bray/ vaas bonneted series knife gate valve 980/982/985 ...… · 980/982/985/741 series operation...

Bray/ VAASBonneted Series Knife Gate Valve

980/982/985/741 SeriesOperation and Maintenance Manual

Table of Contents

Definition of Terms 1

Safety Instructions 1

Introduction 2

Unpacking 2

Storage 2

Installation 2

Commissioning 3

Cylinder-Operated Valves 3

Manual Valves 3

Bonnet Packing Replacement 3

Cylinder-Operated Valves 3

Manual Valves 4

Valve Seat and Packing Replacement 4

Bonnet Purge 4

Actuator Maintenance 4

Parts List 6

Spare Parts 6

For information on this product and other Bray products please visit us at our web page - www.bray.com.

Bidirectional - Perimeter Seat Series

Operations and Maintenance Manual

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Bonneted SeriesOperation and Maintenance Manual

Definition of Terms - Safety Instructions

READ AND FOLLOW THESE INSTRUCTIONSSAVE THESE INSTRUCTIONS

DEFINITION OF TERMS

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury

NOTICE Used without the safety alert symbol indicates a potential situation which, if not avoided, may result in an undesirable result or state, including property damage

HAZARD-FREE USEThis device left the factory in proper condition to be safely installed and operated in a hazard-free manner The notes and warnings in this document must be observed by the user if this safe condition is to be maintained and hazard-free opera-tion of the device assured

Take all necessary precautions to prevent damage to the valve due to rough handling, impact, or improper storage Do not use abrasive compounds to clean the valve, or scrape metal surfaces with any objects

The control systems in which the valve is installed must have proper safeguards to prevent injury to personnel, or damage to equipment, should failure of system components occur

QUALIFIED PERSONNEL• A qualified person in terms of this document is one who is familiar with the installation, commissioning, and operation

of the device and who has appropriate qualifications, such as:

• Is trained in the operation and maintenance of electrical equipment and systems in accordance with established safety practices

• Is trained or authorized to energize, de-energize, ground, tag, and lock electrical circuits and equipment in accordance with established safety practices

• Is trained in the proper use and care of personal protective equipment (PPE) in accordance with established safety practices

• Is trained in first aid

• In cases where the device is installed in a potentially explosive (hazardous) location – is trained in the commissioning, operation, and maintenance of equipment in hazardous locations

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The valve must only be installed, commissioned, operated, and repaired by qualified personnel.

The device generates a large mechanical force during normal operation.

All installation, commissioning, operation, and maintenance must be performed under strict observation of all applicable codes, standards, and safety regulations.

Observe all applicable safety regulations for valves installed in potentially explosive (hazardous) locations.

INTRODUCTIONThe Bray/ VAAS Series 980/982/985/741 features a cast or fabricated body with mounting flange and a cast or fabricated bolt-on bonnet The sealing to atmosphere is achieved using a round gland sealing arrangement on the top of the bonnet

Additional information about the bonneted Series valves – including application data, engineering specifications, and actua-tor selection is available from your Bray/VAAS distributor or sales representative

UNPACKINGEnsure the box is not damaged externally Remove the valve from the packaging and check for any damage to the valve and its components during transit

Valve size and brief material specification of body (markings such as “SS” or “DI”) are marked on the valve body Stainless steel nameplate (below) fixed on to the yoke of valve contains most of the relevant information on the valve including Bray/VAAS work order number and unique serial number of the valve These details should be quoted for all requirements of service and spares

SERIAL NUMBER

SIZE MODEL FLG. DRILL BODY GATE

SEAT PACKING CWP MAX TEMP

STORAGEWrap the valve with a polyethylene cover Cover the ports for pneumatic actuator/accessories with plastic caps Store these valves in the same packing indoors and without direct exposure to the environment

INSTALLATION• On larger sizes (750mm & above), a valve bonnet is provided with two lugs which can be used for lifting/holding the

valve during installation/removal from pipe/ removal of bonnet from valve

• On horizontal lines, if there is a possibility of particles/solids settling at the bottom, it is preferable to install the valve so that the stem is horizontal/inclined

• Install the valve between flanges using fasteners and gaskets

• Bolt holes in the chest area are always blind tapped and care should be taken not to bottom the bolts while tighten-ing Refer to GA Drawing/Technical Bulletin for quantity and size of blind tapped holes on valve chest area If the cor-rect size bolts are not available, use studs and nuts for chest area bolts to avoid damage of body

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Support should be used for valves size 8” and over when installed in vertical pipe Failure to do so can result in improper valve operation and/or valve failure

COMMISSIONING GUIDELINES

• Gland packing is tightened to hold the specified pressure and tested for no leakage before dispatch However, this may require some adjustment at site due to loosening in transit etc

• Check for gland leakage after the valve is subjected to pressure and if any leak is observed, tighten the gland uniformly in a cris-cross pattern until the leakage stops

Wrong electrical supply to accessories will damage the equipment Do not over tighten the gland nuts as this may cause excessive friction and premature damage to packing

Cylinder Operated Valves1 Connect instrument quality air, preferably through an air filter/regulator of adequate size The recommended air pres-

sure is 80-120 psi (5-8 bar) Refer to the appropriate bulletin/drawing for port and cylinder size details

2 Ensure the supply air is free from moisture, dirt, and other foreign particles Drain the filter regulator before operating the actuator so that pipe rust and dirt if any in the air line will be removed before actuation

3 If valves are supplied with electrical accessories like limit switch and solenoid valve, ensure wiring is done as per local electrical safety codes and regulations Ensure correct electrical supply is given to electrical accessories for proper func-tioning and safety of the equipment

4 Open the valve by energizing the solenoid valve/giving air supply to cylinder and operate the valve 2-3 times

Manual valvesOpen/Close the valve manually and observe valve operation

BONNET PACKING REPLACEMENT1 Relieve the line pressure

2 Fully close the valve

3 Ensure the line is empty, and flush if necessary

Cylinder operated valves1 Switch off the electrical supply to the solenoid and limit switches

2 Remove the cylinder tubing and vent the air inside the cylinder

3 Remove stem guard if applicable

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4 Disconnect the piston rod from the bonnet stem by removing the connector bolting

5 Apply air slightly to the bottom port of the actuator so that the piston rod is retracted

6 Remove the actuator assembly from the valve by removing the fasteners connecting the yokes to the bonnet

Manual Valves1 Ensure the valve is fully closed

2 Remove stem guard if applicable

3 Disconnect the hand wheel stem from the bonnet stem by removing the connector bolting

4 Rotate the hand wheel counter-clockwise by holding the stem from rotation, so that the stem retracts fully

5 If valves are supplied with bellows, ensure the stem is not rotating, as rotation will damage the bellows

Procedure1 Remove the bonnet gland fasteners (10) and the gland (9)

2 Remove the old bonnet gland packing (8) from the packing chamber, one layer at a time, using a long thin tool to pry it out

3 If the lowest layer is a wiper ring (copper, Inconel etc ), clean it with a common solvent; if damaged, replace with a new one

4 Insert the new packing (8) one at a time, stagger the cut end of the packing so that they do not line up

5 Tap each packing ring firmly and evenly into the chamber before installing the next ring; the ends of each ring should meet but not overlap

6 Install the bonnet gland (9) and the gland fasteners (10)

7 Tighten the gland nuts (10) finger tight plus half turn

NOTICE

If leakage is observed from the packing area after installing the valve in the pipeline and the valve is pressurized or charged with media, tighten the gland nuts evenly, side to side, just enough to stop leakage Do not overtighten the gland nuts

Valve Seat & Valve Packing Replacement

Remove the actuator assembly / Hand wheel assembly and bonnet from the valve Refer appropriate basic IOM for seat replacement and valve packing replacement

Bonnet purge

Valves are provided with 2 nos purge plugs (7) of ½” or 1” NPT on the bonnet for flushing Remove any one of the purge plugs and connect ½” or 1” pipe Periodic flushing through these ports are recommended to remove any sediment inside the bonnet

Actuator Maintenance

Pneumatic CylinderThe Bray / VAAS pneumatic cylinder actuator is a low maintenance design and does not require routine maintenance It has an FRP tube which is lubricated for life with a special coating on the inside wall Filtered dry instrument quality air (non-lubricated) should be used for its operation at the specified air supply pressure

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* Flange profile may vary based upon model

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Gear unit /Spring return Actuator/ Hydraulic cylinder/AccessoriesRefer to the respective manuals released by the OEM or contact Bray/VAAS sales office or factory for assistance

Parts List

No Description1 Body2 Gate3 Gland Packing4 Gland5 Bonnet Stem6 Bonnet7 Purge Port8 Bonnet Gland Packing9 Bonnet Gland10 Gland Fasteners11 Super Structure12 Yoke Sleeve13 Hand Wheel

Recommended Spare PartsFollowing are parts recommended as spares, which may be stocked Following are general recommended spares for bon-net construction Respective basic valve IOM may be referred for the spares for valves Provide the valve serial number and work order number from the nameplate for proper parts

Bonnet Gland PackingCylinder Repair Kit

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Troubleshooting

Trouble Possible cause Solution

Media oozing out of gland packing Packing deteriorated Replace packing

In fully closed position, valve leaks

Seat is worn out or torn Replace seat

Gate is scratched Replace gate

High torque during valve seating and unseating

Misalignment between gate and stem

1 Remove the clevis fasteners2 Loosen the superstructure fasteners3 Adjust the alignment of the stem and

gate4 Connect the clevis fasteners5 Retighten superstructure fasteners

Packing is not tightened properly Adjust gland nuts

Valve jerks during open and close

Superstructure fasteners loosen Tighten the super structure fasteners

Insufficient air supplyPneumatic operated valves: Increase supply pressure

Solenoid valve dust accumulation Remove and clean solenoid valve

Piston rod seal damaged Replace seal

Unable to close or open the gate (Appli- cable only for unidirectional valves)

Gate is bent

1 Check for valve orientation, flow direc-tion and flow indication

2 Re-orient the valve3 Replace gate

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All statements, technical information, and recommendations in this bulletin are for general use only Consult Bray/VAAS representatives or factory for the specific requirements and material selection for your intended application The right to change or modify product design or product without prior notice is reserved Patents issued and applied for worldwide

Bray® is a registered trademark ofBray International, Inc © 2015 Bray International, Inc All rights reserved

OM_Bonneted Series_12_20_2016

Bray/VAASDivision of Bray International, Inc 13333 Westland East Blvd Houston, Texas 77041Tel: 281 894 5454 • www bray com

bray/ vaas bonneted series knife gate valve 980/982/985 ...… · 980/982/985/741 series operation...

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