DezuriK Molykote Reco 44 and G Rapid - Project Sales Corp

  • 540 views
Uploaded on

 

More in: Business
  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
  • Get a customised B2B digital marketing solutions from VALVE SOLUTIONS. visit us and drop us your valuable enquiries for a special promotional offer.
    Are you sure you want to
    Your message goes here
    Be the first to like this
No Downloads

Views

Total Views
540
On Slideshare
0
From Embeds
0
Number of Embeds
0

Actions

Shares
Downloads
14
Comments
1
Likes
0

Embeds 0

No embeds

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
    No notes for slide

Transcript

  • 1. DeZURIK® 2" THRU 16" 3-WAY AND 4-WAY TAPERED PLUG VALVES INSTRUCTIONS © FOR DeZURIK 3-WAY AND 4-WAY TAPERED PLUG VALVES D-10188 December 1993December 1993© 1993 DeZURIK, A UNIT OF GENERAL SIGNAL D-10188
  • 2. DeZURIK® 2" THRU 16"3-WAY AND 4-WAYTAPERED PLUG VALVESThe DeZURlK 2" thru 16" Tapered Plug valves will provide dependable, trouble free INTRODUCTION service provided the application is correct and the valve is installed and maintained to DeZurik specifications. Each DeZurik valve is tested at the factory to some of the most stringent standards in the industry. A copy of these instructions should be made available to the personnel responsible for the installation and maintenance of this equipment. Refer to the applicable sales bulletin and to the valve data plate regarding materials of construction and product limitations. The following instructions are written following a modular concept. Each separate major assembly in this product will have a separate instruction. Thus the basic valve will have a separate instruction, as will the actuator and any accessories your unit may have. The assembly drawings you receive also follow this concept. This concept was created to make the entire product seem less complicated by breaking it down into smaller, easier to understand modules. SAFETY MESSAGES Safety messages in these instructions and on label(s) on the valve are flagged with one of the words Caution, Warning or Danger. The messages must be carefully read and followed to avoid personal injury and/or equipment damage. After installation, if a safety label on the valve becomes difficult to see or read, or if a label has been removed, please contact DeZURIK for replacement label(s). Include the 7-digit part number from the data plate on the valve, the quantity of valves, and an appropriate name and mailing address. INSPECTION This equipment has been adequately packaged and protected for shipping; however, due to improper handling, the possibility of damage in transit exists. When the valve arrives at its final destination, it should be carefully inspected for damage and equipment malfunction. STORAGE Because the rubber lined seat and plug in this valve may deteriorate if it is not protected from dust, freezing water, sunlight or other ultraviolet rays, store the valve in a clean, dry, cool location with the flange protectors intact. The valve should be stored with the plug horizontal and partially open. If it is necessary to store the valve outdoors, it should be wrapped in plastic and stored high enough off the ground to ensure it will not be immersed in water or buried by snow. The plastic plugs in the cylinder or positioner (if equipped) must be replaced with pipe plugs. REPLACEMENT It is advised that one set of Recommended Spare Parts be inventoried for each valve PARTS size and type. Recommended Spare Parts are identified on the Assembly Drawing. When ordering parts, please include the valve size and part number (7-digit) from the data plate. If possible, also include the Assembly Drawing number, Part Name, Balloon Number and Quantity of parts as shown on the Assembly Drawing.D-10188 December 1993
  • 3. DeZURIK® 2" THRU 16" 3-WAY AND 4-WAY TAPERED PLUG VALVES DESCRIPTION The DeZurik 3-Way and 4-Way Tapered Plug valves are available with material, actuator and accessory options to meet a wide range of application requirements. Three plug styles are offered to provide flow paths with 90 and 360 degree plug rotation. Each different flow path arrangement has a unique number called a Combination Number. See the Product Bulletin for these valves for a complete description of the Combination Numbers. WARNING THIS VALVE IS A PRESSURE VESSEL. PIPELINE PRESSURE MUST BE COMPLETELY RELEASED BEFORE DISASSEMBLY. USE EXTREME CAUTION WHEN REMOVING THE BONNET. THE BONNET WILL BLOW OFF THE VALVE IF THE BOLTS ARE REMOVED WITH PRESSURE IN THE VALVE. INSTALLATION This Instruction Manual covers the installation requirements of the valve only. For actuator or accessory installation information, see the Instruction Manual for that component. FLANGE DRILLING Flanges on U.S. Standard valves are drilled to ANSI Class 125/150 specifications. For flange drillings other than U.S. Standard, see DeZurik Data A-16374. FLOW DIRECTION It is recommended that the valve be installed so pipeline pressure will push the plug into the seat(s) of the port(s) being sealed. TOOLS REQUIRED This valve is assembled using only standard SAE fasteners. To service this valve, you should have a full set of combination wrenches, a pin punch, and a dead blow hammer. You may want to machine a shaft to aid you in removing the lower bearing from the body. See the DISASSEMBLY section for details. LUBRICATION This valve does not require routine maintenance lubrication. If the valve is disassembled, the plug journals and packing must be lubricated as follows: PACKING Packing lubrication requirements are dependent upon the packing material. PTFE Packing - Requires no lubrication. All Packing Other Than PTFE - Apply a light coat of Keystone Nevastane HT-2 to the inside and outside diameters of the packing rings. PLUG JOURNALS Plug journal lubrication is dependent upon the materials used in construction of the valve. Hard Rubber Lined (RS53) Valves - Lubricate the journals on the plug with Dow Corning #44.December 1993 Page 1 of 6 D-10188
  • 4. DeZURIK® 2" THRU 16"3-WAY AND 4-WAYTAPERED PLUG VALVES Cast Iron, Ni-Resist, Bronze and Acid Bronze Valves - Lubricate the journals on the plug with Keystone Nevastane HT-2. All Valves except Hard Rubber Lined, Cast Iron, Ni-Resist, Bronze and Acid Bronze Valves - Spray the journals on the plug with a light coat of Molykote G Rapid Spray, then lubricate with a mixture of powdered graphite and Standard Oil #140 Gear Lube. ADJUSTMENTS All standard DeZurik Tapered Plug valves feature adjustable stem seal packing. If a stem seal packing leak should occur, tighten the gland nuts evenly just until the leakage stops. Do Not continue tightening after leakage stops. If packing leakage cannot be stopped by tightening the gland nuts, the packing must be replaced. On valves not utilizing a Lift, Turn, Reseat actuator, the seat/plug clearance can be adjusted by removing the locknut and wrenching square from the top of the valve, then turning the plug adjusting nut to change the seat/plug clearance. Turning the nut clockwise will increase the clearance between the seat and plug; turning the nut counterclockwise will decrease the clearance. Recommended seat plug clearance is .030" for paper stock and .010" for all other applications. PACKING When Tapered Plug valves are mounted in a vertical pipeline, or mounted in a REPLACEMENT horizontal pipeline with the plug stem horizontal, there is a chance that gravity will cause the plug to swing to a lower position in the valve body when the actuator is removed. To avoid this hazard, place the plug in the lowest position before removing the actuator. Follow these steps to replace the packing: 1. Discontinue pipeline flow and relieve pipeline pressure. 2. Scribe the adaptor and bonnet for alignment when reassembling. 3. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or electrical power to prevent accidental operation of the actuator. WARNING Moving parts from accidental operation of power actuator can cause personal injury or equipment damage. Disconnect and lock out power to actuator before servicing. 4. Remove the actuator from the valve as described in the Actuator Instruction Manual, under the ACTUATOR REMOVAL heading. 5. Remove the six screws fastening the actuator adaptor to the valve, then separate the adaptor from the valve. 6. Remove the two packing gland nuts, then slide the packing gland off the valve shaft. 7. Pull the packing out of the bonnet.D-10188 Page 2 of 6 December 1993
  • 5. DeZURIK® 2" THRU 16" 3-WAY AND 4-WAY TAPERED PLUG VALVES 8. Lubricate the new packing, then install it one ring at a time in the sequence shown in Figure 1. 9. Slide the packing gland down the valve shaft and over the studs. 10. Turn the packing gland nuts onto the studs until they contact the packing gland, then one additional turn. It will be necessary to adjust the packing gland nuts after the valve is pressurized. 11. Fasten the adaptor to the valve, lining up the scribe marks made during disassembly. 12. Install the actuator on the adaptor as described in the Actuator Instruction Manual, under the ACTUATOR INSTALLATION heading. 13. If the actuator is a powered actuator, reconnect power to the actuator. 14. The valve is now ready to control flow. DISASSEMBLY When Tapered Plug valves are mounted in a vertical pipeline, or mounted in a horizontal pipeline with the plug stem horizontal, there is a chance that gravity will cause the plug to swing to a lower position in the valve body when the actuator is removed. To avoid this hazard, place the plug in the lowest position before removing the actuator. Together, the DISASSEMBLY and REASSEMBLY sections cover the steps required to replace all the recommended spare parts in this valve.December 1993 Page 3 of 6 D-10188
  • 6. DeZURIK® 2" THRU 16"3-WAY AND 4-WAYTAPERED PLUG VALVES WARNING THIS VALVE IS A PRESSURE VESSEL. PIPELINE PRESSURE MUST BE COMPLETELY RELEASED BEFORE DISASSEMBLY. USE EXTREME CAUTION WHEN REMOVING THE BONNET. THE BONNET WILL BLOW OFF THE VALVE IF THE BOLTS ARE REMOVED WITH PRESSURE IN THE VALVE. 1. Discontinue pipeline flow and relieve pipeline pressure. 2. Scribe the adaptor, bonnet and valve body for alignment when reassembling. 3. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or electrical power to prevent accidental operation of the actuator. WARNING Moving parts from accidental operation of power actuator can cause personal injury or equipment damage. Disconnect and lock out power to actuator before servicing. 4. Remove the actuator from the valve as described in the Actuator Instruction Manual, under the ACTUATOR REMOVAL heading. 5. Remove the six screws fastening the actuator adaptor to the valve, then separate the adaptor from the valve. 6. Remove the screws securing the bonnet to the valve body, then separate the bonnet from the valve. 7. Note the orientation of the plug in relationship to the valve ports, then lift the plug from the valve body. 8. Remove the two packing gland nuts, then slide packing gland off the valve shaft. 9. Pull the packing out of the bonnet. 10. Reaching in thru the packing chamber in the bonnet, drive the upper bearing out of the bonnet using a hammer and pin punch. 11. Remove the lower bearing from the valve body. The bearing can be chiseled out; or, it can be hydraulically forced out by filling the ID of the bearing with water, then pounding a shaft with the same OD as the lower journal of the valve plug into the bearing. This will create a hydraulic force under the bearing that will force it out. See Figure 2. 1. Push a new lower bearing into the valve body. REASSEMBLY 2. Place the plug in the valve body. Turn it so it is in the position noted during disassembly. 3. Push a new bearing into the bonnet.D-10188 Page 4 of 6 December 1993
  • 7. DeZURIK® 2" THRU 16" 3-WAY AND 4-WAY TAPERED PLUG VALVES 4. Place the bonnet on the valve, line up the scribe marks, then fasten the bonnet in place. 5. Lubricate the new packing, then install it one ring at a time in the sequence shown in Figure 1. 6. Slide the packing gland down the valve shaft and over the studs. 7. Turn the packing gland nuts onto the studs until they contact the packing gland, then one additional turn. It will be necessary to adjust the packing gland nuts after the valve is pressurized. 8. Fasten the adaptor to the valve, lining up the scribe marks made during disassembly. 9. If the actuator is a powered actuator, reconnect power to the actuator. 10. Install the actuator on the adaptor as described in the Actuator Instruction Manual, under the ACTUATOR INSTALLATION heading. 11. The valve is now ready to control flow. VALVE REMOVAL To remove the entire valve assembly from the pipeline, follow these steps carefully. FROM PIPELINE 1. Relieve pipeline pressure and drain the portion of the system where the valve is located. 2. Close the valve. 3. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or electrical power to prevent accidental operation of the actuator.December 1993 Page 5 of 6 D-10188
  • 8. DeZURIK® 2" THRU 16"3-WAY AND 4-WAYTAPERED PLUG VALVES WARNING Moving parts from accidental operation of power actuator can cause personal injury or equipment damage. Disconnect and lock out power to actuator before servicing. 4. Support the valve assembly, then remove the flange bolts. 5. Remove the valve from the pipeline.D-10188 Page 6 of 6 December 1993