SEMPEll PREssURE sEAL GATE VALVEs - sTyLE A

Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends

Installation and maintenance instructions

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 should be carried out in the lifting points and at 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.

ValVE StOragE

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 wedge in the closed position.

2. The weld ends surface shall be protected with suitable protective like Deoxaluminite.

The end shall be closed with plywood or plastic disc fixed at the edge by strips.

3. All actuated valves must be carefully securely palleted or crated, in order to ensure that the 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 shall be appropriate to ensure safe transportation to final destination and eventual conservation before installation.

B - Unpacked valves

1. The lifting and the handling of these valves has to be carried out by using appropriate means and at respecting the carrying limits.

The handling must be carried out on pallets, protecting the machined surfaces to avoid any damage.

2. With valves of large dimensions, the sling and the hooking of the load must be carried out 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.

Emerson.com/FinalControl © 2017 Emerson. All Rights Reserved.

VCIOM-04586-EN 18/01

SEMPEll PREssURE sEAL GATE VALVEs - sTyLE A

Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends

VALVE sLInGInG

FIGURE no. 1

Storage and preservation before installation

In case the valves have to be stored before installation, the storage has to be carried out in a controlled way, and has to be performed in accordance with the following criteria:

1. The valves have to be stocked in a closed, clean and dry storage room.

2. The wedge must be in the closed position, and the end faces must be protected with plastic or wooden discs fixed with straps. If possible, keep the original protection.

3. Periodical checks have to be carried out in the storage area to verify that the above mentioned conditions are maintained.

For actuated valves, in addition to the above, please refer to the warnings in the manual of the actuator.

NOtE storage in an open area for a limited period can be considered only in case the valves have appropriate packing (packed in cases lined with tarred paper, and contents well protected with barrier sacks).

Do not place consignment packages directly on the ground.

Do not expose consignment packages to the weather or directly to the sun.

Check the packaging every two months.

INStallatION

Preparation before installation

1. Carefully remove the valve from the shipping package (box or pallet) avoiding any damage to the valve or, in case of automated valves, to the electric or pneumatic/ hydraulic actuator or instrumentation.

2. The valves are shipped with the ends protected by caps and coated with a thin layer of protective grease. Before installation, remove the caps of the ends and the protective grease by cleaning them completely with a solvent liquid. Clean the inside of the valve using an air line. Ensure that there are no solid objects such as pieces of wood, plastic or packing materials within the valve or on the valve seat.

3. Confirm that the materials of construction listed on the valve nameplates (service and temperature) are appropriate for the service intended and are as specified.

4. Define the preferred mounting orientation with respect to the system pressure.

If any (see arrow on the body), identify the upstream side (high pressure) and downstream side (low pressure).

CautION

For 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.

Do not use the lifting points located on the actuator, if any, to lift the valve. These lifting points are for the actuator only.

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.

WarNINg

Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body. Valves without the arrow are bi-directional.

See the actuator user manual for the actuator preparation.

2

SEMPEll PREssURE sEAL GATE VALVEs - sTyLE A

Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends

90° max.

IMPOrtaNt

After the valves installation and before the line testing, it is recommended to perform an accurate cleaning of the lines to eliminate dirt and any foreign objects that could seriously jeopardize the tightness between seat/disc and the correct operation of the valve. It is therefore recommended to leave the valve in the open position.

FIGURE no. 2

InsTALLATIon PosITIons RECoMMEnDED

WarNINg

Before welding, check that valve is completely opened.

Installation instructions

Gate valves are normally installed in horizontal pipe with vertical stem.

These valves can also be installed in vertical or horizontal pipe with stem other than vertical, but this may require special construction depending on valve size, service condition, material and type of operator.

For a correct operation, we recommend that the valve shall be installed and oriented following the indications of Fig. 2.

This can help minimize any problem associated with solid particles present in the fluid that otherwise could deposit in the lower part of the body and be obstacle to the wedge complete closure.

Install the valve with the wedges in closed position unless otherwise stated. Thus, the sealing surfaces will not be damaged during installation.

Particular care should be taken with those valves equipped with ‘fail-open’ actuators.

For operating temperatures above 200°C

(392°F) thermal insulation of the valve body is recommended.

Handling and lifting of the valves during installation MUsT be performed following the same criteria and instructions described in previous points ‘Valve handling’ and ‘storage and Preservation before Installation’.

Buttweld valves

1. open the valve.

2. Place the valve, check the alignment with the pipe and weld in accordance with the welding standard procedures as stated by the Engineering society.

Valve verification before start up

1. Tighten the packing just enough to prevent stem leakage. over-tightening will decrease packing life and increase operating torque.

The bolt torque figures for the packing bolts can be calculated as indicated in Table I.

In the case that leaking from the packing occurs during the start up, proceed as follows:

- Tighten the nuts to the indicated torque

(see table), operate the valve and re-tight the nuts to the indicated torque.

- Repeat the operation until the leakage stops.

2. Check the operation of the valve by stroking it to ‘full open’ and ‘full close’.

3. In case of electric actuated valves, see paragraph for instructions on the adjustment of the actuator.

IMPOrtaNt

If piping system is pressurized with water for testing, and in case the piping system has been shut down after testing for a long time, the following recommendations should be adopted.

a. Use corrosion inhibitor with water to pressurize the piping system b. After testing, the piping system should be depressurized and the test water completely drained.

Scheduled maintenance

1. style A series Gate Valves do not require special care to work properly.

The following instructions will help provide a satisfactory and long life service.

2. Make sure to perform periodic valve verification as described in paragraph '

Adjustment of electric actuators'.

3. In case of actuated valves always follow the specific instructions given by the actuator’s manufacturer.

4. never change the setting of torque and/or limit switches which have been carefully set during the final test at the manufacturing plant.

3

SEMPEll PREssURE sEAL GATE VALVEs - sTyLE A

Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends tablE I: bOlt tOrquE FIgurES FOr PaCkINg bOltS

For system pressures < 2533 psi

Torque (ft lbs) = (24.87) x (oD2 _ ID2) x (d)

Torque (nm) = multiply Torque (ft lbs) x 1.3558

Where:

For system pressures ≥ 2533 psi

Torque (ft lbs) = (s.P./101.8) x (oD2 _ ID2) x (d) oD = stuffing Box Bore (ln.)

ID = stem Diam (In.) d = Gland stud Diam (in.) s.P. = system Pressure (psi)

This ‘Torque method’ may result in more or less than 30% compression.

tablE II: bOlt tOrquE tO ENSurE tIgHtNESS OF PrESSurE SEal gaSkEt

Position 31 for gate valves

Stud torque ft.lbs.

torque Nm

¾

⅞

1

⅜

½

⅝

1 ⅛

1 ¼

1 ⅜

125

207

310

18

37

74

443

627

811

24,5

50

100

170

280

420

600

850

1100

IMPOrtaNt

To ensure tightness of pressure seal gasket, pull up bolts must be tightened when valve is under fully hydrostatic test pressure.

41.3

44.5

47.6

50.8

54.0

57.2

60.3

22.2

25.4

28.6

31.8

34.9

38.1

63.5

69.8

73.0

76.2

79.4

82.5

85.7

88.9

95.3

98.5

101.6

108.0

111.1

tablE III: CONStaNt FOr CalCulatION OF PaCkINg bOlt tOrquES

Stem diameter ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ 1 1 ⅛ 1 ¼ 1 ⅜ 1 ½ bolts gland diameter

1 ⅝ 1 ¾ 1 ⅞ 2 2 ¼ 2 ½ 2 ¾

1.72

1.82

1.93

2.43

2.56

3.14

3.28

0.64

0.71

1.03

1.11

1.21

1.60

3.43

3.71

3.85

4.62

4.14

5.08

1.15

1.28

1.85

1.99

2.17

2.87

3.09

3.26

3.47

4.37

4.59

5.64

5.89

1.65

1.84

2.65

2.86

3.10

4.12

4.42

4.67

4.97

6.26

6.58

2.14

2.38

3.43

3.71

4.02

5.34

5.74

6.06

6.45

2.65

2.95

4.25

4.59

4.98

6.61

7.10

7.50

7.98

3.13

3.49

5.02

5.42

5.89

7.82

8.40

3.64

4.05

5.84

6.30

6.85

4.15

4.61

6.65

7.18

7.80

4.62

5.14

7.41

8.00

8.68

5.11

5.68

8.19

8.84

9.60

5.59

6.21

8.96

9.67

10.50

6.06

6.74

9.71

10.48

11.39

5.25

5.84

8.42

9.09

9.87

5.65

6.28

9.05

9.77

10.61

6.04

6.72

10.45

11.35

7.99

8.89

13.82

15.01

8.98

9.98

15.53

16.87

9.94

11.06

17.20

18.68

10.91

12.13

9.68

12.81

14.39

15.93

17.48

18.87

20.50

9.09

10.35

11.53

12.74

13.94

15.12

13.11

14.09

15.07

19.93

22.39

24.80

27.21

9.76

11.12

12.38

13.68

14.97

16.23

14.07

15.13

16.18

21.40

24.04

26.63

29.22

8.87

10.31

11.74

13.08

14.45

15.81

17.15

14.87

15.98

17.09

22.61

25.40

28.13

30.86

9.44

10.97

12.49

13.91

15.37

16.82

18.25

15.82

17.00

18.18

24.06

27.02

29.93

32.84

8.12

10.05

11.88

13.81

15.73

17.52

19.36

21.18

22.97

19.91

21.40

22.89

30.28

34.02

37.68

41.34

8.54

10.57

12.49

14.52

16.54

18.42

20.36

22.27

24.16

20.94

22.51

24.08

31.85

35.78

39.63

43.47

8.09

10.49

12.98

15.35

17.84

20.32

22.63

25.01

27.36

29.68

25.73

27.65

29.58

39.13

43.95

48.68

53.41

8.45

10.95

13.55

16.03

18.64

21.22

23.64

26.12

28.57

30.99

26.87

28.88

30.89

40.86

45.90

50.84

55.78

6.15

6.66

6.92

8.82

11.43

14.15

16.73

19.45

22.15

24.67

27.26

29.83

32.35

28.05

30.15

32.24

42.65

47.91

53.07

58.22

9.55

12.38

15.32

18.12

21.06

23.98

26.71

29.52

32.29

35.03

30.37

32.64

34.91

46.18

51.88

57.46

63.04

9.92

12.86

15.91

18.82

21.88

24.91

27.75

30.66

33.54

36.38

31.54

33.91

36.26

47.97

53.89

59.68

65.48

8.29

11.89

15.41

19.07

22.56

26.22

29.86

33.26

36.75

40.21

43.61

37.81

40.64

43.47

57.50

64.59

71.54

78.49

7.44

10.66

13.82

17.10

20.22

23.51

26.77

29.82

32.95

36.05

39.10

33.90

36.44

38.97

51.55

57.91

64.14

70.37

9.12

13.07

16.95

20.97

24.80

28.83

32.83

36.57

40.41

44.21

47.95

41.57

44.69

47.79

63.22

71.02

78.66

86.30

4.94

5.10

8.87

9.16

12.72

13.13

16.49

17.02

20.41

21.06

24.13

24.91

28.06

28.96

31.95

32.97

35.58

36.73

39.32

40.58

43.02

44.40

46.66

48.16

40.45

41.75

43.48

44.88

46.50

48.00

61.52

63.50

69.11

71.33

76.54

79.00

83.98

86.67

5.57

10.00

14.34

18.59

23.01

27.20

31.63

36.01

40.11

44.33

48.49

52.60

45.60

49.02

52.42

69.35

77.91

86.29

94.67

6.48

11.65

16.69

21.64

26.78

31.67

36.82

41.93

46.70

51.61

56.46

61.24

53.10

57.07

61.04

80.75

90.71 100.46 110.22

6.71

12.05

17.27

22.39

27.71

32.76

38.09

43.37

48.31

53.38

58.40

63.35

54.92

59.03

63.13

83.52

93.82 103.92 114.01

7.02

12.61

18.08

23.44

29.01

34.30

39.88

45.41

50.58

55.89

61.15

66.33

57.50

61.81

66.10

87.45

98.23 108.80 119.36

8.22

14.77

21.17

27.45

33.98

40.18

46.71

53.19

59.24

65.46

71.62

77.68

67.35

72.39

77.42 102.42 115.06 127.43 139.81

NOtES

1. select the constant according to both, stem diameter and bolts size.

2. In order to obtain the packing bolt torque in nm, multiply the selected constant for the pressure in MPa.

Example:

Valve operating at 24MPa pressure with 44.5mm stem diameter and packing size of M16.

a. The constant is equal to 4.67

b. Packing bolt torque is equal to 4.67 x 24= 112.8 nm

4

SEMPEll PREssURE sEAL GATE VALVEs - sTyLE A

Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends

Periodic valve verification during service

A - normal check

1. Verify monthly that there is no leakage from packing or in the body/bonnet area.

In the case that a leakage from the packing occurs, tighten the gland nuts (fig. 4, pos 16) slowly and uniformly. Calculate torque value as indicated in table I.

If the leakage does not stop, follow the procedure for packing maintenance (page

6).

If the leakage has been detected from the body/bonnet, tighten the nuts (pos. 31) as indicated in Table II.

If the leakage does not stop, follow the maintenance procedure for the replacement of the body/bonnet gasket.

2. Every 3 / 6 months, depending on operating frequency, verify the greasing of bearings and stem thread.

3. For actuated valves, in addition to the above, please refer also to the warnings in the actuator manual.

B - Preventive actions

1. Every 3 months verify the tightness of gland bolts.

2. Every 6 months on motorized valves and every 8 months on hand operated valves, grease stem and bearings.

3. Every 4 years disassemble the critical service valves and/or actuated valves, verifying the sealing surfaces and lap them again when necessary. substitute the bonnet gasket and the packing, grease the stem.

4. For the actuator, proceed as indicated in its maintenance manual.

adjustment of the electric actuators

Wegde gate valves must be set up with the micro limit switch in open position and by torque in close position.

Failure to do so may result in personal and/or property damage.

WarNINg

Do not modify the torque values and/or limit switch settings. Default configurations have been set up during final tests at our workshops.

trOublESHOOtINg guIdE

Symptom stem packing leaking

Body-Bonnet leaking

Valve leaking

Jerky operation

Backseat leakage

Possible cause Solution

1. Gland flange nuts too loose

2. Packing damaged

1. Gasket bolting loose (pos 31)

2. Gasket damaged

1. Valve not fully closed

2. Debris trapped in valve

1. Check gland nuts torque

2. Replace packing (see Page 6)

1. Tighten bolting (pos 31)

2. Replace the gasket

1. Close valve

2. Cycle and flush (with valve open) to remove debris

3. sealing surface damaged

1. Packing is too tight

3. Recondition the seat surface

1. Loosen gland nuts, cycle the valve, retighten

2. Air supply inadequate (for pneumatic act.) 2. Increase air supply pressure

1. Backseat damaged 1. Repair backseat surface

5

SEMPEll PREssURE sEAL GATE VALVEs - sTyLE A

Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends

MaINtENaNCE

The style A series valves have been designed to require minimum maintenance.

This manual describes on site repairs as:

- Packing replacement

- Body/bonnet gasket replacement

All the other repairs should be performed by

Emerson or nominated service company.

Packing maintenance

If a leakage from the packing cannot be stopped by tighten the gland nuts, replace the packing as follows:

Please refer to Figure no.3 and 4.

1. open completely the valve up to the backseat position.

2. Remove the nuts (16) of the gland bolts (15)

3. Lift the gland flange (10) and the gland (9)

4. Remove the worm-out packing using a hooking wire

5. For a better tightness, proceed to an accurate cleaning of the stem and stuffing box and make sure there are no scratches or signs of seizing

6. The repacking shall be carried out by placing one ring at a time around the stem, inside the stuffing box and by making sure that they are correctly oriented. Press it into the bottom (refer to Figure no. 3).

7. When the stuffing box is filled, replace the gland (9 figure no. 4) and gland flange (10

Figure no. 4) in their original position.

8. Tighten gland nuts in accordance with Table I

(Bolt torque figures for packing bolts).

9. Cycle the valve.

10. Pressurize the line.

11. If a leakage is detected, tighten the gland nuts slowly and evenly until the leakage stops.

FIGURE no. 3

1 = Braided graphite

2 = Die formet graphite (5 or 6 ring)

3 = Metal ring

WarNINg

Before starting any maintenance, depressurize, drain and vent the line; check that the valves are not in temperature; disconnect any electrical power supply.

Failure to do so may cause serious personal injury and/or equipment damage.

FIGURE no. 4

6

SEMPEll PREssURE sEAL GATE VALVEs - sTyLE A

Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends

Lifting lugs

FIGURE no. 5

For nPs 6 For nPs 4 For nPs 3 bonnet gasket replacement ValVE rEMOVal

WarNINg

Before starting any maintenance, depressurize, drain and vent the line; check that the valves are not in temperature; disconnect any electrical power supply.

Failure to do so may cause serious personal injury and/or equipment damage.

If the valve needs to be removed from the line for some extraordinary reason, the user should ensure the following:

1. The valve is depressurized, drained and vent.

2. The pipe shall be cut as far away from the valve as possible.

grEaSES aNd SPECIal tOOlS

Please refer to Figure no. 5.

1. Unscrew the body bonnet nuts (pos.12) and the gland nuts (pos.16)

2. Lift up the yoke (pos.24) operating by the handwheel or gearbox handwheel

3. When the stem nut is free from the stem threads, lift up the yoke.

4. Unscrew the nuts (pos.31).

5. Remove the retaining ring (pos.311).

6. Remove the segment rings, push them out from the body groove by using the body holes placed radially on the top of the body.

7. Lift up the bonnet (pos.6) and pressure seal body gasket (pos.5). Make sure not to damage the packing. We suggest to replace the packing when changing the body gasket.

8. Carefully clean all the gasket housing and lubricate with suitable grease.

9. Replace the body gasket.

10. Reassemble all parts following backwards the above mentioned steps.

greases

To lubricate the bearings on manual and gearbox operated valves, we suggest to use the grease AGIP GRMUEP2 or an equivalent product, as showed in the following table: tablE IV: grEaSE aNd lubrICaNt lISt

Manufacturer

AGIP

API

BP

Esso

FInA

MoBIL

Q8 sHELL

TEXACo

ToTAL

VIsCoL sTAToIL

CautION

The nuts (pos.31) need to be retightened after valve first pressurization, as indicated in Table II.

For the lubrication of the stem thread, use the grease sIGnAL CEP 30 produced by Viscol. As an alternative you can utilize:

- CEPLATTyn 300 produced by REInER-FUCHs

- GRAFLosCon produced by KLUBER you can also use a grease having more than

25% pure graphite content (carbon 98%) granulometry 5m, without any abrasive agent.

For the lubrication of the actuator, refer to the relevant manual.

Special tools no special tool required for the Maintenance operation described in this Manual.

grease

GRMUEP2

PGX2

GREAsE LTX2

BEACon 2

FInAGREAsE HP FInAGREAsE EPL2

MoBILUX EP2

REMBRAnDT EP2

ALVAnIA R2 sUPERGREAsE A

MULTIFAK EP2 GREAsE L2

MULTIs EP2 MULTIs 2 sIGnAL RoLsFER 2

UHIWAyLI LI G2

WarNINg

Before starting any operation, depressurize the line with the valve in open position so no pressure remains in the body cavity. Close the valve by way and not by torque.

7

neither Emerson, Emerson Automation solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product.

Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

sempell is a mark owned by one of the companies in the Emerson Automation solutions business unit of Emerson Electric Co. Emerson Automation solutions, Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

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