TERRA NOVA MEC-RELA L20-A1 Series User manual

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
a TERRANOVA® Srl brand - www.terranova-instruments.com - VAT IT07848810151
Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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Pag. 1/24
GLOBE VALVES SERIES L20-A1

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
a TERRANOVA® Srl brand - www.terranova-instruments.com - VAT IT07848810151
Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
Head Office: Via Rosso Medardo 16 –20159 Milano –Italy Ph: [phone] –Fax: +39 0377
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Pag. 2/24
1  DESCRIPTION..........................................................................................................................4
2  DEFINITION AND SYMBOLS......................................................................................................4
3  SAFETY INFORMATIONS ..........................................................................................................5
3.1  Intended Use.....................................................................................................................5
3.2  Access...............................................................................................................................5
3.3  Lighting ............................................................................................................................5
3.4  Hazardous Fluids In The Pipe .............................................................................................5
3.5  Environmental Situations ..................................................................................................5
3.6  Temperature.....................................................................................................................5
3.7  System..............................................................................................................................6
3.8  Pressurized Systems ..........................................................................................................6
3.9  Tools And Consumable Parts .............................................................................................6
3.10  Protection Clothes...........................................................................................................6
3.11  Qualification Of The Operators In Charge Of The Works...................................................6
3.12  Handling .........................................................................................................................7
3.13  Freezing ..........................................................................................................................7
3.14  Other Risks......................................................................................................................7
3.15  Disposal ..........................................................................................................................7
3.16  Risk Of Corrosion And/Or Erosion ....................................................................................7
4  INSTALLATION.........................................................................................................................8
4.1  Fitting The Valve To The Pipe ............................................................................................9
5  ACTUATOR CONNECTION.......................................................................................................10
5.1  Pneumatic Actuator Connection ......................................................................................10
5.2  Connection Of Electric Actuator....................................................................................... 10
6  MAINTENANCE......................................................................................................................11
6.1  Replacement Of Actuator Diaphragm..............................................................................11
6.2  Replacement Of On/Off Piston Disc On/Off Valve ............................................................13
6.3  Valve / Actuator Separation............................................................................................ 14
6.4  Replacement Of The Seat/Plug Of The Standard Valve..................................................... 15
6.5  Replacement Of The Seat/Plug Of The Valve With Quick Change Seat..............................16

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
a TERRANOVA® Srl brand - www.terranova-instruments.com - VAT IT07848810151
Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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6.6  Replacement Of The Seat/Plug Of The Balanced Valve ....................................................17
6.7  Replacement Of The Seat/Plug Of The Valve With Bellows .............................................. 18
6.8  Replacement Of The Stem Packing Gland ........................................................................19
7  TIGHTENING TORQUES ..........................................................................................................20
8  SIZES OF THE ACTUATOR CONNECTIONS ................................................................................ 22
9  PERIODICAL CHECKS .............................................................................................................. 23
10  AVAILABLE SPARE PARTS ..................................................................................................... 23

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
a TERRANOVA® Srl brand - www.terranova-instruments.com - VAT IT07848810151
Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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1 DESCRIPTION
Manufactured under ISO 9001 quality assurance system, the Mec-Rela L20 series is a top
entry globe valve style body construction with a wide range of different single stage trims
available. L20 series combine the advanced modular design and the wide range of
actuators to satisfy the needs of the industrial demand.
L20 valves are designed to control a broad variety of fluids, like steam, water, most of the
medium and gases. One of the main features of this series is the top guided construction
that assure a stable plug travel over entire stroke of the valve minimizing vibration and
wear.
2 DEFINITION AND SYMBOLS
In this manual are used the following symbols and labels:
WARNING!
Warning label, used to warn about hazardous materials, locations, or objects, including
electric currents, poisons, and other things.
PROHIBITION!
Prohibition label, used to indicate something is not permitted.
MANDATORY!
Mandatory label, used to set obligation tasks to be performed by the user.

INFORMATION!
Information label, used to set general information for the user or warn about hazards for the
equipment.

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
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Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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3 SAFETY INFORMATIONS
The safe operation of this product is ensured only if it is installed, commissioned, used and
maintained in an appropriate way by qualified personnel in compliance with the operating
instructions.
3.1INTENDED USE
Verify that the valve is suitable for the intended use and application by checking:
that the material of which the valve is made up of is compatible with the process
fluid.
that the valve is suitable for the pressures and temperatures of the process fluid.
that a suitable safety device is fitted to the system to prevent any hazardous
overpressures or overtemperature in the system.
Mec-Rela valves are not intended to withstand any external stresses which can be induced
by the systems in which they are inserted. The installer must take account of these
stresses and take the appropriate measures to prevent them.
3.2ACCESS
Ensure safe access and, if required, a safe working platform (with a suitable protection) is
provided, before operating or installing the product. Arrange the suitable lifting means, if
required.
3.3LIGHTING
Ensure the area around the valve is adequately lit and is suitable to safely work on the
valve.
3.4HAZARDOUS FLUIDS IN THE PIPE
Take account of the content of the pipe (process fluid) or anything it may have previously
contained. Take special safety precautions where flammable, hazardous substances are
present, or where fluid pressure or temperature may be hazardous to health.
3.5ENVIRONMENTAL SITUATIONS
Take account of: areas at risk of explosion, lack of oxygen (such as tanks, wells, etc.…),
hazardous gases, temperature limits, high or low temperature surfaces, risk of fire (for
example during welding operations), excessive noise, moving machines.
3.6TEMPERATURE
Wait until the temperature normalizes after the interception to prevent any risks of burn
or freezing.

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
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3.7 SYSTEM
Take account of the possible effects on the whole expected working system.
In particular, you must assess any proposed actions and the consequences that may
result in any other part of the system, you must ensure the system remains safe at all
times. Make sure that the control valve is isolated via shut-off valves to prevent any abrupt
variations to the system.
3.8 PRESSURIZED SYSTEMS
Make sure that the pressure is isolated and discharged to the atmospheric pressure in safe
conditions. Take account of a double insulation (double block and vent) and the blocking or
the labelling of the closed valves. Do not consider the system depressurized even if the
pressure gauge indicates zero pressure. The depressurization process should include taking
the valve through its full stroke, to ensure all pressure is allowed to exhaust to
atmosphere.
During the operation the valve is pressurized. Before performing any maintenance
operation or action on the flanges and closing caps, make sure that the line is
depressurized (0 bar) and at ambient temperature.
3.9 TOOLS AND CONSUMABLE PARTS
Before starting the work, make sure to have at your disposal all the tools required to
perform it, do not make use of inappropriate tools. Use only Mec-Rela original spare parts.
3.10 PROTECTION CLOTHES
Take account of whether you and/or others need some clothes against the hazards, such as
chemical products, temperatures, radiations, noise, fall of objects, risks for eyes and face.
3.11 QUALIFICATION OF THE OPERATORS IN CHARGE OF THE WORKS
All works must be performed and supervised by some skilled, trained and competent
personnel.

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
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Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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3.12 HANDLING
Use suitable lifting means for the handling of the products by assessing all the risks
concerning the lifting, the environment load, the individual and the circumstances of the
work which is about to be performed.
3.13 FREEZING
Protect the product in freezing environments where temperatures are lower than the
freezing point of the process fluid.
3.14 OTHER RISKS
During the operation, the external surface of the product can be at temperatures which
are hazardous to touch. Take account of this risk.
3.15 DISPOSAL
The product should be disposed of in accordance with local legislation. This may be
different in each State/Country/Nation. It is the users responsibility to dispose of the
product according to local requirements.
3.16 RISK OF CORROSION AND/OR EROSION
Periodically verify any phenomena of internal and/or external corrosion and/or erosion as
they may significantly damage the pressurized parts by locally reducing the thickness and
as a consequence the safety degree.
Correct
Correct
Wrong!

OPERATIVE MANUAL
MN-L20-A1
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MEC-RELA® - www.mecrela.it –[email protected]
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4 INSTALLATION
The valve body casting is marked with an arrow showing the direction of flow and its
normal flow path. The casting also has markings which show the type of material and
maximum operating pressure. Before installing the valve, make sure that the inside of the
is clean, by performing, if required, an energetic blowing with steam or compressed air.
This should be done with caution.
The installation of a filter (pos. A Fig. 1) upstream the valve will prevent dirt entering the
valve.
To allow periodical maintenance of valves that are installed on continuously operating
systems, it is recommended to install two Isolating valves, located upstream (pos. B Fig. 1)
and downstream (pos. C Fig. 1) of the control valve, and a by-pass one (pos. D Fig. 1). Use
the by-pass valve (pos. D Fig. 1) to manually regulate the process when the control valve is
temporarily disconnected.
The two shut-off valves must have the same internal diameter of the control valve. During
the installation of the valve, make sure that the flow in the pipe goes in the same direction
as indicated by the arrow on the valve body.
Fig. 1 - Installation diagram
The assembling position of the valve does not limit its operation, but it is recommended to
assemble the valve with the actuator pointed upward (pos. E Fig. 1) as other positions may
allow the accumulation of any impurities which are contained in the fluid thus damaging
the valve itself.

OPERATIVE MANUAL
MN-L20-A1
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MEC-RELA® - www.mecrela.it –[email protected]
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Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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4.1 FITTING THE VALVE TO THE PIPE
To ensure a uniform load and a uniform alignment, the flange bolts must be gradually
tightened in criss-cross sequence, as indicated in Fig. 2.
MANDATORY!
Prevent any excessive tightening. Use the recommended tightening torques. Prevent any pipe
misalignment. Choose the flange gaskets according to the operating conditions.
WARNING!
For valves with braze-on connections, the welding operation must be performed
only by qualified personnel and, in order to prevent any damages to the valves, keep the
valve body cold during the above-mentioned operation.
Fig. 2 –Tightening sequence
WARNING!
Any excessive weight of the valve might damage the system structure. If required, support the
valve by using suitable devices (Fig. 3) and/or ropes (Fig. 4).

OPERATIVE MANUAL
MN-L20-A1
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MEC-RELA® - www.mecrela.it –[email protected]
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Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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Fig. 3 - Installation with supports on the ground
Fig. 4 - Installation with lifting ropes
5 ACTUATOR CONNECTION
5.1PNEUMATIC ACTUATOR CONNECTION
The pneumatic actuator is provided with two 1/4" NPT connections, one of which is closed
by a filter. Connect the control air pipe to the connection which has remained free. The
control air must be clean, dry and free from oil and grease and must not exceed an allowed
maximum pressure. The signal required to control the valve is provided on the plate fixed
on the actuator’s yoke. If the valve is provided with a pilot positioner, refer to its
manual.
5.2 CONNECTION OF ELECTRIC ACTUATOR
For the connection of the electric actuator refer to its specific manual.

OPERATIVE MANUAL
MN-L20-A1
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MEC-RELA® - www.mecrela.it –[email protected]
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Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
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6 MAINTENANCE
All operations described below must be performed and supervised by skilled, trained and
competent personnel.
The Mec-Rela valves are uniquely identified by a serial number fixed on the plate located
on the actuator’s yoke. To order any spare parts or for any other need, always refer to the
above-mentioned number.

INFORMATION!
During operation the valve is pressurized. Before performing any maintenance operation or
action on any pressure retaining part, make sure that the line is depressurized (0 bar) and at
ambient temperature.
6.1REPLACEMENT OF ACTUATOR DIAPHRAGM
Separate the actuator from the valve (see section 6.3). In reference to the Fig. 6and Fig.
8for reverse action actuators and the Fig. 5and Fig. 7for direct action actuators, proceed
as follow:
Remove carefully the screws (1) slowly in a crisscross way.
Remove the housing lid (2) by loosing the plate locknut (3) and removing the clamp
(5) then replace the diaphragm (4).
Refit all the items in reverse order.
WARNING!
In order to avoid serious damages, when the valve is provided of bellows, take care not to
turn the plug stem (6).

OPERATIVE MANUAL
MN-L20-A1
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MEC-RELA® - www.mecrela.it –[email protected]
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Fig. 5
Fig. 6
Fig. 7
Fig. 8
CAUTION!
Spring under tensive stress!

OPERATIVE MANUAL
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6.2 REPLACEMENT OF ON/OFF PISTON DISC ON/OFF VALVE
Separate the actuator from the valve (see section 6.3). In reference to the Fig. 9 for
reverse action actuators and the Fig. 10 for direct action actuators, proceed as follow:
Remove the housing screws (1) gradually in a crisscross way.
Remove the housing lid (2) by loosing the plate locknut (3) and removing the clamp
(5) then replace the disc (4).
Refit all the items in reverse order.
WARNING!
In order to avoid serious damages, when the valve is provided of bellows, take care not to
turn the plug stem (6).
Fig. 9
Fig. 10

OPERATIVE MANUAL
MN-L20-A1
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6.3 VALVE /ACTUATOR SEPARATION
By referring to Fig. 11 (for valves 1/2” ÷ 4”) or to Fig. 12 (for valves 6” ÷ 8”) perform the
following steps:
Set the valve to the 50% stroke.
Fully unscrew the screws (1) and remove the terminals (2).
For valves 1/2” ÷ 4” fully unscrew the ring nut (3).
For valves 6” ÷ 8” fully unscrew the screws (4).
Remove the actuator.
To re-assemble the valve and actuator the above steps must be performed in the reverse
order by paying attention to the alignment of stem to the value (A).
Fig. 11 - Valves 1/2” ÷ 4”
Fig. 12 - Valves 6” ÷ 8”

OPERATIVE MANUAL
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6.4 REPLACEMENT OF THE SEAT/PLUG OF THE STANDARD VALVE
By referring to Fig. 13 perform the following steps:
Separate the actuator from the valve body as described in the previous paragraph.
Loosen the nut (10) and fully unscrew the bolts (15).
Separate the bonnet group (9) from the valve body (1).
Remove the complete plug (3) from the bonnet (9).
If required, unscrew and replace the seat (2) by using the specific wrenches.
Insert in the bonnet (9) the new plug by paying attention to grease the stem with
some silicone oil.
Always replace the body gasket (11) and carefully clean the supporting surfaces.
Re-assemble everything by repeating the steps in the reverse order and pay specific
attention to the realignment of stem, seat and plug.
Gradually tighten the nuts (15) in criss-cross sequence, as indicated in the example
in Fig. 2 paragraph 4.01 by applying the torques indicated in chapter 7.

INFORMATION!
Attention: when the plug is being replaced it is also necessary to replace the packing gland
(see next paragraphs).
Fig. 13 - Standard valve

OPERATIVE MANUAL
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6.5 REPLACEMENT OF THE SEAT/PLUG OF THE VALVE WITH QUICK CHANGE SEAT
By referring to Fig. 14 perform the following steps:
Separate the actuator from the valve body as described in the previous paragraph.
Loosen the nut (10) and fully unscrew the bolts (15).
Separate the bonnet group (9) from the valve body (1).
Remove the complete plug (3) from the bonnet (9).
Remove the seat blocking cage (13)
If required, remove and replace the seat (2).
Insert in the bonnet (9) the new plug by paying attention to grease the stem with
silicone oil.
Always replace the body gasket (11) and the seat gasket (14) and carefully clean the
supporting surfaces.
Re-assemble everything by repeating the steps in the reverse order and pay specific
attention to the realignment of stem, seat and plug.
Gradually tighten the nuts (15) in criss-cross sequence, as indicated in the example
in Fig. 2 paragraph 4.01 by applying the torques indicated in chapter 7.

ATTENTION!
When the plug is being replaced it is also necessary to replace the packing gland (see next
paragraphs).
Fig. 14 - Valve with Quick Change seat

OPERATIVE MANUAL
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6.6 REPLACEMENT OF THE SEAT/PLUG OF THE BALANCED VALVE
By referring to Fig. 15 perform the following operations:
Separate the actuator from the valve body as described in the previous paragraph.
Loosen the nut (10) and fully unscrew the bolts (15).
Separate the bonnet group (9), the balancing chamber (7), the complete plug (3)
and the balancing piston (8) of the valve body (1).
Remove any cage (5).
Replace the sealing gasket of the balancing piston (8) by unscrewing the nut (16).
If required, unscrew and replace the seat (2) by using the specific wrenches.
Insert in the bonnet (9) the new plug by paying attention to grease the stem with
the silicone oil.
Always replace the body gasket (11) by carefully cleaning the supporting surfaces.
Re-assemble everything by repeating the operations in the reverse order by
consequently paying attention to the re-alignment of stems, seat and plug.
Gradually tighten the nuts (15) in criss-cross sequence, as indicated in the example
in Fig. 2 paragraph 4.01 by applying the torques indicated in chapter 7.

ATTENTION!
When the plug is being replaced it is required to replace also the packing gland (see next
paragraphs).
Fig. 15 - Valve with balanced plug

OPERATIVE MANUAL
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6.7 REPLACEMENT OF THE SEAT/PLUG OF THE VALVE WITH BELLOWS
By referring to Fig. 16 perform the following steps:
Separate the actuator from the valve body as described in the previous paragraph.
Loosen the nut (10) and fully unscrew the bolts (15).
Separate the bonnet group (9) from the valve body (1).
Remove the complete plug (3) from the bonnet (9).
Remove the pin (17) and remove the plug (3).
If required, unscrew the bellows block (19) and replace it, by replacing also the
gasket (18).
If required, unscrew and replace the seat (2) by using the specific wrenches.
Insert in the bonnet (9) the new plug by paying attention to grease the stem with
the silicone oil.
Always replace the body gasket (11) by carefully cleaning the supporting surfaces.
Re-assemble everything by repeating the steps in the reverse order and pay specific
attention to the realignment of stem, seat and plug.
Gradually tighten the nuts (15) in criss-cross sequence, as indicated in the example
in Fig. 2 paragraph 4.01 by applying the torques indicated in chapter 7.

ATTENTION!
When the plug is being replaced it is also necessary to replace the packing gland (see next
paragraphs).
Fig. 16 - Valve with bellows

OPERATIVE MANUAL
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6.8 REPLACEMENT OF THE STEM PACKING GLAND
By referring to the figure corresponding to your packing gland model (from Fig. 17 to Fig.
24) perfom the following steps:
Remove the plugs as described in the previous paragraphs.
Fully unscrew the screw (1).
Remove the upper packing gland (2).
Remove the spring (3).
Remove the lower packing gland (4).
Replace the O-ring (5) if present.
Carefully clean the housing chamber and grease it with silicone oil.
Insert the new packing gland as indicated in the figure corresponding to your model.
Screw the nut (1) but not completely.
Insert the plug by paying attention to grease the stem with the silicone oil.
Always replace the body gasket, and carefully cleaning the supporting surfaces.
Re-assemble everything as described in the previous paragraphs.
Tighten the nut (1) as indicated in chapter 5.
Fig. 17 - “LP 200”
Fig. 18 - “SP 200”
Fig. 19 - “HP 200”
Fig. 20 - “Eco Pack 1”
Fig. 21 –“LP 400”
Fig. 22 - “SP 400”
Fig. 23 –“HP 400”
Fig. 24 –“Eco Pack 2”

OPERATIVE MANUAL
MN-L20-A1
DC-18-10
MEC-RELA® - www.mecrela.it –[email protected]
a TERRANOVA® Srl brand - www.terranova-instruments.com - VAT IT07848810151
Factory & Sales: Via Gramsci 1 –26827 Terranova dei Passerini (LO) –Italy
Head Office: Via Rosso Medardo 16 –20159 Milano –Italy Ph: [phone] –Fax: +39 0377
855720
Pag. 20/24
7 TIGHTENING TORQUES
VALVE DIAMETERS
SEAT (1)
Nm ± 10%
BONNET NUTS (2) Nm ± 10%
SCREWS
(3)
Nm ±10%
NUT (4)
Nm ±10%
VD10-
KD10-KA10
KD20-KA20
1/2“ ANSI
190
30
45
//
190
3/4“ ANSI
190
30
45
//
190
1“ ANSI
240
30
45
//
190
1” ½ ANSI
550
50
85
//
190
2” ANSI
570
50
85
//
190
3” ANSI
700
100
110
//
190
4” ANSI
850
100
110
//
190
6” ANSI
900
140
160
85
240
8” ANSI
950
145
160
85
240
Fig. 25