gate valve - installation, operation & mantainance manual

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022012OF11

GMR

INSTALLATION,OPERATIONANDMAINTENANCEMANUAL

GATEVALVE

DOCNO CAMTS0030REV.NO 00DATE 15022012PAGENO 4OF11

PREPAREDBY:D.K CHECKEDBY:KMP APPROVEDBY:GMRFORMATNO:0401F12REV.NO:00DATE:01022012

6.1 PREPARATIONBEFOREINSTALLATION1. Asarule,theengineeringcontractor,ConstructionCompanyoroperator/userisresponsibleforthe

positioningandinstallationofthevalves.Planningandinstallationerrorsmayimpairthereliablefunctionofthevalvesandposeasubstantialsafetyhazard.

2. Confirmthatthematerialsofconstructionofthevalve,andthemaximumpressure/temperaturespecifiedinthenameplatesareappropriatefortheserviceintendedandareasspecified.

3. Thoroughlycleanadjacentpipingsystemtoremoveanyforeignmaterial,weld,piecesofwood/plastic.

4. Verifythatthespaceavailableforinstallationisadequatetoallowthevalvetobeinstalledandtobeoperated.

5. Cleanthoroughlytheaccessibleinteriorspacesofbodyends,surfacesandfunctionalpartsandmountingparts(stem,flangeforactuator,mountingetc.)

6. Gatevalvescanbeinstallednormallyinhorizontalpipelineswithverticalstemandwithflowfromeitherdirection.Valvescanalsobeinstalledinverticalpipeline.

7. Valveshallnotbeusedattheendofthepipeline.

THEFOLLOWINGPROVISIONSSHALLBEMADEINTHEPIPELINEa) Drainingandventing.Valvesareprovidedwithbossesfordrainingandventing.Drilled,tappedand

pluggedconnectionsfordrainingandventingareprovidedwhenrequestedbythecustomer.b) Dangerousdischargeofpressurereliefblowoff.c) Appropriatemeasureinthepipelineduetodecompositionofunstablefluidswhereexist.Operator

shallhavethoroughknowledgeofsuchfluidsandoperatethevalveasperestablisheddocumentedinstructions.

d) Pressurereliefvalve,whereunexpectedincreaseinpressure,waterhammerisanticipatedandallowablepressurelimitcanbeexceeded.

e) Valvesarenotprovidedwithfillingordischarge.Suchprovisionswhererequired,shallbeprovidedinthepipeline.

6.2 VALVEINSTALLATION1. Installthevalvewithwedgeintheclosedposition.2. Supportthevalveandadjacentpipelines,suchthatpipelinethrustandtorsionalforcesarenot

transmittedtothevalve.

A. FLANGEDVALVES1. Cleantheflangefacestoensurethatitisfreefromdamage.2. Thegasketsonthematingflangesareproperlycentered.Onlyfastenersandgasketsofapproved

materialsshallbeused.Placethevalvebetweenthetwoflangesofthepipeandputthegasketbetweenthevalveflangesandthepipeflange.Makesurethatitiscorrectlypositioned.Tightentheflangeboltsprogressivelyandcrosswise.Usetorquewrenchtotightentotherequestedtorquespecifiedbythespecification.Ensurethattheflangesarestraightandalignedtothepipe.

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GATEVALVE



Nominalboltsize(inch)

Torque(Nm)

Nominalboltsize(inch) Torque(Nm)

1/2" 80 13/8" 17805/8" 160 11/2" 23003/4" 275 15/8" 30007/8" 440 13/4" 37001" 650 17/8" 4700

11/8" 950 2" 570011/4" 1300

2. ValveTorqueandMountingofactuator

Thevalvetorquedependsuponmanyparameterslikesize,class,maximumoperatingpressure,frequencyofoperation,fluiddetails,viscosityandflowvelocity.Pleasecontactcamtech,whoselectstheoptimumsizeofactuatorandsupplyofmountingplatesforfieldconversion.

8.1 PREVENTIVEMAINTENANCEAllvalvecomponentshavebeendesignedtobelargelymaintenancefree.Thematerialofthemovingpartshasbeenselectedforminimumwear.Howevermalfunctioncausedbywrongoperation,lackofmaintenanceorimproperusereducesvalvelife.Allrepairandmaintenanceworkshallbeperformedbyqualifiedpersonnelfollowingallsafetyinstructions.Maintenanceintervalsshouldbeselectedbythevalveuserincompliancewiththeapplicationcondition.

9.0 TROUBLESHOOTINGTROUBLE POSSIBLECAUSE HOWTOELIMINATE

Nofluidflow

Endflangecoversnotremoved.

Valveinclosedposition.Pipelineupstreamof

valveisblocked.

Openthevalve.Cleanthevalve.

Cleanorreplacestrainer/otherblockingequipment.

Inspectthepipeline

FlowRatenotsufficientValveisnotfullopen.Sedimentsinsidethe

valve.Dirtystrainer.

Openthevalve.Cleanthevalve.

Cleanorreplacestrainer/otherblockingequipment.

Inspectthepipeline.


GATEVALVE



Valveisleaking

Valveisnotfirmlyclosed.Excessivedifferential

pressure.Seatandwedgeseatfaces

damages.Excessiveloadfromthe

pipeline.

Closethevalve.Checkthesystem.

Remachine/lapseatfaces.

Valvecannotbeoperatedoritisdifficulttoopen/close

Operatingconditionmightbeoutsidethespecification.

Bentshaftorthreadsdamaged

Valvecavityclogged.

Checktheline/Valve.

Checkandreplaceworn/bentparts.

10.0 VALVEDISASSEMBLYANDASSEMBLY

VALVEDISASSEMBLYFollowthefollowingstepstodisassemblethevalve.A. BONNETASSEMBLY

1.Loosenandremovestud(16,17)2.Liftthebonnetassembly(02)fromthebody3.Removethebonnetgasket(15)

B.WEDGE(03)1.Removethewedgefromthestem(06)

C.STEM1.Removethehandwheelnut(09)bylooseninginanticlockwisedirections2.Removethehandwheel(10)fromthestemnut(07)3.Removethestemnutretainernut(08)fromthebonnet4.Removethestemnutfromstembyturningclockwisedirection5.Loosentheglandnut(19)andpullthestemfromdownsideandremoveit.

VALVEASSEMBLYFollowreversesequenceofdisassemblyandassemblethevalve

11.0 GREASESANDSPECIALTOOLSThefollowinggreasesorequivalentothermakecanbeusedforbearing/stem/nut/gearboxes/stemBEACON2ESSO,MOBILELUXEP2MOBL,ALVANIAR2SUPERGREASESHELL,MULTIFAKEP2GREASE,TEXACOSPECIALTOOLNoSpecialtoolisrequiredforthemaintenance.

12. RECOMMENDEDSPARES

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GATEVALVE



thesurfacetemperatureduetooperatingfluidispotentialsourceofexplosion,provideinsulation/otherappropriatemeasures.

2.0 ProjectedstemEnsurethattheprojectedstemdonottouchanypipingorotherpartthatcancreatespark.

3.0 BearinglubricationBearingsareslowmovingpartsanddonotrequirelubrication.Howeverlubricationisprovidedforsmoothoperation.

4.0 DustdepositRemovedustatregularintervalsforexplosiveatmosphere.Ensurethatdustisnotpresentinthegapsandoutsidesurfacestoexcludethepossibilityofexplosion.Ensurethatthesurroundingsarecleanandnoexternalpartfallonthesurface.

5.0Valvesarenotprovidedwithanyopeningorenclosureforexplosionprevention.

gate valve - installation, operation & mantainance manual

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