible for evaluate the presence of this risk and, when necessary, to adequately protect the valve to limit the involved risks. When stated in the purchase order, the ATEXs nameplate bears the maximum surface temperature. No other special measure is foreseen by LVF about this risk. The installer/end user is responsible for evaluate the presence of this risk and, when necessary, to adequately protect the valve to limit the involved risks. The installer/end user shall inertise1 the line during any shutdown or whenever the line is put at atmospheric pressure The installer/end user is responsible for evaluate the presence of this risk and, when necessary, to adequately protect the valve to limit the involved risks. The installer/end user shall inertise1 the line during any shutdown or whenever the line is put at atmospheric pressure PREVENTIVE ACTION
Internal temperature of a line in atmospheric pressure may increase due to the external sun flashover. In case of failures (e.g. breaking of springs, galling of moving components) with the line at atmospheric pressure, the increment of the external temperature is negligible. Hot Gases and/or liquids Hot gas or liquid may escape during the line draining or venting Leakage of hot gas or liquid from the packing, lateral flanges, body-tobonnet joints, drain/vent plugs, etc...
The installer/end user is responsible for evaluate the presence of risks related to this source of ignition. The installer/end user is responsible for carry out a periodic check of tightening the bolting, according to the instructions given in this manual
Mechanically generated sparks Maintenance by

1
Characteristics of the tools to be used in an explosive
Inertisation: adding of inert substances to avoid the presence of explosive atmospheres (UNI EN 1127-1 clause 3.21) Document DT01-05e- B - Published on: July 2005
Page 1.28

General
RISK machining of external surfaces, touch up of paint, tightening of bolting, etc... Mechanical activities such as grinding, welding, cutting, dismantling of the line, etc... PREVENTIVE ACTION atmosphere shall comply appendix A of EN 1127-1. The tools shall be used upon specific permission only.
Characteristics of the tools to be used in an explosive atmosphere shall comply appendix A of EN 1127-1. In case of cutting, grinding... the user shall check for presence of explosive atmosphere (both external and internal the line) before starting. In case of dust, remove it before proceed. The tools shall be used upon specific permission only. After opening a flange, clean the line by fluxing it before service. Seal the flange which has been opened in case of activities longer than half a day. The LVF valves are produced by using material with no more of 7,5% magnesium in weight.
During maintenance on a valve with a side open, particulates of foreign substances (stones, rust, welding particulate, etc...) may enter and bump into the line during service flow.
Heat generated by friction Valve operated under load. Valves at low/medium temperature. Valves with handwheel. Lack of lubrication See clause 3.2.2 for periodic lubrication activities. The material of the yoke sleeve of standard LVF valves is bronze, aluminium-bronze, martensitic steel. Speed for manual opening/closing is very slow: the relevant increment of temperature is typically negligible. See clause 3.2.2 for periodic lubrication activities. The material of the yoke sleeve of standard LVF valves is bronze, aluminium-bronze, martensitic steel. Speed for manual opening/closing is very slow: the relevant increment of temperature is typically negligible. Gear and/or actuator shall comply as minimum with classification Ex II 2 GD under the ATEX Directive. Assembly and maintenance shall be performed strictly in accordance with the relevant instruction manual of the gear and/or actuator. Gear and/or actuator shall have a flexible collar to compensate the expansion of the stem by temperature. Gear and/or actuator shall comply as minimum with classification Ex II 2 GD under the ATEX Directive. Assembly and maintenance shall be performed strictly in accordance with the relevant instruction manual of the gear and/or actuator.
Valve operated under load. Valves at low/medium temperature. Valves with gear and/or actuator. Valve operated under load. Valves at high temperature. Valves with gear and/or actuator.
Travelling of the closure Check the correct functionality of the valve by means of member in touch with the operating test in the workshop. seats, with valve at Inertise2, flux and drain the line close to the valve before
2
Inertisation: adding of inert substances to avoid the presence of explosive atmospheres (UNI EN 1127-1 clause 3.21)
Page 1.29

General
RISK atmospheric pressure. Travelling of the stem in touch with bonnet and lantern (if any), with valve at atmospheric pressure. PREVENTIVE ACTION operating it. Check the correct functionality of the valve by means of operating test in the workshop. Inertise2, flux and drain the line close to the valve before operating it.
Friction of antifriction ball See clause 3.2.2 for periodic lubrication activities. bearing on non-rotating The material of the yoke sleeve of standard LVF valves is stem valve operated by bronze, aluminium-bronze, martensitic steel. gear/ actuator Electrical material Spark may be generated when electric circuits are opened/closed The LVF valves are normally lacking in electric devices. When electric devices are required, they are as minimum with classification Ex II 2 GD under the ATEX Directive. Assembly and maintenance of the electric devices shall be strictly in accordance with the relevant instruction manual.
Spark may be generated The LVF valves are normally lacking in electric devices. by the electric connection When electric devices are required, they are as minimum with classification Ex II 2 GD under the ATEX Directive. Assembly and maintenance of the electric devices shall be performed strictly in accordance with the relevant instruction manual. Electric arcs Ignition of electric arc in case of breaking of feeding cables for electric auxiliary devices The LVF valves are normally lacking in electric devices. When electric devices are required, they are as minimum with classification Ex II 2 GD under the ATEX Directive. Assembly and maintenance of the electric devices shall be performed strictly in accordance with the relevant instruction manual.
Ionising radiations The ionising radiations may be light explosive atmospheres by means of the absorption of energy Ultrasounds Ultrasounds may The LVF valves do not produce ultrasounds. increase temperature into In case of use of devices with ultrasounds sources, those the components by devices shall comply with clause 6.4.12 of EN 1127-1 absorption of energy Auto ignition of dusts In case of machining activities on the line with valves end open, dusts may deposit into the inner parts of the valve Page 1.30 After maintenance which involve the opening of flanges, clean the line by fluxing it before service. Seal the flange which has been opened in case of activities longer than half a day. The LVF valves do not produce ionising radiations. In case of use of devices with radioactive sources, those devices shall comply with clause 6.4.11 of EN 1127-1

General
RISK Vibrations Vibrations caused by movement of the manual actuator and/or transmitted by the valve The manual actuator is fastened to the valve (or to the extension of the underground valves) by means of bolting. The inner parts of the valve are sized and assembled with tolerances sufficient to support eventual vibrations caused by the movement of the component itself. See also clause 2.3. PREVENTIVE ACTION
Pollution Polluting materials and/or The installer/end user is responsible to verify that the material solvents used in the plant used of the seals (Graphite, PTFE, Viton etc) is compatible may damage the sealing with the eventual solvents and detergent used on the plant O-rings of the housing of the manual actuator
15.2.3
Other instructions This document does not cover the instructions related to the tools and/or devices which can be additionally fitted on the valves. For such a tools/devices refer to their own instruction manuals. In order to satisfy the minimum safety requirements under the the Annex II of the European Directive 94/9/EC ATEX, here below are the clauses excluded as not applicable: Clause 1.0.6 Argument Instructions limited to: [...] indication of the danger areas in front of pressure-relief devices3 [...] training instructions Enclosed structures and prevention of leaks Protection against other hazards limited to: radiation which would cause a danger conditions of overload Overloading of equipment Flameproof enclosure systems
1.2.3 1.2.7
1.2.8 1.2.9
Classification of hazardous areas into zones is a task for the user whose premises/work activities contain or create such hazards.
Page 1.31

General
Clause 1.3.1 Argument Hazards arising from different ignition sources limited to: flames induced currents Leakage currents Lightning Electromagnetic waves with radio frequency (RF) from 104 Hz to 3x1012 Hz Electromagnetic waves with radio frequency (RF) from 3x1011 Hz to 3x1015 Hz Adiabatic compressions Shock waves Chemical reactions Thermal reactions Acoustic energy Stray electric Hazards arising from pressure compensation operations Hazards arising from external effects limited to: changing environmental conditions extraneous voltages humidity contaminations other external effects Requirements in respect of safety-related devices Manual override must be possible... When the emergency shutdown system is actuated... Hazards arising from power failure Placing of warning devices as parts of equipment [...] Higher temperatures in exceptional circumstances may be allowed only if the manufacturer adopts special additional protective measures.
1.3.5 1.4
1.5 1.6.1 1.6.2

1.6.3
1.6.5 2.3.1.2
15.2.4
CLASSIFICATION OF THE VALVES UNDER ATEX
15.2.4.1 GROUP The valves designed and produced by LVF belong to the: Group II The group II include the devices intended to be used in places liable to be endangered by explosive atmospheres. The LVF valves are therefore NOT intended to be used in underground parts of mines and to those parts of surface installations of such mines liable to be endangered by firedamp and/or combustible dust, under Annex I of Directive 94/9/EC - ATEX.
Page 1.32

General
15.2.4.2 CATEGORY The valves designed and produced by LVF belong to the: Category 2 or Category 3 Category 2 comprises products designed to be capable of remaining within their operational parameters, stated by the manufacturer, and based on a high level of protection for their intended use, in areas in which explosive atmospheres caused by mixtures of air and gases, vapours, mists or air/dust mixtures are likely to occur. The explosion protection relating to this Category must function in such a way as to provide a sufficient level of safety even in the event of equipment with operating faults or in dangerous operating conditions which normally have to be taken into account Equipment in this category must comply with the supplementary requirements referred to in clause 2.2 of Annex II, Directive ATEX. Conditions of operation: equipment remains energized and functioning in Zones 1, 2 (G=gas) and/or 21, 22 (D=dust) Category 3 comprises equipment designed to be capable of functioning in conformity with the operating parameters established by the manufacturer and ensuring a normal level of protection. Equipment in this category is intended for use in areas in which explosive atmospheres caused by gases, vapours, mists, or air/dust mixtures are unlikely to occur or, if they do occur, are likely to do so only infrequently and for a short period only. Equipment in this category ensures the requisite level of protection during normal operation. Equipment in this category must comply with the supplementary requirements referred to in clause 2.3 of Annex II, Directive ATEX. Conditions of operation: equipment remains energized and functioning in Zone 2 (G=gas) and/or 22 (D=dust)
Page 1.33

Annex A Valves Components ANNEX A VALVES COMONENTS
Gate valves
Globe valves
Page A.1

Annex A Valves Components
Piston and ball check valves
Swing check valves

NUT WASHER HANDWHEEL YOKE SLEEVE NAMEPLATE STEM GLAND NUT GLAND FLANGE GLAND BOLT BONNET BODY/BONNET NUT BODY GASKET DISC WIRE JOINT SEAT GLAND PACKING
Angle valves
Page A.2

Annex A Valves Components
Ball valves
Page A.3

Annex B Recommended torque values for bolting ANNEX B RECOMMENDED TORQUE VALUES FOR BOLTING
Here below are the typical values of torque to be used for the bolting on standard Gate, globe and check valves. The values are valid regardless to the valves pressure rating.
Size Reduced Bore Full Bore 1/2 3/8 3/4 1/2 1 3/4 1 1/4 1 1 1/2 1 1/4 2 1 1/2 / 2
Packing studs Size Torque M8 13Nm M8 13Nm M8 14Nm M10 21Nm M10 21Nm M10 25 Nm M12 37Nm
Body/Bonnet bolts Size Torque M10 55Nm M10 55Nm M12 95Nm M12 95Nm M14 150Nm M16 230Nm M20 450Nm
Page B.1

Annex C - Material Corrosion Guide ANNEX C MATERIAL CORROSION GUIDE

Stainless Steel 304 Stainless Steel 304 Stainless Steel 316 Stainless Steel 316
Carbon Steel
CORROSIVE MEDIA
CORROSIVE MEDIA Inconel Monel
Carbon Steel
Inconel
Acetate Solvents, Crude Acetate Solvents, Pure Acetic Acid, 95% Acetic Anhydride, Boiling Acetone Alcohols Amines Ammonia, Anhydrous Ammonium Hydroxide, Hot Ammonium Nitrate Aniline Hydrochloride Antimony Trichloride Asphalt Barium Chloride, 5% Barium Hydroxide Barium Nitrate Benzene, Hot Benzoic Acid Blood Bromine, Dry Gas Bromine, Moist Gas Buttermilk Calcium Bisulfite, Hot Calcium Chloride, Dilute Calcium Hydroxide, 20%, Boiling Calcium Hydrochloride, < 2% Carbolic Acid, 90% Carbon Dioxide, Dry Carbon Disulphide Chloroacetic Acid Chloric Acid Chlorinated Water, Sat. Chlorine, Dry Gas Chlorine, Moist Gas Citric Acid, Dilute Citric Acid, Hot, Conc. Creosote, Hot Cupric Chloride, 5% Ethyl Chloride Ethylene Glycol Ferric Chloride < 1%
D C D D B B B B B B D D B C C C B B D D D D D C D C C C B D D D B D D D B D A A D
A A B B A A A A A A D D A A A A A A A A D A C B A C A A A D D D B D A C A D A A C
A A A A A A A A A A C C A A A A A A A A D A B A A B A A A C C C B C A B A C A A B
A A A A A A A A A A B B A A A B A A A B D A D A A B A A A B C C A D A B A D A A B
B A A A A A A A D C B B A A A C A A A A C A D A A C B A B B C C A C A B A D A A C
Ferric Nitrate, 5% Ferric Sulfate, 5% Ferrous Sulfate, 10% Flourine, Dry Gas Flourine, Moist Gas Freon, Wet Fuel Oil, 140F Furfural Gasoline Sour Gasoline Refined Gelatine Glucose Glycerine Hydrofluoric Acid, Boiling Hydrofluosilicic Acid Hydrogen Chloride, Dry Hydrogen Chloride, Moist Hydrogen Fluoride, Dry Hydrogen Peroxide, Boiling Hydrogen Sulfide, Dry Hydrogen Sulfide, Moist Iodine, Dry Kerosene Lactic Acid, 5% Lactic Acid, 10% Lactic Acid, Boiling, 5% Lactic Acid, Boiling, 10% Lead Acetate, Hot Magnesium Chloride, Hot, 5% Magnesium Hydroxide Magnesium Sulfate Magnesium Sulfate, Boiling Mercury Mercuric Chloride, < 2% Mercuric Cyanide Methyl Chloride, Dry Milk Molasses Naptha Nickel Chloride Nickel Sulfate, Boiling
D D C C D C A B B A D B B D D B D C D B C D A D D D D D D B B C B D D D D B B D D
B B A C D C A B A A B A A D D D D D C A B D A B B C D A C A A A A D B B A A A C C
A A A B D C A B A A A A A D C C D C B A A B A A A B B A B A A A A D B B A A A B C
C B B A B B A B C B A A A D B A D A B A A A A A A B B B A A B C A D B A A A A B B
D C A A A A B B C A A A A B A A C A B A B A A B B C C B A A A A B D D A B A A B A
Page C.1
Monel

Annex C - Material Corrosion Guide
Stainless Steel 304
Stainless Steel 316
Stainless Steel 304
CORROSIVE MEDIA
CORROSIVE MEDIA Inconel Monel
Stainless Steel 316
Carbon Steel
Carbon Steel
Inconel
Nitric Acid, 20% Nitric Acid, Boiling, Conc. Nitrous Acid Nitrobenzene Oils - Miner. Oxalic Acid, Boiling, 10% Oxalic Acid, Boiling, 50% Oxygen Picric Acid Potassium Bromide Potassium Carbonate Potassium Chlorate Potassium Chloride Potassium Chloride, Hot Potassium Cyanide Potassium Sulfate, Dil. Propane, Liquid & Gas Pyrogallic Acid Rosin, Molten Salicylic Acid Silver Bromide Silver Chloride Silver Nitrate Sodium Acetate Sodium Bisulfate Sodium Bromide, Dil. Sodium Cyanide Sodium Fluoride, 5% Sodium Hydroxide, 50% Sodium Hyposulfite Sodium Nitrate
D D D D B C D B C D B B D D B B B B D D D D D C D D B D B D B
A D B B A A D A A C A A A C B A A A A B B D A A B B B B A B B
A D B A A A C A A B A A A B B A A A A B A D A A B B B A A A A
B D B B C A B A D A A A A B B A A B A B C C A A B B B B A B A
D D C B B A B A D A A B A A B A A A A B B B C A A A A A A A B
Sodium Perborate Sodium Peroxide Sodium Phosphate, Tribasic Sodium Silicate Sodium Thiosulfate Stannous Chloride, Sat. Steam, 212F Steam, 600F Sulfite Liquors Sulfur Chloride Sulfur Dioxide, Moist Sulfuric Acid, Conc. Sulfurous Acid, Sat. Tannic Acid, 10% Tar, Hot Tartaric Acid, 120F Toluene Trichlorethylene Turpentine Varnish, Hot Vegetable Oils Vinegar Water, Acid Mine Water, Boiler Feed Water, Distilled Water, Salt Sea Whiskey, Boiling Wine Xylene, Boiling Zinc Chloride, 5% Zinc Sulfate, Boiling
C C C B D D A C D D D B D D B D A B B C B D D B D D D D D D D
A A A A B D A A C C B B B A A B A A A A A A A A A C A A A C A
A A A A A B A A B D A B B A A A A A A A A A A A A B A A A B A
A A A A B B A A D B D B D B A A A A A A A A A A A B A A A B B
B B A B B B A A D B D D D A B A A A A A B A C A A A C C A B A
A = Substantial resistance - Preferred material of construction. B = Moderate resistance - Satisfactory for use under most conditions. C = Questionable resistance - Use with caution. D = Inadequate resistance LVF doesn't assume any responsibility from the use of a.m. data which are purely theoretical. The user must verify the best conditions of use.
Page C.2
Monel

Annex D Lubrication data ANNEX D LUBRICATION DATA

Gate valves
Location Class Diameter Component Method Product Italiana Petroli IP BIMOL GREASE 481 or equivalent Lubricant Temp* Q.ty 58 (gr) Cleaning + Application 610 (gr) Procedure Frequency (month) 6 (or 300 hours of operation) 4 (or 200 hours of operation)
150 800 900 4500 API 6A
1/4 4 DN 8100
Stem Yoke Sleeve Bearings Brush
* Ignition temperature declared by the lubricant manufacturer, measured according to IEC 66079-4
Globe valves
Location Class Diameter Component Method Product Italiana Petroli IP BIMOL GREASE 481 or equivalent Lubricant Temp* Q.ty 58 (gr) Cleaning + Application 610 (gr) 4 (or 200 hours of operation) Procedure Frequency (month)
150 800 900 4500 API 6A
1/4 4 DN 8100
Stem Yoke Sleeve Bearings Brush
* Ignition temperature declared by the lubricant manufacturer, measured according to IEC 66079-4
Check and ball valves Check valves and ball valves are not required for lubrication
The lubricant and/or cooling fluids, required to prevent sparks or hot surfaces which can result in ignition source for explosion atmosphere, must have a ignition temperature at least 50 K over the maximum surface temperature of the valve or the device where the lubricant /cooling fluid is used on.
Page D.1

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Edition 2005

Installation, operation and maintenance instructions

Gate, globe, check and ball valves

MAIN PLANT & FACTORY:

Installation, operation and maintenance instruction

Document DT01-05e- B - Published on: July 2005Page 1.1

Installation, operation and maintenance instruction

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

ROUTINE INSPECTION AND MAINTENANCE

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

ADDING RINGS TO THE PACKING

RE-PACKING DURING A SHUT DOWN

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

RE-PACKING THE VALVE UNDER PRESSURE

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

MAINTENANCE ON BOLTED BONNET GATE VALVE TRIM

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

and new seats must be assembled by expansion

MAINTENANCE ON BOLTED BONNET GLOBE VALVE TRIM

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

MAINTENANCE ON BOLTED BONNET CHECK VALVE TRIM

BALL AND PISTON

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

SEAT OF BALL OR PISTON VALVES

SWING TYPE VALVE

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

GATE, GLOBE AND CHECK VALVES WELDED BONNET

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

MAINTENANCE OF BALL VALVES

MAINTENANCE OF OTHER COMPONENTS

MAINTENANCE OF BALL, STEM AND SEATS

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

General 11 VALVES WITH ELECTRIC/PNEUMATIC ACTUATOR

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

Document DT0-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

RECOMMENDATIONS FOR FIELD WELDING

EVALUATION OF CODE REQUIREMENTS

SELECTION OF WELD FILLER METAL

SELECTING THE WELDER

Document DT01-05e- B - Published on: July 2005

Installation, operation and maintenance instruction

FIT-UP (SOCKET WELD VALVES)

Document DT0-05e- B - Published on: July 2005