Avk 54 series Instruction manual

SERIES 54 METAL SEATED GATE VALVES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Instruction for use

Thank you for selecting an AVK product. With correct use, it will give long and reliable service. This manual

has been prepared to assist you install, operate and maintain the valve to the maximum efficiency. For ease of

reference, it has been divided into sections covering all aspects of use, and it is in the users best interests to

read it and ensure that it is fully understood.

Health and Safety

It is always recommended that wherever work is being carried out on a valve that the valve is fully

depressurised prior to carrying it out, and for the convenience draining of the line may be beneficial.

It is essential that the user of the valve is aware of the weight of the components and/or assembles that must

be handled and manipulated during installation and maintenance. It is the users responsibility to ensure that

safe working practices are followed at all times.

Whenever AVK products are installed, operated, or maintained, it is essential that the staff that undertake

these operations be adequately trained. The hazards of pressurised liquids and gases can be severe, and it

is the responsibility of the users to ensure that trained, competent staff undertake these duties. This manual

has been designed to assist, but it can never fully replace quality training in the workplace. AVK technical staff

will always be available to answer any questions relating to specific problems that may not be covered by this

manual.

AVK products are designed and manufactured to be fit for purpose, and to a high and reliable standard. This

provides a safe product with minimum risk to health when used correctly for the purpose for which it was

designed. However, this assumes that the equipment is used and maintained in accordance with the manual,

and the user is advised to study this manual, and to make it available to all staff that may need to refer to it.

AVK cannot be held responsible for any incidents arising from incorrect installation, operation or maintenance.

The responsibility for this must rest wholly with the user.

AVK Valves Pty Ltd - 559A Grand Junction Road, Wingfield, SA 5013, Australia - Tel: +61 8 8368 0900 - Email: [email protected] - www.avkvalves.com.au Version number 2

SERIES 54 METAL SEATED GATE VALVES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

1. Introduction

AVK series 54 gate valves are available in DN750, DN800, DN900, DN1000 and DN1200. The valve has a full and straight bore

corresponding to the nominal diameter and can be installed independent of the ﬂow direction. To keep the advantage of the full

and straight bore vertical installation is recommended, however, ﬂow/pressure limitations outlined below should be observed.

The valves are 100% factory tested hydrostatically.

The valves have a standard gland ﬂange according to ISO 5210. Various optional extras can be supplied factory ﬁtted or in kit

form for retroﬁtting. See data sheet.

A complete by-pass system is factory ﬁtted. The by-pass system secures an optimum installation due to slow ﬁlling and

emptying of the pipe line and passing of air.

IT IS IMPORTANT TO STATE OPERATING TEMPERATURE, PRESSURE, MEDIUM AND OPERATING CONDITIONS WITH

ENQUIRIES/ORDERS, SO THE MOST SUITABLE VALVE WILL BE SUPPLIED FOR YOUR SPECIFIC PURPOSE.

AVK Valves Pty Ltd - 559A Grand Junction Road, Wingfield, SA 5013, Australia - Tel: +61 8 8368 0900 - Email: [email protected] - www.avkvalves.com.au Version number 2

Materials:

Castings (body, bonnet, stem cap, wedge, stuffing box,

handwheel and bypass bends)

Ductile Iron

Coating

DN700-900:

Fusion bonded epoxy (FBE)

DN1000-1200:

Two pack epoxy

Bolts, nuts and stem

Stainless Steel

Refer to individual datasheets for specific information

SERIES 54 METAL SEATED GATE VALVES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

AVK Valves Pty Ltd - 559A Grand Junction Road, Wingfield, SA 5013, Australia - Tel: +61 8 8368 0900 - Email: [email protected] - www.avkvalves.com.au Version number 2

Component list

1. Body

2. Bonnet

3. Wedge

4. Distance piece

5. Body seat ring

6. Wedge ring

7. S t e m

8. Stem nut

9. Body, bonnet, O-ring seal

10. Gland packing

11. Gla nd

12. Fasteners

13. Plug

14. Gasket

SERIES 54 METAL SEATED GATE VALVES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

2. Installation

• When installing the gate valves, ensure that the seats and the ﬂange faces are clean.

• When valves are provided with lifting lugs, plates or eye nuts, these must be used to lift the valve.

• To ensure adequate sealing it is important to select the correct type of gasket for the medium concerned, 2 gaskets with

the correct ﬂange size must be used.

• Place valve between pipe ﬂanges, and insert the bolts.

• Tighten bolts loosely.

• Tighten bolts in a diagonal sequence to ensure ﬂanges are pulled parallel.

• Finally tighten bolts to correct torque levels as recommended in WSA 109.

Once the valve has been installed (Commissioning)

• Check that the valve still functions correctly by operating it for a minimum of ﬁve turns.

• Direct mounted electric actuator open and close positions are pre-set at the works, and should not need adjustment but

torque settings may need adjustment by a suitably qualiﬁed engineer.

• Pedestal mounted actuators must be set on site.

• Where pedestals are ﬁtted with open/close indicators, attention must be made during connection to ensure that they

correctly reﬂect the position of the valve.

• Packed Glands are the traditional method of sealing stems from the line pressure and are extremely reliable over a long

period of time. However, they do require an initial adjustment during the commissioning period and for this reason we

cannot guarantee “no leakage” until the valve is installed and adjusted. See 4. Maintenance.

• Where a venting plug or valve is ﬁtted, this should be used to remove the air from the valve. Alternatively, where this is not

provided, air can be removed by loosening the gland bolts.

• When all the air has been safely vented, the cap, valve or gland bolts must be re-tightened ensuring that any gaskets or

washers are correctly seated.

• If the valve is ﬁtted with a jacking screw ensure that this is retracted after use and before attempting to close the valve.

• When the pipeline has been charged, inspect the valve for any leaks and adjust as necessary in accordance with

maintenance instructions.

• All external debris and foreign matter should be cleaned off from the external surfaces of the valve.

• Any paint/coating which has been damaged during installation should be appropriately touched up.

AVK Valves Pty Ltd - 559A Grand Junction Road, Wingfield, SA 5013, Australia - Tel: +61 8 8368 0900 - Email: [email protected] - www.avkvalves.com.au Version number 2

SERIES 54 METAL SEATED GATE VALVES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

2.1. Exchange/retroﬁt a by-pass System

IMPORTANT! Before mounting a by-pass system:

1. The main valve must not be under pressure.

2. The medium must be below the level of the by-pass ﬂanges on the side of the valve.

Preparation of the main valve.

Clean the ﬂanges of the valve carefully to remove dirt and impurities.

Preparation of the main valve

Clean the ﬂanges of the valve carefully to remove dirt and impurities.

Preparation of the by-pass system

Screw the stud bolts into the two cast iron bends and ﬁt the bends to the by-pass valve together with the mating gaskets (see

drawing).

Fasten the nuts loosely to ensure that the bends can move freely in relation to the valve.

Mounting

Mount the by-pass system on the main valve together with new gaskets and re-use the nuts and washers removed previously

for fastening.

Tighten all nuts with 100 Nm. The by-pass system is now ready for use.

AVK Valves Pty Ltd - 559A Grand Junction Road, Wingfield, SA 5013, Australia - Tel: +61 8 8368 0900 - Email: [email protected] - www.avkvalves.com.au Version number 2

SERIES 54 METAL SEATED GATE VALVES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

3. Operation

The series 54 gate valves are suitable for use with clean water or neutral liquids up to 70°C; minimum liquid temperature must

be above freezing. Insulation is essential for use with low external temperatures.

The valves can be operated manually either by ring key and bar to tee key, handwheel, gearbox or electric actuation. Direction

of closing is on the ISO Mounting Gland Flange and the Gland Flange of a by-pass valve if ﬁtted.

Note: These valves are not designed for “end of line” services. In the event of a valve being mounted on the end of a pipeline,

we strongly advise the use of blanking ﬂange or plug.

3.1. Right-hand closing valves

3.1.1. Closing

During manual operation the valve is closed by turning the handwheel clockwise until the valve is completely closed, however

only up to max. operating torque (see table).

For valves supplied with gears, the handwheels are also turned clockwise. It is IMPORTANT that the interchange of the gear is

taken into consideration, so that the valve is not operated at a higher torque than max. operating torque (see table).

When closing valves with actuators, adjust the actuator so that the output shaft moves clockwise, and adjust the on/off torque

switch so that the valve is not operated at a higher torque than the max. operating torque (see table).

3.1.2. Opening

The valves are opened by turning the handwheel, gear or actuator anti-clockwise until the valve is completed open. This is

recognised by a powerful (and sudden) stop.

3.2. Left-hand closing valves

3.2.1. Closing

During manual operation the valve is closed by turning the handwheel anti-clockwise until the valve is completely close,

however only up to max. operating torque (see table).

For valves supplied with gears, the handwheels are turned anti-clockwise. It is IMPORTANT that the interchange of the gear is

taken into consideration, so that the valve is not operated at a higher torque than the max. operating torque (see table).

When closing valves with actuators, adjust the actuator so that the output shaft moves clockwise, and adjust the of/off torque

switch so that the valve is not operated at a higher torque than the max. operating torque (see table).

3.2.2. Opening

The valves are opened by turning the handwheel, gear or actuator clockwise until the valve is completely open. This is

recognised by a powerful (and sudden) stop.

AVK Valves Pty Ltd - 559A Grand Junction Road, Wingfield, SA 5013, Australia - Tel: +61 8 8368 0900 - Email: [email protected] - www.avkvalves.com.au Version number 2

Torque Differential

DN Number 16 Bar 10 Bar 5 Bar

of Turns Nm Nm Nm

750 70 2466 1600 795

800 70 2466 1600 795

900 78 3260 2051 1043

1000 86 4108 2581 1308

1200 103 6561 4114 2075

SERIES 54 METAL SEATED GATE VALVES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

4. Maintenance

To improve the life of the Series 54 Gate Valve and ensure satisfactory working at all times the following procedures should be

carried out at regular intervals throughout the life span of the product (every 6 months).

Although some procedures can be carried out with the valve under pressure, it is strongly recommended that there is no

pressure in the pipeline whenever possible.

• The stufﬁng box should be checked to conclude that there is no leakage from the packing.

An additional strand might be required after a period of service and occasionally repacking may be needed.

• Care should be taken to ensure the gland is tightened up evenly to prevent binding of the spindle, and should be tightened

up just enough to prevent leakage.

• If the valve has been left standing un-operated for lengthy periods and conditions allow, monthly or more frequent

operation of the screw throughout the length of its travel should be carried out. Failing this, at least operation through part

of the travel should be effected if at all possible.

• The bolts on the valve should be checked for tightness, after long periods of operation, where vibration is experienced.

• Visual checks of coating for any signs of damage or corrosion.

Packed Gland (Applies to all sizes)

Packed Glands are the traditional method of sealing stems from the line pressure and are extremely reliable over a long

period of time. However, they do require an initial adjustment during the commissioning period and for this reason we cannot

guarantee “no leakage” until the valve is installed and adjusted.

Adjustment is a simple matter of alternately tightening the gland nuts by a small amount until any weeping creases, this can

be safely carried out whilst under pressure. If the gland is already down and further adjustment is not available or does not

stop the leak, then the gland will need re-packing. If this is necessary, the pressure in the pipeline should be shut off at another

point, and the line drained.

To repack the valve, complete the following:

• Undo the gland nuts and then remove the gland and the packing.

• Lubricate the spindle with WRc Approved Grease.

• Repack the gland using the correct size and type of packing and ensure that there is a snug ﬁt between the spindle and

the stufﬁng box wall, and that all joints are staggered by 120 degrees.

• Secure the gland but do not tighten the nuts more than necessary to prevent leakage.

Recommended Spare Parts

The use of interior materials or parts in a valve can have serious consequences. It is AVK policy therefore, to use only materials

of the highest quality, manufactured to our own designs and thoroughly checked and tested in accordance with our internal

Quality Assurance system that is approved to ISO 9001:2000. It is absolutely essential therefore, that in order to guarantee the

highest level of safety and performance, only genuine AVK spare parts are used. AVK can accept no responsibility whatsoever

for the ﬁtting and subsequent failure of any non-AVK or non-approved parts.

AVK recommend that these spare parts are purchased when ordering series 54 Gate Valve

• Full set of Gaskets and Seals

• Gland Packing

• Grease for stem

• Touch up Paint

AVK Valves Pty Ltd - 559A Grand Junction Road, Wingfield, SA 5013, Australia - Tel: +61 8 8368 0900 - Email: [email protected] - www.avkvalves.com.au Version number 2

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