Installation and Maintenance Instructions VANESSA Vanessa ... docs/Pentair Valves and...
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VANESSA Vanessa Series 30,000 Installation and Maintenance Instructions Pentair reserves the right to change the content without notice VANLT-0006-US-1305 Installation and Maintenance Instructions Vanessa Series 30,000 - Basic Configuration Body Style Double Flanged, Wafer, Lug and Buttweld Applicable Product Range • Series 30,000 Basic Configuration, Double Flanged Body Style, which can be installed between two flanges or stud-bolted to either flange. • Series 30,000 Basic Configuration, Lug-Single Flange Body Style, which must be bolted to either flange. • Series 30,000 Basic Configuration, Wafer Body Style, which can be installed between two flanges. • Series 30,000 Basic Configuration, Buttweld ends, which must be welded to the line. SECTION 1 Valve Storage 1.1 Preparation and Preservation for Shipment All valves are properly packed in order to protect the parts that are subject to deterioration during transportation and storage on site. In particular, the following precautions should be taken: 1 The valves must be packed with the disc in the closed position. The flange sealing surfaces (raised faces) of the valves will be protected with suitable protective grease. The end faces of the valve must be protected with plastic or wooden discs fixed with straps. 2 Bare Shaft Valves: the ends of the shaft must be protected with plastic tubes. 3 Valves with Actuators: in case of “Fail open” pneumatic - hydraulic actuators with manual override, the manual override shall be used to manually close the valves and to lock them in position. If there is no manual override, cut outs are made in the flange protectors for the disc, and the disc is securely protected. All actuated valves must be securely palleted or crated with particular attention, in order to ensure that parts of actuator (especially pneumatic piping or accessories) do not extend beyond the skid/crate. 4 The type of packing must be defined in the Customer’s Order and will be appropriate to ensure safe transportation to final destination and eventual conservation before installation. 1.2 Handling Requirements A - Packed Valves Crates: Lifting and handling of the packed valves in crates will be carried out by a fork lift truck, by means of the appropriate fork hitches. Cases: The lifting of packed valves in cases will be carried out in the lifting points and in the center of gravity position which have been marked. The transportation of all packed material must be carried out safely and following the local safety regulations. B - Unpacked valves 1 The lifting and the handling of these valves has to be carried out by using appropriate means and by respecting the carrying limits. The handling must be carried out on pallets, protecting the machined surfaces to avoid any damage. 2 With large dimension valves, the sling and the hooking of the load must be carried out by using the appropriate tools (brackets, hook, fasteners, ropes) and load balancing tools in order to prevent them from falling or moving during the lifting and handling. www.pentair.com/valves
Transcript of Installation and Maintenance Instructions VANESSA Vanessa ... docs/Pentair Valves and...
VANESSA
Vanessa Series 30,000Installation and Maintenance Instructions
Pentair reserves the right to change the content without notice VANLT-0006-US-1305
Installation and Maintenance InstructionsVanessa Series 30,000 - Basic ConfigurationBody Style Double Flanged, Wafer, Lug and Buttweld
Applicable Product Range• Series30,000BasicConfiguration,DoubleFlangedBodyStyle,whichcanbeinstalledbetweentwoflangesorstud-boltedtoeitherflange.
• Series30,000BasicConfiguration,Lug-SingleFlangeBodyStyle,whichmustbeboltedtoeitherflange.
• Series30,000BasicConfiguration,WaferBodyStyle,whichcanbeinstalledbetweentwoflanges.
• Series30,000BasicConfiguration,Buttweldends,whichmustbeweldedtotheline.
SECTION 1Valve Storage
1.1 Preparation and Preservation for Shipment
Allvalvesareproperlypackedinordertoprotectthepartsthataresubjecttodeteriorationduringtransportationandstorageonsite.Inparticular,thefollowingprecautionsshouldbetaken:
1 Thevalvesmustbepackedwiththediscintheclosedposition.Theflangesealingsurfaces(raisedfaces)ofthevalveswillbeprotectedwithsuitableprotectivegrease.Theendfacesofthevalvemustbeprotectedwithplasticorwoodendiscsfixedwithstraps.
2 BareShaftValves:theendsoftheshaftmustbeprotectedwithplastictubes.
3 ValveswithActuators:incaseof“Failopen”pneumatic-hydraulicactuatorswithmanualoverride,themanualoverrideshallbeusedtomanuallyclosethevalvesandtolocktheminposition.Ifthereisnomanualoverride,cutoutsaremadeintheflangeprotectorsforthedisc,andthediscissecurelyprotected.
Allactuatedvalvesmustbesecurelypalletedorcratedwithparticularattention,inordertoensurethatpartsofactuator(especiallypneumaticpipingoraccessories)donotextendbeyondtheskid/crate.
4 ThetypeofpackingmustbedefinedintheCustomer’sOrderandwillbeappropriatetoensuresafetransportationtofinaldestinationandeventualconservationbeforeinstallation.
1.2 Handling Requirements
A-PackedValvesCrates:Liftingandhandlingofthepackedvalvesincrateswillbecarriedoutbyaforklifttruck,
bymeansoftheappropriateforkhitches.
Cases:Theliftingofpackedvalvesincaseswillbecarriedoutintheliftingpointsandinthecenterofgravitypositionwhichhavebeenmarked.Thetransportationofallpackedmaterialmustbecarriedoutsafelyandfollowingthelocalsafetyregulations.
B-Unpackedvalves1 Theliftingandthehandlingofthesevalveshastobecarriedoutbyusingappropriatemeansandbyrespectingthecarryinglimits.Thehandlingmustbecarriedoutonpallets,protectingthemachinedsurfacestoavoidanydamage.
2 Withlargedimensionvalves,theslingandthehookingoftheloadmustbecarriedoutbyusingtheappropriatetools(brackets,hook,fasteners,ropes)andloadbalancingtoolsinordertopreventthemfromfallingormovingduringtheliftingandhandling.
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Vanessa Series 30,000Installation and Maintenance Instructions
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1.3 Storage and Preservation before Installation
Incasethevalveshavetobestoredbeforeinstallation,thestoragehastobecarriedoutinacontrolledway,andhastobeperformedinaccordancetothefollowingcriteria:
1 Thevalveshavetobestockedinaclosed,cleananddrystorageroom.
2 Thediscmustbeintheclosedposition,andtheendfacesmustbeprotectedwithplasticorwoodendiscsfixedwithstraps.Ifpossible,keeptheoriginalprotection.
3 Periodicalcheckshavetobecarriedoutinthestorageareatoverifythattheabovementionedconditionsaremaintained.
NoteStorageinanopenareaforalimitedperiodcanbeconsideredonlyincasethevalveshaveappropriatepacking(packedincaseslinedwithtarredpaper,andcontentswellprotectedwithbarriersacks).
CautionFor valve handling and/or lifting, the lifting equipment (fasteners, hooks, etc.) must be sized and selected while taking into account the valve weight indicated in the packing list and/or delivery note.Lifting and handling must be made only by qualified personnel.
Fasteners must be protected by plastic covers in sharp corner areas.
Caution must be taken during the handling to avoid that this equipment passes over the workers or over any other place where a possible fall could cause damage. In any case, the local safety regulations must be respected.
Figure no. 1a
Figure no. 1b
Lifting and Handling of Valves Installed in Horizontal Pipeline
Lifting and Handling of Valves Installed in Vertical Pipeline
Note
SolutionsAandCareapplicablewhentheprotrusionofthebottomhubfromtheflangeorbodyissufficienttopositionsecurelytheliftingstrap.SolutionsBandDareapplicablewhentheprotrusionofthebottomhubfromtheflangesisNOTsufficienttopositionsecurelytheliftingstrap.InpresenceofsolutionB,insertastudboltandfixitsecurelywithnutsasindicatedinthedrawingdetail.InpresenceofsolutionD,insertaliftingeyeletintheflangethreadedholesclosetothebottomhubandfixitsecurelyasindicatedinthedrawingdetail.
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SECTION 2Installation
2.1 Valve Inspection1 Carefullyremovethevalvefromtheshippingpackage(boxorpallet)avoidinganydamageto
thevalveor,incaseofautomatedvalves,totheelectricorpneumatic/hydraulicactuatororinstrumentation.
2 Thevalvesareshippedwiththeendsprotectedwithcapsandathinlayerofprotectivegrease.Beforeinstallingthevalve,removethecapsandcleancarefully,thende-greasebothsurfaceswithasolvent.Cleantheinsideofthevalveusinganairline.Ensurethattherearenosolidobjectssuchaspiecesofwood,plasticorpackingmaterialswithinthevalveoronthevalveseat.
3 Inspectthesealringtoensurethatitwasnotdamagedduringhandling.Thisisespeciallyimportantincaseofvalvesshippedwiththediscintheopenpositionandwith“fail-open”actuators.
4 Confirmthatthematerialsofconstructionlistedonthevalvenameplateareappropriatefortheserviceintendedandareasspecified.
5 Ensurethatthepackingglandadjustingnutsagainstthepackingglandflangecannotberotatedbyhand.
2.2 Valve InstallationVanessarecommendsthattheoptimumvalveinstallationiswiththeshaftinthehorizontalplane,afterwhichitispreferabletohavetheshaftatananglesoastominimizeanyproblemassociatedwithsolidparticlespresentinthefluidthatotherwisecoulddepositinthelowerbearingarea.
NoteTheVanessavalveisdesignedtowithstanddesigndifferentialpressureinbothdirections.
Isolating applicationsThevalveoperatingtorqueaffectsthesealingperformances.VanessaattachedtheindicationplateΔP(figure2)ontheupstreamflangeasareferenceforthedirectionoftheinstallation.Thebestsealingperformance,alsoforbi-directionalservice,willbemaintainedwhenpressureactsontheshaftsideofthevalve,whichisrecommendedwhentheservicetightnessrequirementsaremorestringentinonespecificdirection.
Control applications (uni-directional, where perfect sealing is not required)Theplatecouldbefixedoneitherflangeindicatingthepreferreddirection.Pleaserespectthedirectionofinstallationindicatedontherelevantflange.Theselectionoftheactuatorhasbeenmadeforthatspecificdirectionofinstallation.
UnlessotherwiserecommendedbyVanessa,thevalveshouldbeinstalledwiththediscintheclosedpositiontoensurethatthesealringinthediscisnotdamagedduringinstallation.Particularcareshouldbetakenwiththosevalvesequippedwith‘fail-open’actuators.Foroperatingtemperaturesabove200°C(392°F)thermalinsulationofthevalvebodyisrecommended.Ifthevalvehasthreadedtappedholesinthehubareas,Vanessarecommendstousehexagonalheadboltsorshorterstudstoconnectthevalveinthiszone.ThedepthofthetappedholesinthebodiesofallSeries30,000valvesisspecifiedinthetechnicalliterature.Failuretousecorrectbolts/studsmayresultindamagetothevalve.Ifthevalvehasweldedends,perfectlycleananddegreasetheendstobewelded(ofbothvalveandpipe),usingaclothwithacetoneorsimilarproduct.Insertcorrectlythevalvebetweentheedgesofthepipetobewelded,takingcareoftheplatethatindicatesthepreferentialsideforsealing.Carryoutaninitialaccuratespotweldingverifyingtheperfectalignmentoftheedgeandaxisofthevalve.Carryouttheweldingoftheedgeproceedinginalternatewayonbothsidestoreducethetensionsintroducedbythewelding.Itisimportanttorespecttheinterpasstemperaturewhichmustnotgoabove150°C (302°F).HandlingandliftingofthevalvesduringinstallationMUSTbeperformedfollowingthesamecriteriaandinstructionsdescribedinpreviouspoints“1.2HandlingRequirements”and“1.3StorageandPreservationbeforeInstallation”.
Important
Itisrecommendedtoperformpipingflushingbeforeinstallationofvalve.Ifthisisnotpossible,thevalvesmustbesetwiththediscinfullopenpositionbeforestartingwithflushing.
CautionsWhen the pipe is lined, be careful that the disc does not come into contact with the lining during its stroke, especially in Lug and Wafer body styles. This verification is very important to avoid any damage to the valve.
Figure 2
Important
Thevalvetrimisdesignedtowithstandandtosealagainstthedesigndifferentialpressuremarkedonthevalvenameplatewhichdataaresuppliedtogetherwiththepresentdocument.Sinceitisimpossibletomaintaincompletecontrolontheexternalinputforcestothetrimcomingfromgear/actuator,thevalvetrimshallnotbeusedasafinalprotectivemeanagainstthehazardcausedbytheclosedvalveupstreampressure.
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2.3 Valve Verification1 Tightenthepackingjustenoughtopreventstemleakage.Over-tighteningwilldecreasepackinglife
andincreaseoperatingtorque.2 Checktheoperationofthevalvebystrokingitto“fullopen”and“fullclose”.Toverifythevalve
orientation,thediscpositionindicatormarkontheshaft(duringthenormalopentoclosecycle)shouldrotateclockwisefromapositioninlinewiththepipe(seefigure3a)toapositionparalleltothepipeflanges(seefigure3b).
Important
Ifpipingsystemispressurizedwithwaterfortesting,andincasethepipingsystemhasbeenshutdownaftertestingforalongtime,thefollowingrecommendationsshouldbeadopted:
a.Usecorrosioninhibitorwithwatertopressurizethepipingsystem.b.Aftertesting,thepipingsystemshouldbedepressurizedandthetestwatercompletely drained.c.Aftertesting,valvesmustbemaneuveredthroughacompleteopening/closingcycle anddiscleftinhalf-openposition.Applyafilmofprotectiveoilinthepackingareaby meansofapaintbrush.Theprotectiveoilmustfilltheareabetweenshaftand packingbushing.
Figure no. 3A
Figure no. 3B
Clockwisetoclos
e
Clockwisetoclos
e
Shaftkey
Discinopenposi
tion
Discinclosedpo
sition
Discposition
indicatormark
Disc-shaftkeya
nd
positionindicator
markplane
Disc-shaftkeya
nd
positionindicator
markplane
Discposition
indicatormark
Shaftkey
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2.4 Troubleshooting Guide
Symptom Possible Cause Resolution
Valvewon’trotate 1. Packingistootight 1. Loosenglandnuts 2.Actuatorhasfailed 2.Replaceorrepair 3.Valvepackedwithdebris 3.Flushorcleanvalvetoremovedebris 4.Stemkeyhassheared 4.Determinecauseofshearingandcorrectlyreplacestemkey 5.Fluidsolidificationbetweenbearings 5.Flushbearingsbyflushingholes(ifpresent) andshaft
Stempackingleaking 1. Glandflangenutstooloose 1. Tightenglandflangenuts 2.Packingdamaged 2 Replacepacking-SeeParagraph3.1
Bottomflangegasketleaking 1. Bottomflangeboltingloose 1. Tightenbottomflangebolting 2.Spiralwoundgasketdamage 2.Replacegasket-SeeParagraph3.3
Valveleaking 1. Valvenotfullyclosed 1. Closevalve 2.Debristrappedinvalve 2.Cycleandflush(withvalveopen)toremovedebris 3.Actuatormechanicalstopsimproperlyset 3.Removethestopforclosureandresetproperly 4.Sealringdamaged 4.Replacesealring-SeeParagraph3.2
Jerkyoperation 1. Packingistootight 1. Loosenglandnuts,cyclevalve,retighten 2.Airsupplyinadequate 2.Increaseairsupplypressureand/orvolume 3.Actuator/stemadaptermisaligned 3.Removeactuatormountingandrealign.
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Warning!
Depressurizethelinebeforestartinganymaintenance.Failuretodosomaycauseseriouspersonalinjuryand/orequipmentdamage.
SECTION 3Maintenance
TheVanessaSeries30,000hasbeendesignedtorequireaminimumofmaintenance.
3.1 Packing MaintenanceIfshaftleakageisobservedthroughthepacking,tightentheglandnutsslowlyandevenlyuntiltheleakagestops.
CautionDo not over-tighten packing gland nuts. Over-tightening will increase the torque required to operate the valve.When tightening the gland nut, use half-turn increments until leakage has stopped.
PleaserefertotheFigureno.4.Toreplacethepackingproceedasfollows:1 Removethegear/actuatorandrelevantconnectingkeys(4f).Pleasenotetheactuatorposition
relativetothevalvepositionforreassemblyofgear/actuatorlater.2 Removeglandnuts(5d).Ifpresent,removebellevilIesprings(5n),takingcareofnotingtheir
assemblyconfigurationtoreassemblethemcorrectly(point7).3 Removepackingglandflange(5f),antiblow-outringifpresent(5g),andglandbushing(5c).4 Removepacking(5a).Ifvalveiswithpackingflushoption,removelanternringalso(5h).5 Carefullycleanpackingcavityandshaft(4a).6 Applyathinfilmoflubricantoneachnewpackingring(5a)surfaces(lubricantshouldbein
accordancewithTableIV).Insertnewpackingrings,payingattentiontoinsertthetwobraidedringsatthebottomandtopoftheentirepacking.Ifvalveiswithpackingflushoption,insertthelanternring(5h)inthesamesequenceaspreviouslyremoved(orasindicatedinfigure4).Ifthepackingringsareofthesplitvariety,installwithsplitsstaggeredat180°fromeachother.
7 Reassembleglandbushing(5c),antiblow-outringifpresent(5g),andglandflange(5f).Ifpresent,assemblethebellevillesprings(5n),followingtheassemblyconfigurationnotedinthepreviouspoint2,thenassemblebyhandtheglandnuts(5d)withouttightening(afterapplyingathinfilmoflubricantonthethreadsofthestudbolts,inaccordancewithTableIV).
8 Reassemblekeys(4f)ontheupperstemend.9 Reassemblegear/actuatorandclosethevalve.
CautionDo not force actuator on the stem! This should be a free moving fit.
10 Tightenglandnuts(5d)inaccordancetoTableI(Torquevaluesforglandnuts).11 Cyclethevalve.12 Pressurizeagaintheline.13 Ifaleakageisdetected,tightentheglandnutsslowlyandevenlyuntiltheleakagestops.
Figure no. 4
Vanessa Series 30,000Installation and Maintenance Instructions
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3.2 Sealing Elements Maintenance
Toreplacethesealingelementsproceedasfollows(pleaserefertofigureno.5):
Warning!
Depressurizethelinebeforestartinganymaintenance.Failuretodosomaycauseseriouspersonalinjuryand/ordamagetothevalve.
1 Removethevalvewiththediscintheclosedpositionfromline.Cleanthevalveaccordingtopropercleaningprocedureasoutlinedbytheplantoraccordingtoarecommendedprocedure.
2 Openthevalveafewdegrees.3 Loosenthesealretainerringscrews(2c).4 Openvalvetofullopenposition.
NoteInsmallsizevalvesitmaybeeasiertounbolttheactuatorandrotatethediscbeyondthefull-openpositiontoprovidemorespacetoworkwithcomponents.
Figure no. 5
5 Carefullyremovetheretainerringscrews(2c)withsecuritywashers(2d),thenremovethesealretainingring(2b).
6 Removesealring(3a)andspiralwoundgasket(3b).7 Inspectthebodyseat.Cleanit,ifnecessary,withfineabrasivecloth(No.600orfiner),afterhaving
cleaneditperfectlywithsolvent.8 Inspectandcleanthediscsealringareaandspiralwoundgasketgroove.Noforeignparticlesmust
bepresentbeforespiralwoundgasketandsealringassembly.9 Applyathinfilmoflubricantonthesurfaceareaofthedisc(2a)wheresealring(3a)andspiral
woundgasket(3b)willbelocated(lubricantshouldbeinaccordancewithTableIV).
CautionApply only a thin film of lubricant where indicated. Failure to do so will hinder the assembly and may cause damage to the valve.
10 Assemblethenewspiralwoundgasket(3b)inthediscgroove,withoutforcingandtakingcarenottodamageit.
11 Replacesealring(3a)onthediscthroughtheshaftsideofthebody.Toproperlylocatethesealring,therearetwodifferentsolutions:
•solution1-ref.tofigureno.6a-aligntheinternalslotofthesealring(3a)tothereferencepin(F). •solution2-ref.tofigureno.6b-alignthereferencemark(C)onthesealring(3a)withthe
relevantreferencemark(D)onthedisc.12 Assemblethesealretainerring(2b).Therearetwodifferentsolutionsasperpreviouspoint11: •solution1-ref.tofigureno.6a:makesurethattheslotontheedgeofthesealretainerring(B)is
incorrespondencewithreferencepin(F). •solution2-ref.tofigureno.6b:ensuretolocatethehole(E)ofthesealretainerringwiththe
relevantmarksonthedisc(D)andsealring(C).13 Handtightenallthefasteningscrews(2c),withrelevantlockwashers(2d)afterapplying
Loctite® 270orequivalentonthebottomsideofthethreads(theyhavetobeperfectlycleanedwithsolventbeforeapplyingLoctite®).Then,verifythatthesealringcanbemovedfreelybyhandwithoutrotatingit.
14 Applyathinfilmoflubricanttothebodyseatandtotheexternaledge(sealingconicalsurface)ofthesealring(3a).LubricantshouldbeinaccordancewithTableIV.
15 Seatandunseatthevalvetwice.16 Keepthevalveintheclosedpositionwithoutapplyingtorque.Tightenatleasttworetainingscrews
(2c)toavoidthesealringmovingfromthepositionfound.
Vanessa Series 30,000Installation and Maintenance Instructions
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17 Openthediscafewdegreesandtighten,usingatorquewrench,allscrews(2c).UseatorquevaluefromTableIIIforvalvesaccordingtosolution1(ref.tofigureno.6a).UseinsteadatorquevaluefromTableIIforvalvesaccordingtosolution2(ref.tofigureno.6b).
Itisrecommendedtousethecrossovermethodtotightenallretainingscrews.
Important!
• Solution 1 - ref. to figure no. 6a:Thesealringissuppliedwithanindexmarking(A).Afterthecompleteassembling,verifythattheindexmarking(A)canbeseenintheslot(B)ofthesealretainerflange.Slot(B)andmarking(A)havetobeperfectlyaligned.Ifnotvisibleornotaligned,loosentheretainingscrews,re-aligntheindexmarkingandstartagaintheprocedurefrompoint12.
• Solution 2 - ref. to figure no. 6b:Thesealringandthediscarecompletedwithtworeferencemarkings,(C)and(D).Afterthecompleteassembling,verifythatbothmarkingscanbeseenthroughthehole(E)ofthesealretainerflange.Thetwomarkingshavetobeperfectlyaligned.Ifnotvisibleornotaligned,loosetheretainingscrews,re-aligntheindexmarkingsandstartagaintheprocedurefrompoint12.
3.3. Bottom Flange Gasket MaintenanceIfnecessarytoreplacethebottomspiralwoundgasket,proceedasfollows(seefig.no.7):
1 Removethebottomflange(6a).2 Removethespiralwoundgasket(6c).3 Inspectandcleanthegrooveofthespiralwoundgasketinthebodyandinthebottomflange.4Applyathinfilmoflubricantonthebottomspiralwoundgasket(6c),theninsertitonthebottom
flange(6a),centeringandpositioningallonthebodybore(lubricantshouldbeinaccordancewithTableIV).Rotatethebottomflangetoaccommodatethecorrectpositionandcentertheholeswiththethreadedholesonthebody.
5Applyathinfilmoflubricantonthethreadsofthescrews(6b),thenintroduceandtightenthemusingatorquevaluefromTableIII(lubricantshouldbeinaccordancewithTableIV).
Figure no. 6a
Figure no. 7
Figure no. 6b
4.1 Bearing & Packing Flushing
4.1.1 Bearing FlushingThebearingflushingoptionisobtainedbyaddingtwotappedholes,oneinthebottomflangeandoneintheneckofthevalve(seefig.9).Thisoptionincludestheintroductionofalanternringatthebottomofthevalvepacking.Bearingflushingisrecommendedwhenthevalveisinstalledinaservicewheretheparticlespresentinthefluidorthelinefluiditselfcanmigrateintotheshaft/bearingareacausingproblems.Atypicalexampleissulphurrecoveryservices,wherethesulphurinaliquidorgaseousstatemayenterthisareaandcrystalliseasaconsequenceoftheplantshutdown.
Thiscrystallisationmayresultinanincreaseinthetorquerequirementofthevalve.Anotherexamplemaybeafluidthatcontainsparticles(e.g.catalyst)thatmaycausesimilarproblemstothosehighlightedabove.Inthesetypesofsituationsthebearingflushingmaybeusedtointroduceaninertfluidcompatiblewiththeprocessviathebearingflushtaps(seefig.8)soastocreateapressurebarrierwhichpreventstheintroductionoftheunwantedproductsfromthelineintotheshaft/bearingarea.Thepressureoftheflushingfluidmustbeslightlyhigherthanthelinepressure(i.e.P1+approx5%).Thisbothactsasasafetymeasureandisapositivestepinincreasingthelifetimeofthevalve,aswellasmaintainingtheconstanttorquerequirementandhenceoperabilityofthevalve.Thebearingsmaybecontinuouslyflushed,thisisrecommendedbyVanessaforcriticalservicessuchasdescribedabove.Periodicflushingmaybeusedforlesscriticalservicesinordertocleanthebearing/shaftinterfaceorinordertopreparethevalveforashutdownoftheprocess.Thebearingflushtapsmayalsobeusedtointroducealubricantcompatiblewiththeprocesstothebearingareasforhighcycleordrygasservice.Thepresenceofthebearingprotectordrasticallyreducestheconsumptionoftheflushingorlubricantbyreducingtheamountoffluidrequiredtogiveefficientservice(seefig.8).FurtherinformationisavailablefromVanessaonrequest.
Vanessa Series 30,000Installation and Maintenance Instructions
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SECTION 4Standard Options
Thissection(4)isreferredonlytoVanessaproductsconfiguredwiththefollowingoptions:-bearing&packingflushing,-liveloadedpacking.
Figure no. 8
Figure no. 9
Thebearingprotectorminimizestheconsumption
ofthecleanfluid
Upperflushinginlet
Lowerflushinginlet
Upperbearingflu
shing
connection
Lowerbearingflu
shing
connection
Packingflushing
connection
Discside
Shaftside
Flushpressure=P+5%
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Figure no. 10
4.1.2 Packing Flushing
Thepackingflushingoptionisobtainedbytheintroductionofatappedholethatcommunicatesdirectlytothepackingsetintheneckofthevalveviaalanternring.Thisoptioncanbeusedtomonitortherateofemissionofthelinefluidtowardtheatmosphere(itisimportanttopointoutthatthepackingoftheVanessavalvefullycomplieswithTALuftandEPArequirements).Thisflushtapmayalsobeusedtocaptureandevacuatelinefluidsoastopreventanyatmosphericloss,withthelanternringandsplitpackingconfigurationactingasadoubleblockandbleedunit.
Asuitablefluidmayalsobeintroducedviathepackingflushtapintothepackingareasoastoeliminateanypossiblefugitiveemissions(seefig.9).Bykeepingthefluidpressurisedatapressurethatishigherwithrespecttothelinepressure,thepassageofanylinefluidtowardstheatmospherecanbeeffectivelyblockedgivingthevalveexcellentfugitiveemissionscontrol.However,thefluidusedmustbecompatiblewiththelinefluidasitmayhavethepossibilityoffindingitswayintothelineaswellastowardtheatmosphere.
Aswiththebearingflushingoptionthismayalsobeusedtointroducealubricantcompatiblewiththeprocess.
Thetypeoflubricantusedforflushingisattheclients’care.Vanessamaybecontactedtosupplyfurtherdetailed,processspecificinformation.
4.3 Live Loaded Packing
TheliveloadedpackingoptionisdesignedtosupplementthealreadyexcellentcharacteristicsoftheVanessavalvepacking.ThisoptionguaranteesaconstantcompressionofthepackingsetgivingafurtherguaranteeofthefugitiveemissionscontroloftheVanessavalve.ThefactthatthepackingissubjecttoanearconstantforcesuppliedbytheBellevillewashersreducesthemaintenancecyclerequiredbythepacking(seefig.10).
CareshouldbetakeninreplacingtheBellevillespringsastheirorder(parallelorseries)shouldbenoted.ThepackingnutsshouldbetightenedinaccordancewithTableI.
AtthispointitisworthmentioningthattheTALufttesthasshownthattheVanessaSeries30,000std.Packingismorethanadequateinpassingitsstringentrequirements.
Theliveloadedpackingoptionshouldbeconsideredinvalvesthataresubjecttoseverecyclingdutyorvalvesthataresubjecttoseverethermalcycles.Thedrawingshowstypicalsetupsfortheliveloadedpackingoption.
3 80 - - 15 11 15 11 30 22 - -4 100 - - 15 11 15 11 30 22 - -6 150 - - 15 11 20 15 35 26 50 378 200 - - 15 11 20 15 60 44 105 7810 250 - - 25 18 20 15 70 52 135 10012 300 - - 25 18 25 18 75 55 240 17714 350 - - 30 22 30 22 75 55 240 17716 400 - - 30 22 35 26 100 74 175 12918 450 - - 35 26 40 30 205 151 480 35420 500 - - 35 26 45 33 320 236 195 14424 600 - - 45 33 55 41 420 310 605 44628 700 30 22 85 63 100 74 465 343 - -30 750 30 22 105 78 135 100 485 358 - -32 800 30 22 105 78 165 122 505 372 - -36 900 30 22 110 81 220 162 545 402 - -40 1000 30 22 110 81 225 166 - - - -42 1050 30 22 110 81 230 170 - - - -48 1200 30 22 110 81 235 173 - - - -54 1350 50 37 155 115 - - - - - -60 1500 65 48 160 118 - - - - - -64 1600 65 48 - - - - - - - -72 1800 65 48 - - - - - - - -84 2100 65 48 - - - - - - - -
8 12 9 10 24 18 12 41 30 14 66 49 16 103 76 18 142 105 20 201 148 22 274 202 24 348 257
6 10 7 8 20 15 10 45 33 12 70 52 14 110 81 16 175 129 18 235 173 20 335 247 22 370 273 24 460 339 27 595 439 30 760 561 33 785 579 36 1010 745 39 1315 970 42 1625 1199 45 2035 1501
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Table I: Torque Values for Gland Nuts
ND Trim A Trim B Trim C Trim D Trim E
in. mm Nm FT-LB Nm FT-LB Nm FT-LB Nm FT-LB Nm FT-LB
Note:Thetorquevaluesarethosesuggestedforthehydraulictestofthebody.
Table II: Tightening Torque Values
for Bolts & Screws
Bolt Dimensions Torque Values
(mm) Torque (Nm) Torque (Ftlb)
Table III: General Torque Values
for Bolting
Bolt Dimensions Torque Values
(mm) Torque (Nm) Torque (Ftlb)
Table IV: Lubrication
Type Component to Lubricate
Lightmineraloil 1. PackingRings(5a) 2.DiscSurfaceareas(2a)forSealRingand SpiralWoundGasketlocation 3.SpiralWoundGasket(6c)
Molykote®-P74(grease) 1. StudBolts/Nuts(5d)orequivalent 2.Screw(6b)
Molykote®Spray-321R(drylubricant) 1. SealRing(3a)orequivalent 2.BodySeat
