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Yoneki Gate Valve

gate valve

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phuong
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586 views16 pages

Yoneki Gate Valve

gate valve

Uploaded by

phuong
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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: w-1_| Rev.o INSTRUCTION MANUAL FOR INSTALLATION /MAINTENANCE OF VALVES (BOLTED BONNET /COVER) YONEKI VALVE CO., LTD. Sheet 1 of 15 HANDLING /INSTALLING, MANUAL PRECAUTIONS IN HANDLING AND INSTALLING 1, Transport, unpack and store carefully not to scratch the surfaces of flanges or gaskets and not to allow inclusion of hazardous matters into the valves. (Blind plates or plastic caps should not be removed until the piping installation.) Prior to the installation, confirm that there is no scratch on the surfaces of flange and stem, and clean insides of the valve with dry cloth. Especially, as the seat surfaces are the most. important portion for obtaining the effective valve function, special atten~ tion should'be paid so as not to scratch and/or damage these sur~ faces. 2. When moving the valves after unpacked, confirm that the valve is in a completely closed position, If the valve is in an open position, the disc may move and the surface of the seat may be damaged or some foreign matters may enter the valve and further, an unexpected accident may occur by the rotation of handwheel. 3. When installing, confirm the marking (Ratings, Sizes, and Materials) of the valves and the nameplate located at the top of handvheel in order to avoid a mistake. 1) The directions of installing the gate valve are normally free. However, install the valves carefully according to the flow direction arrow, when the disc is provided with pressure balance holes to prevent abnormal pressure increase. 2) As the flow direction of fluid of the check valve and the globe valve is fixed, installation shall be made according to an arrow showing the flow direction. 4. The weld~end type valve shall be welded and heat treated at slight~ ly opened position, where the disc contacts slightly the seat. Further, for local annealing, cease the heating within the required range and be careful not to over-heat the seat portion, Also welding slags and spatters are to be completely removed and cleand, because the majority of leakage on the valve seat is caused by the seat portions damaged by weld spatters, galling of the welding slags and sinter. ‘ For our gate valves with flexible wedge type discs, the discs are provied to maintain complete contact with the seat surface, even if the valve body is deformed due to the flow pressure, thermal expan— sion or other stresses, If closing the valve too tight, the disc nay be deformed and damaged, or is subjected to abnormal pressure increase inside the valve body, which may cause a difficulty in opening the valve and an unexpected accident. Do not use haker or Sheet 2 of 15 10. i, 12. 13. other equipment which may increase the torque when closing the valve. Further, stopper is provided at the top of the stem in order to prevent excessively closing. Do not adjust this stopper unless the valve is completely closed due to the worn disc, etc. When closing the globe valve, larger torque than closing the gate valve is required. However, do not tighten excessively by the extention lever, ete. ‘The gate valve should be used in fully opened or completely closed position. If it is used in slight or half-opened position, the disc may vibfate ata high speed flow, which may cause pulsation of the flow, Therefore, do not apply the gate valve for the flow control. Also it is preferable to use the globe valve in fully opened or completely closed position, but to some extent, the flow control is possible. However, if it is used in slightly opened position when the differencial pressure is large, a high speed flow may erode the seat portion . When the valve is to be used for the flow control, it is better to employ the needle disc type valve which corresponds to the conditions. All of our valves close by turming the handvheel clockwise, and open by turning counterclockwise. In case the valve can not be closed completely due to scale, etc., open the valve and close it again after blowing out the obstacles. If the valve is left with the disc tightly shut or left fully opened and bound to the back-seat, opening or closing will become difficult and will cause an unexpected accident. Especially for the gate valve, backlash in the handwheel (about a half turn) after closing the disc. It is necessary to re-tighten the gland packings properly because these packings will shrink at early stages when they contact the fluid. If there is a leakage, re-tighten the eye-bolts and nuts promptly or re-tighten the packings while the inside pressure is low. TE the gland packings is required to be retightened while the fluid is flowing, firstly open the valve fully until the disc tightly contacts the back-seat. Then, rapidly re-tighten the gland pack- ings. Sheet 3 of 15 14, 15. It is preferable to lubricate the thread ‘portions of the stem, the rotating portions such as bearings, etc., periodically. When gland packings are required to be replaced, refer "Instructions for Replacenent of Gland Packing" (W-1~130). and to Sheet 4 of 15 (w- 1 - 130) INSTRUCTION FOR REPLACEMENT OF GLAND PACKINGS 1, SCOPE OF APPLICATION 1-1 This covers the replacing procedure of the gland packings. 2. REPLACING PROCEDURE 2-1 Prior to replacing gland packings, ensure, for the sake of safety, that the pressure is completely removed from the inside of the valve. The packing tool as shown in the figure or commercially available is required to remove the packings from the stuf- fing box. 200mm a 5 Material : 3045.5. a) Loosen the eye-bolt & nut gradually to remove them. b) Pushing the gland flenge upward, remove the eye-bolt from the gland flange. c) Pushing the gland and the gland flange upward, fix them with wire, etc. 4) Remove the used gland packings by the packing tool. (Refer to Fig. 1.) e) After removing the used gland packings, clean the inside of the stuffing box. £) Insert nev gland packings. (Refer to Fig. 2.) The sections of the packings should be 180° apart each other. g) Pass the eye-bolt through the gland flange and tighten the nut evenly. Sheet $ of 15 oe 2. DISASSEMBLING /ASSEMBLING MANUAL, BOLTED BONNET /COVER TYPE VALVES. When disassembling the valve for checking the seat portions, proceed according to the following procedure after confirming that no pressure is remaining inside the valve body, Further, the spare parts such as gaskets, gland packings, etc., and chain block for hoisting a valve (Zor large valves) should be prepared. The valve should be reassembled by the reverse procedure. “A. DISASSEMBLY (1) The valve shall be opened to an intermediate position. Take off the nuts of eye-bolts, lift up the gland and gland flange and remove the gland packings. (2) Loosen and remove the bonnet bolts, At this stage, loosen each nut and its counterpart alternately. (3) When it is difficult to remove the gaskets due to their adhe- rence, separate the body and the bonnet with care so as not to damage the gasket contact. surfaces. (4) Take care not to drop the disc of the gate valve hecause it is only inserted. (5) The disc of the globe valve can be removed by twisting from the disc stem ring after cutting off the spot-welded portion by a chisel or grinder. (6) For the check valve, remove the cover in accordance with the above clauses (2) and (3), take out the plug, lift and support the disc, and then remove the hinge pins. In this case, the hinge pins can be easily removed by inserting the bolts into the female threads located at the edge of the hinge pins. Next, as the disc is fixed to the hinges by the nuts, take out the ‘cotter pin and loosen the nuts, and then the disc can be easily separated from the hinges. (7) When disassembling the stems, first separate the gland packing portions, bodies and bonnets. In this case, if the stopper is provided at the top portion of the stem of the gate valve, renove the stopper (Its position should be marked.) and rotate the handvheel to the opening direction, and then the stem can be taken out. And for the glove valve, loosen the wheel-nute, remove the handvheel, and then take out the stem by rotating it clockwise. Be careful not to damage the stem surface and the thread portions in all cases. Sheet 6 of 15 (8) Unscrew the yoke bolt nuts to remove the gear unit from the yoke (for the gear operated valve). (9) In case of taking the stem out of the bonnet, pull out a pin fron the stopper and turn either the stem or the handwheel to the valve-closing direction. (for the non-rising handwheel globe valve) INSPECTION OF PARTS All the parts should be inspected thoroughly, paying special attention to the followings. (1) Whether the seat surfaces of both the body and the disc are damaged ‘or not. (2) Elasticity of the gland packings due to fatigue (for the gate and the globe valves) (3) Whether the stem surface sliding on the gland packing is damaged or not. (for the gate and the globe valves) (4) Whether the gasket and its surface are damaged or not. (5) Whether the back seat is damaged or not. (for the gate and the globe valves) (6) Whether the connecting section between the disc and the swing lever is sound or not. (for the swing check valve) (7) Whether the sliding sections of both hinge pin and swing lever is sound or not. (for the swing check valve) (8) Whether the body or the swing lever is blocked with scale or not, since it prevents the smooth movement of the swing lever. (for the swing check valve) (9) Whether the seat surfaces of the body and the disc (including the soft seat ring) are damaged or not. (for the soft seat valve) (10) Whether the cavity around the lantern ring is filled with the the silicone grease or not, (for the vacuum service valve) REPAIR (1) Glean cach assembling area thoroughly. (2) Replace the gaskets with new ones. (3) Coat the threads of bolts and nuts with the seizure-free compound such as the graphite compound, Sheet 7 of 15 (4) When the seat surface is required to be lapped, refer to "Lapping Method of Valve Seat Portions". ASSEMBLING Assembling can be generally performed in the reverse order of disassembling, paying attention to the followings. (1) Prior to assembling, clean the inside of the valve thoroughly and also check to see that there is no remnant inside. (2) A damage on the seat surface and the mixing of foreign matters into the body should be avoided. (3) The bolts should be tightened alternately and diagonally so that the gasket is tightened equally. (4) In case of installing the gland packings, refer to "Replacement Method and Adjusting of Gland Packing". (5) The eye-bolts should be tightened one after another in order to tighten equally. (6) It is preferable to use new gland packings as much as possi- ble. They should be tightened sufficiently and tightened further after the flow of fluid. (2) In installing the 1ift stopper, open the valve fully at first and set the lift stopper so that it contacts slightly the upper part of the yoke sleeve. (8) On the completion of assembling, lubricate the threads of the stem and the sliding area of the yoke and the bearings. (9) When the tack welded part is separated, restore the welding to the former condition. (10) When the handwheel of the gear operated valve is required to be changed in its direction, refer to "Change of Handwheel Direction". (11) In case of the grease injector, lubricate with grease complying with the service using a grease gun. Sheet 8 of 15 3. LAPPING METHOD OF VALVE SEAT PORTIONS PROVIDED MATERIALS (1) Lapping compound (Carborundum): Grain size : 400-600 mesh ~ for rough finishing 800-1,200 mesh ~ for fine finishing Carborundum system materials are adequate for the stellited surface. (2) The surface -plate should be of homogeneous cast iron having approximately IIB-250 hardness. It is strictly prohibited to use a surface plate having blow holes because they will damage the lapping surface. (3) Tools and consumables: Surfac plate, machine oil, file, scraper, minium, waste cloth and other necessary jigs LAPPING WORK There are two ways of performing the lapping work. One is to execute the work after disassembling the valve from the pipeline and the other as leaving the valve on the pipeline. As the former method provides a sound lapping within a short time, while the latter method takes much time with uncertain finish, it is preferable to disassemble the valve from the pipeline whenever possible. LAPPING AFTER REMOVING THE VALVE BODY FROM THE PIPELINE. (1) For the gate and the check valve, make the center line of the port perpendicular, then set the seat in the horizontal position by inserting and adjusting the wooden pads between the flange surface and the working table. (2) Clean around the seat portion thoroughly and be careful not to adhere any dust or substance to the lapping suface in order to avoid sintering. (3) Apply a proper quantity of lapping compound to the surface plate. (4) Observe the dryness of the compound, Ocassionally take out the surface plate, wipe out the old compound and replace with the Sheet 9 of 15 4 G) (6) a (8) (9) (10) When lapping manually, the worker should rotate the valve body, and at the same time, rotate the surace plate both clockwise and counterclockwise. An adequate pressure of about lig/em? should be applied to the lapping surface. However, the pressure should be adjusted according to the progress of the work, When lapping by machine, rotate the lapping surface plate as slow as possible. 60 to 80 RPM is adequate for a 8" (200n/m) valve, In this case, the lapping surface should be maintained ina correct position. Check the surface plate occasionally to ensure the exact plane surface. The maintenance frequency should be increased accor— ding to the progress of the lapping work. If there are some local scratches on the lapping surface made by galling, it is necessary to incredse the quantity of compound. For the final mirror finishing, apply a very small quantity of compound and lap until it dries. Do not press heavily or lap too long, otherwise it may cause sintering. After the completion of work, apply minium thinly to the new surface plate and inspect the finished surface. LAPPING WORK AS LEAVING THE VALVE ON THE PIPELINE qa) (2) The lapping work should be performed with special jigs, preferably by machine. The lapping procedure is the same as that for the lapping after removing the valve from the pipeline, but the rotation speed should be a little slower. LAPPING OF DISCS a @) Prior to the real lapping work, lap off the damaged convex to about rough finishing grade. Then, lightly strike the disc into the valve body and check whether the inclined surface is fitted to the seat surface. When the inclined surface becomes well fitted to the seat surface, proceed to the finishing, If not fitted, lightly lap off the convex of the disc by a pencil grinder, etc. If it is only a slight convex, it can be lapped using the compound according to the normal procedure. Sheet, 10 of 15 (3) (4) (5) (6) Set the lapping surface to a horizontal position using pads, and secure it so as not to move during the vork. ‘The lapping procedure is the same as that for lapping the seat. After che completion of lapping, thinly apply minium to the lapped surface of the disc or the seat, then lightly hit the disc into between the seats, Check the disc seat and the valve body seat contact completely. After the lapping work, clean the lapped surfaces of the disc and the seat with petroleum or kerosene, and wipe it off with cloth or soft paper. Sheet 11 of 15 6. LAPPING WORK WHEN THE VALVE IS REMOVED FROM THE PIPELINE If necessary, the seat surface should be lapped as shown in the following figures Lapping Blook FOR GATE VALVE eee | eel Jopine Back [ce fo F Gi a FOR GLOBE VALVE FOR CHECK VALVE Sheet 12 of 15 4, REPLACING /ADJUSTING METHOD OF GLAND PACKINGS. REMOVAL OF USED PACKINGS After disassembling the stem and the relevant parts, the used packings should be removed. Ef the surrounding situation does not allow the stem to be pulled out, the packing tool (shown in Fig. 1) is effective. PROCEDURE BEFORE INSTALLATION OF PAKCINGS ‘The internal surface of the stuffing box (packing box), the stem and the gland should be cleaned thoroughly and carefully. ‘Then, the threads of the gland bolts (eye-bolts) should be examined and the seizure-free con~ pound such as graphite compound shuold be coated on it. PACKINGS (a) New packings should be used and these size and quality should be well complied with the specifi- cation. (b) It is recommendable to use the formed packings. In case of using the rod packing , cut it into @ proper size and shape with a sharp knife as shown in Fig. 2 and 3. INSTALLATION OF PACKINGS (a) Open the packing while twisting fone end when it is installed as shown in Fig. 4. (b) Install the packings firmly and carefully one by one into the stuffing box with equal clear~ ance against the stem. Compress the packing one by one with the gland through a two-piece wooden bushing as shown in Fig. 5. Sheet 13 of 15 Better Not better Fig 3 (c) Insert the packing with the cut ends of the packings alternating each other at right angle as shovn in Fig. 6. (a) In case the lantern ring is used, attention should be given not to block up the plug hole as shown in Fig. 7 (4), (e) and «@). Fig 6 (e) After the completion of instal~ ling the packings, the gland should be clamped alternately. (£) After inserting the packings, tighten the glands. In order to prevent uneven tightening, ‘the bolts should be alternately tightened. Firstly, tighten them sufficiently to settle the packings into the stuffing box, loosen once, then retighten manually. Finally tighten with a wrench for approximately 1/4 revolution. There will be some leak at the initial stage of operation after the packings are changed, but this is quite normal. Leave then as they are for a certain period and gradually tighten and adjust. It is important to make the packings adapt to che surfaces. Be careful because if tightened strongly at first, it may cause thermal expansion and sintering of the rubbing portions. (g) Typical compressing way of packings is shown in Fig. 7 (a) to (£). SESE EE oe o ro} w& we wns Fig. 7 Sheet 14 of 15 5. CHANGE OF HANDWHEEL DIRECTION oF GEAR UNIT (1) All the threads on this valve except for the stem are right- (2) At first, open the valve sligh~ tly. etter Bi (3) Remove the stem cover. (4) Remove the indicator, bolt and nut. ao Lt (5) Remove the cotter pin and lift i i stopper. ok pole (6) Remove the yoke bolt nuts and fesnint- spring washers (the yoke bolts 1 are not required to be removed.) (7) Lift the gear until the yoke bolts are pulled out of the cH tom Cover yoke's bolt holes by turning the A eh ndwheel clockwise. Csdiceter Piste, handvheel clockwise. Jadtenter Ps Sten Wut Bevel Goar Unt: (8) Turn the gear unit to the op- L42} tional position (The position of the. gear unti can be changed at [FS intervals of 45°). (9) Lower the gear until its Lover aoka matau\ f surface contacts the yoke's flan~ yoke ma = ke ge surface by turning the hand wheel clockwise while the gear unit is kept from rotating. (10) Set the spring washers and fasten the yoke bolt nuts symmetrically. (11) Install the lift stopper, indi- ( I cator plate, stem cover, etc. The lift stopper and indicator plate + shall be installed in the same place as before the position of c H D the gear unit is changed. Shoet 15 of 18

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