nlbitdsl plvl non lubricated sleeve plug valve plug valve manual.pdf · 2018-01-05 · nlbitdsl...

N l b i t d Sl Pl V l

Doc. No. 3ZQM-E-01 Approved by H.S.KIM

Rev. No. D Checked by Y.J.KANG

Issued 20,FER,2017 Prepared by J.E.KO

Plug Valve SpecialistsStrong Company! Good Company!

Installation,Operation and

Non lubricated Sleeve Plug Valve

Maintenance

3Z CORPORATION254 SIHWA VENTURE-RO, SIHEUNG-SI, GYEONGGI-DO, SOUTH KOREA (TEL) +82.2.333.1212 (FAX) +82.2.333.4111E-mail : [email protected] Web: http://www.3zvalve.com

0. Contents

Contents

1. Specification & Availability 3

2. Exploded View of Sleeved Plug Valve 4

3. Storage(Preservation) and unpacking 5

4. Installation 5

5. Commissioning and Operation 6

6. Maintenance and Repair (Troubleshooting guide) 7-14

7. The Value of Valve Torque 15

8. The Value of Valve Weight and Lifting Point 16

9. Live Loaded Plug Valve 17g

10. Gear Operator 20

11. Name Plate & Spare Parts 22

-1 -

0. General Introduction

0-1. Introduction

This manual is designed including the explanation of storage • installation • test • maintenance for all

of the sleeved plug valve supplied by 3Z. You must comply with this manual to maintain and manage p g pp y p y g

the sleeved plug valve for a long time.

0-2. User safety

All of the person in charge must fully aware of the contents described here, understand and practice

exactly. But the matters of instructions of this manual are not fully explained for all about any

unforeseeable accident that can occur in sleeved plug valve related equipment and a variety ofunforeseeable accident that can occur in sleeved plug valve, related equipment, and a variety of

working process, so when you act by the contents of this manual, you must handle properly depending

on the common sense and experience of the relevant worker situationally.

The procedures and orders of this manual are composed of maintenance of sleeved plug

valve to assist the user. Please read the notes below.

CAUTIONNever do not attempt to repair the valves or components during under pressure. It can lead to serious injury or death.

!

Please read the instructions before repairing the valves. If you do not follow the instructions of this manual, you can lead to serious injury or death.

WARNING! NOTICEThe instructions of this manual are explain the valves what are produced currently.If you need to repair the discontinued valve, please contact with 3Z service center, and make certain that the correct repair method and instruction.

0-3. Protective Clothing

3Z products are often used in problematic applications (e.g. extremely high pressures, dangerous, toxic

or corrosive mediums). When performing service, inspection or repair operations always ensure that the

valve and actuator are depressurized and that the valve has been cleaned and is free from harmful

substances. In such cases pay particular attention to personal protection (protective clothing, gloves,

glasses, etc.).

Qualified personnel are people who on account of their training experience and instruction and their

0-4. Qualified Personnel

-2-

Qualified personnel are people who, on account of their training, experience and instruction and their

knowledge of relevant standards, specifications, accident prevention regulations and operating

conditions, have been authorized by those responsible for the safety of the plant to perform the

necessary work.

1-1. Specification

1. Specification & Availability

3Z sleeved plug valves have the specifications as following table.

Fig 120 320 620 120FB 320FB 620FB

Rating 150 300 600 150 300 600

Size 0.5” ~ 24” 0.5” ~ 24” 0.5” ~ 16” 0.5” ~ 16” 0.5” ~ 16” 0.5” ~ 8”

Size for CE 15 ~ 600 15 ~ 600 15 ~ 400 15 ~ 400 15 ~ 400 15 ~ 200

Temperature -46°C ~ 326 °C

Connection Flange,BW,SC Flange,BW,SC Flange,BW,SC Flange,BW,SC Flange,BW,SC Flange,BW,SC

Design ASME B16.34, API 599, API 6D

End To End ASME B16.10

Dimension

of FlangeASME B16.5, ASME B16.11, ASME B16.25

Component Materials Operating Temperature (°C)

ASTM A 216 WCB -29 ~ 425

ASTM A 216 WCC -29 ~ 425

1-2. Available Materials

The main materials used in the 3Z sleeved plug valves are used in a following temperature range.

Body/Plug/Cover

ASTM A 351 CF3 -29 ~ 425

ASTM A 351 CF3M -29 ~ 450

ASTM A 351 CF8 -29 ~ 525

ASTM A 351 CF8M -29 ~ 525

ASTM A 351 CN7M -29 ~ 325

ASTM A 352 LCB 46 325ASTM A 352 LCB -46 ~ 325

Jacket

ASTM A 516 70 -46 ~ 425

ASTM A 240 304 -18 ~ 525

ASTM A 240 316 -18 ~ 525

Sleeve

PTFE -29 ~ 204

RTFE -29 ~ 220

250EP 29 250250EP -29 ~ 250

320EP -29 ~ 326

Gasket

RTFE -29 ~ 220

250EP -29 ~ 250

320EP -29 ~ 326

-3-

2. Exploded View of Sleeved Plug Valve

62

14

3

5

8

7

13

12

1

4

9

11

10

No Parts Material Specification

1 Body Carbon Steel ASTM A216 WCB

* Materials of Construction (Standard)

1 Body Carbon Steel ASTM A216 WCB

2 Plug Stainless Steel ASTM A351 CF8M

3 Cover Carbon Steel ASTM A216 WCB

4 Sleeve PTFE -

5 Cover Bolt ALLOY STEEL ASTM A193 B7

6 Adjusting Bolt Stainless Steel AISI 304

7 Hub Stainless Steel ASTM A351 CF8

8 Wrench Carbon Steel AISI 1045

9 Delta Ring RTFE -

10 Reverse Lip RTFE -

11 Metal Diaphragm Stainless Steel AISI 316

12 Thrust Collar Stainless Steel AISI 304

13 Anti-static Device Stainless Steel AISI 304

14 Hub Bolt Stainless Steel AISI 304

* In order to know the correct specification of delivered products, you have to refer the approved Proposal Drawing.

-4-

3-1. When you transport the valve, do not throw, drop, throw down, or drag.

3-2. Before the valves are installed in the piping and operating, you must transport or storage with the valveopen position to prevent damage to the sealing surface of the plug. (Preservation)

3. Storage (Preservation) and unpacking

3-3. The valve shall not be stored in a cool and dry place to protect from the climatic condition such asdust, moisture, or rain.

3-4. The flange cover should not be taken off from the valve until installation to prevent from the damages to the flange and contamination with foreign material into the valve. (Preservation)

3-5. Periodical checks have to be carried out in the storage area to verify that the above mentioned conditionsare maintained a e a ta ed

Avoid the flame, fire or hot/cold temperature, which could damage gasket or seal parts and happen to leakage.

Dry the valve body before painting of the valve because humidity may cause the destruction ofwaterproof joint.

3 6 While unpacking the valve check the packing list against the materials received

!

!

3-6. While unpacking the valve, check the packing list against the materials received. Lists describing the valve and accessories are in each shipping container.

3-7. Contact your shipper immediately if there is shipping damage.

3-8. Should any problem arise, call your 3Z representative.

4. Installation

4-1. A valve being carried, a rope, wire, and shackle should be strong enough to sustain the total weight.

4-2. The valve should be installed with the firm groundwork.

4-3. Flange ends type valves should be fitted parallel with counter flange and use standard gasket. The bolts to fit should be tightened by diagonal axis successively.

!

!

Poorly aligned pipe connections cause leakage, fissuring rupture during use under pressure.

4-4. Please always follow up guidance specified at attached tag plate.

Check material grade on name plate or body to verify compatibility of fluids with the valve!

-5-

Check material grade on name plate or body to verify compatibility of fluids with the valve.

4-5. In case welded ends types valves, the excessive heat may cause the damage on seal parts. There fore heat should not be transferred to the central seal parts of the body.

5. Commissioning and Operation

5-1. No one may treat a valve except the practiced expert.

5-2 If the valve is equipped with a locking device only the concerned operator or the supervisor should5 2. If the valve is equipped with a locking device, only the concerned operator or the supervisor should keep the key. In case the device wants repairs, it should be done right away.

5-3. After installation, the valve shall be fully opened and should remain in this full open position until lines arethoroughly cleaned and flushed.

5-4. During operation, care shall be taken not to adjust the adjusting bolts and cover bolts except for operators.

5-5. Never take away any attached tag or device from the valve nor any function could be removed at discretion.

!

!

5-6. Whatever slight defect if detected in the valve, the operation shall be stopped.

5-7. The application terms must be observed; for example, the pressure limitation and the application for material.

Check the maximum working pressure on the Name plate .

Check marking of maximum operating temperature on the name plate.

!

!

Do not use v-notch stamps on the body which happen to weakness of the body strength andthen cause leakage or serious injury during use under pressure.

5-8. In accord with the manual, the inspection of the function shall be carried out periodically any always right before the operation of the valve.

Keep filtration of the fluid, internal wearing under the effect of an abrasive cause leakage, fi i t d i d! fissuring rupture during use under pressure.

5-9. The maximum force required at the handwheel or wrench to apply the breakaway torque shallnot exceed 360N.

Any tool or other device to operate valves may cause serious problem like leak or malfunction.!

VA

LVE

O

VA

LVE

COP

EN

CL

OS

E

-6-

6. Maintenance and Repair

3Z sleeved plug valves are designed and manufactured for trouble-free for long time using. But, if

problems are encountered in using, you can use it as the new valve by adjusting or maintaining as

followsfollows.

Possible Defect Remedy Guide Remark

Leakage at

flange

1. Tighten the gasket with flange bolt.

2. Replace the gasket.

1. ASME B16.5 (gasket size,

flange bolt for class, size)

2. The Value of bolting torque

6-1. Troubleshooting Guide

g p g g q

(Section 6.7)

Stem leakage

1. Tighten for 90° turning the adjusting

bolt.

If you over-adjust the adjusting bolt,

The torque of valve is increased.

2 Replace the top seal set


(Section 6.7)

2. Replace top seal (Section 6.4)!

2. Replace the top seal set.

Cover leakage1. Tighten the reverse lip with cover bolt.

2. Replace the reverse lip.

1. Assembly Cover (Section 6.6)

2. The Value of Bolting Torque

(Section 6.7)

3. Replace top seal (Section 6.4)

Reverse lip

(Part No.10)

1 Tighten for 90° turning the adjusting

In -line leakage

1. Tighten for 90 turning the adjusting

Bolt.



2. Replace the sleeve.


(Section 6.7)

2. Replace sleeve (Section 6.5)

Sleeve

(Part No.4)

1. Loosen the adjusting bolt until the

!

Excessive torque

torque is decreased.

Leakage can occur at the valve if you

loose too much the adjusting bolt.


(Section 6.7)

6-2. Caution

- If the leakage stop by excessive adjustment of adjusting bolt, perhaps the sealing part is damaged byb i h ld l h li

!

abrasion. So you should replace the sealing part.

- To check the leakage, confirm after performance the opening and closing the valve.

- When the leakage occurs, the operator must not operate arbitrarily. Adjust with supervisor and theperson in charge.

-7-


6-3. Procedure

* Perform the replacing components and maintenance of the valves by the following Guide

Content

Perform the replacing components and maintenance of the valves by the following Guide.

Top Seal Assembly Sleeve / Plug Assembly

See section 6.4 “ replace top seal” See section 6.5 “ replace sleeve”

Cover / Bolting Valve Test

Assembly / Adjusting

See section 6.6-6.7“ Assembly cover & Adjusting plug”

See section 6.8 “ Shell & Seat Test”

-8-


6-4. Replace Top Seal Set

3Z sleeved plug valve has been properly adjusted at the factory, so no further adjustment is necessary.

But if Line Leakage or Stem Leakage occur during use, replace TOP SEAL as following.g g g , p g

5. After completion of claus 4, put ontop of Metal Diaphragm to TopThrust Collar, and match theconcentric.

4. After completion of clause 3, put theGraphite Diaphragm into Top ThrustCollar. You have to use the Graphitesame with corresponding Top ThrustCollar.

3. Seat the Reverse Lip at the Plug Stempart. Check assembling Reverse Lipand Delta Ring.

CAUTION : When assemble the Reverse Lip, prevent the scratch by Plug edge part.

6. After completion of clause 5, put theBtm Thrust Collar to the Top ThrustCollar.

!

1. After cleaning the Plug with cleaningliquid, Check for damage to the surface.

2. Put the Delta Ring over the Plug.

-9-

* Assemble the components same order as the pictures lastly.


6-5. Replace Sleeve

* Sleeve Special Tools

To replace the sleeve, you need the special tools such as following picture. You can purchase Special toolsfrom 3Z separately.

1

Plunger

Sleeve-removing Punch

2

4 6

Spreading Tool

Outside Sleeve Sizing Body

2

5

Loading Punch

3

7

Marking Line

Sizing PlugLoading Ring

You must read the following precautions before

CAUTIONNever do not attempt to repair the valves or

d i d

CAUTIONYou must neutralize and blotclean the material remainingi h i If h l i

! !

precautions before repairing the valve.

components during under pressure. It can lead to serious injury or death.

in the pipe. If the valve isinstalled in the pipeline, usersmust follow the procedure.Safety equipment must beworn at all times. If you donot follow this procedure, itcan result in serious injury.

-10-


6-5. Replace Sleeve

3Z sleeved plug valve has been properly adjusted at the factory, so no further adjustment is necessary. But if

Line Leakage or Stem Leakage occur during use replace and repair the Sleeve as following

CAUTIONNever do not attempt to repair the valves or components during under pressure. It can lead to

Line Leakage or Stem Leakage occur during use, replace and repair the Sleeve as following.

!

5. Push the claus ① Sleeve Sizing Plug. 9. Put on claus ③ Sleeve LoadingRing to Top Seal processingpart of Body, and insert Sleeve.

10. Put on claus ⑤ Sleeve Loading

serious injury or death.

1. Check whether or not there areproblems where the top, bottom,both vertical sides of Body PressureRib that removed the Sleeve.

2 Ch k th l f d h t6. Insert to entry with claus ① Sleeve

Punch to Sleeve, and insert Sleeveinto Body.

2. Check the sleeve for damage whatwill be replaced.

y ①Sizing Plug.

7. Push to the marked part of claus ①Sleeve Sizing Plug.(Keep Sizing state about 1 minute.)

11. When assemble, prevent thescratch on the surface of Sleeve.

8. Turn claus ② Sizing Tool inside outand separate Sleeve with claus ④

3. Check the claus ② external sizingjig assembly. (check the jig

12. Assemble and check for seatingthe Sleeve until reach to theupper jaw, and lower jaw of PortLip.

13. If not seated inside, you shouldseat the Sleeve inside into PortLip inside with push bar.

and separate Sleeve with claus ④remove jig.

jig assembly. (check the jigscratches)

-11-

4. Insert the Sleeve into claus ②external sizing jig assembly.


6-5. Replace Sleeve

3Z sleeved plug valve has been properly adjusted at the factory, so no further adjustment is necessary. But if

Line Leakage or Stem Leakage occur during use, replace and repair the Sleeve as following

CAUTIONReplaced Sleeve that after disuse the existing sleeve can be scratched or wounded. If there is scratch, it can occur

!

Line Leakage or Stem Leakage occur during use, replace and repair the Sleeve as following.

* Consistent state of sleeve assembledin Body

there is scratch, it can occur the internal leakage.

14. Extend the Sleeve at the insideof body with clause ⑥ half moonsizing.

17. Completely expose the Port Lipby removing the Sleeve Burrwhat protrude from Port Lip.

* Check the appearance of Plug(Check the damage of Plug Seat face)

15. Put until 2nd Sizing jig markingline with press.

16. Perform 3rd Sizing samemanner as in 2nd Sizing.

18. After exposure Port Lip, trim itwith knife. And cleanse the valveclean.

CAUTIONWhen perform cutting process after replacement sleeve, if there is excessive scratch it

!

there is excessive scratch, itcan occur the internal leakage.

-12-


6-6. Cover Assembly & Adjustment

3Z sleeved plug valve has been properly adjusted at the factory, so no further adjustment is necessary.

But if Line Leakage or Stem Leakage occur during use, adjust the Cover Bolt and Adjusting Bolt as following.

1 3

CAUTIONNever do not attempt to repair the valves or components during under pressure It can lead to

!

24

4. Tighten the Cover Bolt crossed, and tighten until reach Bolt torque reference to The Value of Bolting Torque (Section 6.7).

5. Check the height of the fix bolt certainly by tightening Adjusting bolt until moving the plug.

pressure. It can lead to serious injury or death.

1. Put on Cover to top of Plug.

2. When you assemble the Cover,you should match Cover materialmarking and Body material marking.

6-7. Adjustment

1. If the leakage occur at cover seal, tighten Cover Bolt uniformly conform to the below table. :

* Recommended Bolting Torqueg y g

Bolt Size A193 B8 (N.M) A193 B7 (N.M)

M8 10 18

M10 21 36

M12 36 63

M16 78 137

3. When you assemble the CoverBolt, tighten diagonally andrepeatedly, and tighten the propertorque with Torque Wrench.

2. If the line leakage occur at plug seal, Tighten for 90° turning the

M20 175 305

M24 302 526

M30 602 1,047

-13-

Adjustment Bolt or Screws.

3. When assemble the Adjusting Bolt, be careful not to exceed thelimit of recommended Boling Torque.


6-8. Shell & Seat test

If you want to test the valve on the field, carry out such as the following contents.

Only if the state of the valve body casting, it must be performed the strength and leakage test by pressure regulation allows pursuant to casting materials, this is called Shell test.

Shell & Seat Test* Table (1) Test Pressure of API 598

ASMEB16.34Group No.

Material CLASS38℃

RATING(BAR)

Shell TestPressure(BAR)

Seat TestPressure(kg/cm²)

1.1 WCB

150

300

19.6

51.1

30

77

About the state of the sealing Seat in valve complete products, it must be performed leakage test by applying the inspection pressure standard as confirmed medium, this is called Seat test.

Inspection object valves are must clean state with no foreign

600 102.1 154

1.3 LCB

150

300

600

18.4

48.0

96.0

28

72

144

2.1 CF8

150

300gsubstance.

All of the valves that produced from 3Z Corp. are pass Shell & Seat Test, and carried out in accordance with the provisions of 3Z(Table (1), Table (2)), and it managed drastically by our quality control regulations.

4~7

(Gas)

60019.0

49.6

99.3

29

75

1492.2 CF8M

150

300

600

2.3CF3

150

300

15.9

41.4

24

63

Code and Standard

API 598 Valve Inspection and Testing

API 6DSpecification for pipeline valves

ASME B16 34

CF3M600 82.7 125

2.8 CD4MCu

150

300

600

20.0

51.7

103.4

30

78

156

1.2WCC

150

300

19.8

51.7

30

78ASME B16.34Valves-Flanged, Threaded, and Welding End

Valve Shell Seat

~2” 15 15

* Table (2) Test Duration (Unit : Sec) of API 598Test Condition

Valves that produced from 3Z Corp. finish the pressure test such as following conditions

LCC600 103.4 156

- Perform the SEAT TEST by 4~7 bar or 1.1 times of 38℃ rating.

~2 15 15

2 1/2”~6” 60 60

8”~12” 120 120

14”~ 300 120

following conditions.

If there are special demand standard from customer, please let us know the requirement.

-14-

7. The Value of Valve Toruqe

7-1. Valve Torque with PTFE Sleeve material

* Table (1) 120/320 PTFE Torque

Following Torque Table is Maximum Allowable Valve Torque.

FIG. SIZE BREAK (N.m) RUNNING (N.m) SEATING (N.m)

120/320 0.5 20 12 16

120/320 0.75 20 12 16

120/320 1 49 29 39

120/320 1.5 89 53 71

Table (1) 120/320 PTFE Torque

120/320 2 128 77 102

120/320 3 147 88 118

120/320 4 289 173 231

120/320 6 565 339 459

120/320 8 977 586 782

120/320 10 1,666 1,000 1,333

120/320 12 2,362 1,417 1,890

120/320 14 3,443 2,066 2,754

120 16 4,645 2,787 3,716

120 18 6,781 4,069 5,425

• If the first time of using PTFE Sleeve, or following of the material, torque can be increased :RTFE = PTFE x 1.25 HTEP = PTFE x 1.3

FIG. SIZE BREAK (N.m) RUNNING (N.m) SEATING (N.m)

120FB 0.75 17 12 14

120FB 1 60 42 48

120FB 1.5 123 86 98

* Table (2) 120FB PTFE Torque

120FB 2 198 139 158

120FB 3 590 413 472

120FB 4 867 607 694

120FB 6 2,212 1,549 1,770

120FB 8 4,732 3,312 3,785

120FB 10 9,714 6,800 7,771, , ,

120FB 12 15,571 10,900 12,457

120FB 14 22,605 15,823 18,084

120FB 16 31,196 21,837 24,956

-15-

• For other inquiries about Torque, Please contact 3Z Head office : 070-7511-9100

8. The Value of Valve Weight and Lifting Point

You must see the following table for the weight of the valve.

CAUTION : The larger the size of the valves, the valves are heavier. So you must be careful

8-1. Valve Weight

!

SIZE 120 320 120FB 320FB

4G 45 59 108 108

6 61 95 218 244

8 107 147 443 505

* Valve Weight (units : kg)when transporting the valve.

10 152 214 702 -

12 230 312 1065 1542

14 336 507 1590 -

16 516 - 1932 -

18 822 979 - -

8-2. Lifting Point

You must see the following picture when transporting the valve.

CAUTION : If you do not transfer in accordance with the instructions of the manual, it can occur

damage to valve and loss of lives.

• For other inquiries about Weight, Please contact 3Z Head office : 070-7511-9100

!

* Lifting into Position

Valves should always be lifted

using suitable mechanical lifting

equipment operated by trained

personnel. Chains, slings and

other lifting equipment should

be regularly inspected. Do not

lift valves using the sealant

fittings, gear unit, hand wheel or

Standard Type

-16-

g g

wrench. Chains or slings should

be fixed around the valve body.

9. Live Loaded Plug Valve

Enhance stem sealing against external leakage by using live loaded disc spring and fugitive emission packing, and Live loaded plug valve is certified by ISO-15848(Industrial valves-Measurement, test and

9-1. Feature of live loaded plug valve

p g, p g y ( ,qualification procedures for fugitive Emissions)

Stud Bolt/Nut

Live Loaded Disk Spring:Keeps effective packing stressto prevent stem leakage

Fugitive Emission Packing:Fugitive emission packing prevents the extrusion of gland packing

Live loaded disc spring: If a valve is frequently cycled, the

packing around the stem will be wore and the stress on the

packing will be reduced and eventually stem leakage will be

-17-

occurred. Normally, frequent retightening of the packing gland

bolts is required to prevent stem leakage . 3Z live loaded plug

valves with a disc spring provide an effective way to control the

amount of stress in the packing set and eliminate the need of

constant retightening.

9-2. Exploded view of live loaded plug valve


19

21

22

2324

No Parts Specification

1 Body ASTM A216 WCB

2 Sleeve PTFE

3 Plug ASTM A351 CF8M

Sample Construction of Material

11

15

16

14

13

17

18 203 Plug ASTM A351 CF8M

4 Gasket RTFE

5 Cover ASTM A216 WCB

6 Cover Bolt ASTM A193 B7

7 Gland Packing PTFE

8 Gland Ring UNS S31803

78

9

10 12

9 Gland Plate ASTM A890 1B CD4MCu N

10 Spring Case AISI 304

11 Disc Spring Washer AISI 304

12 Spring Case Cover AISI 304

13 Gland Packing Nut ASTM A194 8

14 Gland Stud Bolt ASTM A193 B8

4

5

6

15 Stop Positioner AISI 304

16 Thrust Bearing PEEK

17 ADJ Ring UNS S31803

18 ADJ Plate ASTM A890 1B CD4MCu N

19 Spring Washer AISI 304

20 ADJ Stud Bolt AISI 304

1

2

3

4 20 ADJ Stud Bolt AISI 304

21 ADJ Nut AISI 304

22 Wrench AISI 1045

23 Hub ASTM A351 CF8

24 Hub Bolt AISI 304

-18-

* In order to know the correct specification of delivered products, you have to refer the approved Proposal Drawing.


3Z Live loaded plug valves are designed and manufactured for trouble-free for long time using. But, if

problems are encountered in using you can use it as the new valve by adjusting or maintaining as

9-3. Troubleshooting Guide

problems are encountered in using, you can use it as the new valve by adjusting or maintaining as

follows.

Possible Defect Remedy Guide Remark

Stem leakage

1. Tighten for 90° turning the adjusting

bolt.

If you over adjust the adjusting bolt


(Section 9 4)Stem leakage If you over-adjust the adjusting bolt,


2. Replace Gland Packing.

(Section 9.4)

2. Replace Gland Packing

Cover leakage1. Tighten the cover gasket with cover bolt.

2. Replace the cover gasket.

1. Assembly Cover (Section 6.6)

2. The Value of Bolting Torque

(Section 6.7)

1 Tighten for 90° turning the adjusting

In -line leakage

1. Tighten for 90 turning the adjusting

Bolt.



2. Replace the sleeve.


(Section 6.7)

2. Replace sleeve (Section 6.5)

* Recommended Gland Bolting Torque9-4. Adjustment

Valve Size Nut Size Torque (N·m)

0.5” M8 6 ~ 7

1” M10 14 ~ 17

1.5” M10 14 ~ 17

2” M10 14 ~17

1. If the leakage occur Stem seal, tighten Gland bolt uniformly conform to the below table. :

Recommended Gland Bolting Torque

2 M10 14 17

3” M10 14 ~ 17

4” M16 60 ~ 70

6” M20 145 ~ 160

8” M20 145 ~ 160

10” M20 145 ~ 160

-19-

12” M24 250 ~ 300

14” M30 500 ~ 600

16” M30 500 ~ 600

18” M30 500 ~ 600

3. When assemble the Adjusting Bolt, be carefulnot to exceed the limit of recommended Boling Torque. (Section 6.7)

2. If the line leakage occur at plug seal, Tighten for 90°turning the Adjustment Bolt or Screws.

10. Gear Operator

10-1. Lubrication

The actuator is lubricated at the factory, and dose not require further lubrication.

10-2. Adjustments

The open and closed position stops prevent the operator from rotating beyond the open and closed positions of the valve. Each stop is adjustable. If the is factory-mounted on the valve, the stops are preset, and do not require further adjustment.

If the is not factory mounted on the valve or if the has been removed the stops will requireIf the is not factory mounted on the valve, or if the has been removed, the stops will require adjustment as described below. Refer to Figure 1 for component identification.

To adjust the closed position stop:

1. Loosen the handwheel nut on the closed position stop screw, and back out the stop screw.2. Turns the handwheel so that the valve is in the closed position.3. Turn the closed position stop screw clockwise until resistance is felt from the stop screw contacting the gear inside of the operator.4. Hold the stop screw from turning, and tighten the nut.

To adjust the open position stop:

1. Loosen the nut on the open position stop screw, and back out the stop screw.2. Turn the handwheel so that the valve is in the open position.3. Turn the open position stop screw clockwise until resistance is felt from the stop screw contacting the gear inside of the operatorcontacting the gear inside of the operator.4. Hold the stop screw from turning, and tighten the nut.

-20-

FIG 1 Operator Component

10. Gear Operator

10-3. Removing Operator From Valve

Refer to Fig 1 for component identification.Refer to Fig 1 for component identification.

1.Remove the four mounting screws and washers.2.Remove the operator from the valve.

10-4. Replacing Operator On Valve

Refer to Fig 1 for component identification.

1.The bracket is mounted to the flange pads (or cover bolts), with the body and plug ports aligned.2. Install the compensator over the valve stem.3. Turn the operator input shaft until the position indicator is on “open”.4. Insert the torque bar into the operator.5. Lower the operator onto the bracket with the operator input shaft perpendicular to theflow path engaging the torque bar with the compensatorflow path, engaging the torque bar with the compensator.6. Insert and tighten the four operator bolt.7. Adjust the actuator travel stops for 90 operation, being sure that the plug and body ports are aligned in the open position.

10-5. Changing Actuator Mounting Position On Valve

Before changing the mounting position, check to assure that dimensional clearance is available for the proposed location. To change the position, follow the steps in the Removing Actuator from Valve section and in the Replacing Actuator on Valve section.

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11. Name Plate & Spare Parts

11-1 Name Plate

The nameplate attached to sleeved plug valve provides the lot information, the rated working

pressure and temperature range that valve is designed to handle.

NEVER remove the nameplate from the valve, and always provide to keep it clean and protected.

Refer to the following name plate drawing for 3Z Standard

11-2 Spare Parts

The Use only 3Z original spare parts. 3Z cannot accept responsibility for any damages that occur

from using spare parts or fastening materials from other manufactures.

Refer to the following standard spare parts list

No Parts Specification

1 Sleeve PTFE / RTFE/ 250EP /320EP

2 Delta Ring RTFE / 250 EP/320EP

3 Reverse Lip RTFE / 250 EP/320EP

4 Metal Diaphragm AISI 316

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5 Top Thrust Collar AISI 316

6 BTM Thrust Collar AISI 316

7 Grafoil Diaphragm Graphite

8 Cover Seal Graphite

3Z Headquarters

254 SIHWA VENTURE-RO, SIHEUNG-SI, GYEONGGI-DO, KOREA

(TEL) 82.2.333.1212

(FAX) 82.2.333.4111

E-mail : [email protected]

2014 3Z Corporation, www.3zvalve.com

3Z provide perfect products.The copyright of this manual owned by 3Z Corp.

You cannot act various action against copyright of this manual such as printing, reproduction, binding, etc

nlbitdsl plvl non lubricated sleeve plug valve plug valve manual.pdf · 2018-01-05 · nlbitdsl...

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