Galli Cassina Plug Valves: OMI-PB-CAN.0

GALLI & CASSINA PLUG VALVES
OMI-PB-CAN.0
CONTENTS 1 2 3 4 5 6 SCOPE 7 OPERATING PRODUCT DESCRIPTION 8 ROUTINE MAINTENANCE HANDLING 9 NON-ROUTINE MAINTENANCE STORAGE APPENDIX A SEALANT REQUIREMENTS INSTALLATION APPENDIX B LUBRICANT/SEALANT GUIDE PRE-COMMISSIONING APPENDIX C TROUBLE SHOOTING GUIDE
GALLI & CASSINA S.p.A. - Via Drizza, 30/32 - 20020 SOLARO (MI) Italy - Email: valves@gallicassina.it
OPERATING & MAINTENANCE MANUAL
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1. SCOPE The purpose of this manual is to provide the end user with information for: - Operating GALLI & CASSINA plug valves. - Maintenance of GALLI & CASSINA plug valves. - Safety of the operating personnel. 2. PRODUCT DESCRIPTION
OMI-PB-CAN.0
The GALLI & CASSINA plug valve design is based on the principles of the standard taper plug valve, but it has been modified to extend the application range to larger sizes (up to 30) and higher operating pressures (ANSI Class 2500 / API 10000): - The pressure balanced system (see Fig. 1) creates a reduction of torque and the frequency for normal maintenance. - The inverted plug position and the separate stem are connected by means of an Oldham coupling. f FIG. 1
- Seating is metal to metal. A film of lubricant between the mating surfaces of the plug and the body guarantees bubble tight sealing. - On-off service is the normal application for GALLI & CASSINA plug valves. GALLI & CASSINA plug valves are supplied with: - Sealant injector fitting (Fig. 2). - Stem sealing injector fitting (Fig. 3). - Anti blow-out stem design starting from 1.5 (40) size. - Fire safe design. - A locking device is optional. - A stem extension is optional.
Fig. 2
Fig. 3
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3. HANDLING
OMI-PB-CAN.0
Lift valves using suitable lifting equipment such as a chain or sling positioned around the body valve. Do not lift valves by means of the gear operator, wrench, hand wheel, stem extension or fittings. Use the lifting lugs if fitted. Valves should be lifted by trained personnel that understand the possibility of injuries and death that may be caused by falling loads. During lifting operations, attention must be made not to damage the raised face flange surfaces or the butt-welding ends of the valve. VALVES EQUIPPED WITH WELDED LIFTING LUGS: Before lifting, pay attention to the fact that a multileg assembly is being used to transport the load. Note that the angle inclination of the sling means there will be higher loads at the lifting point. Lifting capacity is reduced due to angle variations as shown below: b = 0 100% of design load 0 <b 45 70% of design load 45< b 60 50% of design load Valves are fitted with a label wired to the welded lifting lugs indicating valve weight; lifting lugs design load and safety rules described here. WARNING: Check the load ring for possible deformation or damaged welds before lifting. Do not modify the load ring in any manner from its original design. A falling load may cause serious injury or death. 4. STORAGE GALLI & CASSINA recommend storing valves in a location that is dry and covered, and that the end protection or end caps (applied in the GALLI & CASSINA factory before shipping) should be left in-place. 5. INSTALLATION Before installing GALLI & CASSINA plug valves always: - Remove end protection and caps from end connections. - Remove any rust inhibitor from the end connections. - Check the flow passage inside the valve. NOTE: Plug valves are bi-directional valves and the stem position does not affect their functionality, except for valves fitted with power actuators. In this case the valve working position must be clearly indicated on the purchase order and adequate supports must be provided for the power actuator. WARNING: External loads must not be applied to valve end-connections - this includes external loading from wind, earthquake, ice or snow. WARNING: If the working temperature exceeds +70C the end-user should provide suitable protection against the possibility of the operating staff coming in contact with hot valve surfaces.
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6. PRE-COMMISSIONING
OMI-PB-CAN.0
Valves installed in new plants or that have been stored for a long time before installation should be lubricated as described in section 8. This operation is also recommended for valves that are being re-installed in a new application. 7. OPERATING Wrench operated valves: are normally supplied in the bare shaft state and wrenches are supplied separately. The correct wrench can be identified from the dimensions of the top of the valve stem. It is important that only a correct size wrench is used to operate the valve. The operating sense of the valve is clockwise to close and anti-clockwise to open. Gear operated valves: should be operated by means of the hand wheel. To close the valve the hand wheel is turned clockwise until the position indicator on the top of the gear unit is perpendicular to the direction of the flow. To open the valve the hand wheel is turned anti-clockwise until the position indicator is pointing in the direction of the flow. The indicator on the top of the gear unit rotates with the valve stem to give a clear indication of the plug position. Power actuated valves: see the operating and maintenance manual issued by the original equipment manufacturer. Valves should normally be left in the fully open or the fully closed position. WARNING: Personnel should never stand downstream of a valve that is being opened to atmosphere. 8. ROUTINE MAINTENANCE GALLI & CASSINA plug valves are designed to require a minimum of maintenance. If a valve is operated infrequently, or not at all, it is recommended good practice to exercise it occasionally by cycling the plug, even partially. To ensure maximum valve life and performance GALLI & CASSINA recommend the routine injection of plug sealant. Sealant injection is normally required to prevent the valve operating torque from increasing and to maintain bubble tight sealing. It is important to use only a plug sealant that has been recommended by GALLI & CASSINA. Incorrect sealant selection may: - Cause valve leakage. - Cause valve seizure. - Require valve disassembly for sealant removal and cleaning. WARNING: GALLI & CASSINA is not responsible for any event or damage caused by sealant selection that is different from GALLI & CASSINA recommendations. IDENTIFICATION OF INJECTORS: GALLI & CASSINA plug valves are equipped with a stem packing injector (see Fig. 3) and a sealant injector (see Fig. 2). LOCATION OF SEALANT INJECTOR: The sealant injector is a giant buttonhead type. It is usually located on the side of the valve body (see Fig. 4). The sealant injector is located on the top of the stem extension is a stem extension is installed.
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OMI-PB-CAN.0
LUBRICATION EQUIPMENT: A high-pressure sealant pump with a giant buttonhead coupler and sealant that is suitable for the operating conditions. FREQUENCY OF LUBRICATION: This depends on the frequency of valve operation, the valve operating conditions and the mechanical condition of the valve. The following lubrication schedule may be considered as a useful guide: - After a period of 12 months and the valve kept in the open/closed position: ANNUALLY. - 10 to 100 operations per week: DAILY. - Up to 10 operations per week: WEEKLY. - Up to 10 operations per year: MONTHLY. - Less frequently: TWICE ANNUALLY. SEALANT INJECTION: This operation can be performed with the valve under pressure. A more effective distribution of sealant will be achieved when the valve is in the fully open position. After injecting sealant the valve should be cycled in order to spread the sealant between the plug and the seating areas. GALLI & CASSINA suggest the use of a power operated sealant pump to service valves larger than NPS 6. GALLI & CASSINA recommend that the following procedure be followed when performing routine sealant injection: a. Check that the surface of the giant buttonhead fitting is in good physical condition and is clean and free of dirt, paint and old dry sealant. b. Check that the pump is filled with the recommended sealant and it has a working pressure gauge (0 to 15,000 psi / 0 to 100,000 kPa). c. Connect the pump coupler to the giant buttonhead fitting (see Fig.5).
FIG. 5
GALLI & CASSINA S.p.A. - Via Drizza, 30/32 - 20020 SOLARO (MI) Italy - Email: valves@gallicassina.it 5/11
OMI-PB-CAN.0
d. Consult the table shown in Appendix A for the suggested quantity of sealant to inject during routine servicing. e. Begin to inject sealant. f. Monitor the movement of the pressure gauge to determine if the sealant is entering the valve. As sealant is being pumped into the valve the gauge will rise. When pumping is stopped the gauge should drop. If the gauge does not drop check for a possible obstruction in the hose connecting the pump to the valve or the buttonhead fitting, or a problem with the pump. g. Cycle the valve after injecting 1/3 of the amount of sealant shown in Appendix A to spread the sealant around the plug surface. Repeat this process 2 times until the total suggested amount of sealant has been injected and the valve has been cycled 3 times. h. Disconnect the pump and wipe any residual sealant off the buttonhead fitting. CAUTION: Do not inject sealant into a valve that is partially open - the sealant will be forced out of the valve by line pressure. NOTE: Cold ambient temperatures will harden valve stem packing. This can make a plug valve hard to turn. If this occurs it is recommended that the end user inject sealant into the valve. Hot ambient temperatures may cause the stem packing to dissolve and may create a stem leak. If this occurs see Section 9.1 below. 9. NON-ROUTINE MAINTENANCE 9.1 STEM PACKING INJECTION In the unlikely event of stem leakage occurring it is necessary to determine exactly where the leakage is occurring. If the leakage is around the stem (i.e. up the side of the stem) it can normally be stopped by injecting stem packing compound. LOCATION OF STEM PACKING INJECTOR: The stem packing injector is located on the side of the body valve adjacent to the stem (see Fig. 4) INJECTION OF MASTIC: Remove the bolt (or grub screw) that is located on the end of the packing injector. Do not remove the packing injector from the valve body. Place a pellet or a stick of stem sealing compound inside the injector. Replace the bolt (or the grub screw) and use a 6 crescent wrench to tighten the bolt. Repeat the process until the leakage is stopped or the bolt is hard to turn. NOTE: it may be beneficial to cycle the valve to assist in spreading the mastic around the valve stem. 9.2 LEAKAGE THROUGH SEALANT FITTING External leakage through the buttonhead sealant injection fitting can sometimes be stopped by injecting sealant if the ball inside the check valve is not seated. If this does not stop the leakage, isolate and depressurise the valve. Remove the buttonhead fitting and the check valve. Install a new check valve and a new buttonhead fitting. Inject sealant into the valve. WARNING: Do not attempt to replace either the buttonhead fitting or the check valve unless the valve is isolated and vented. 9.3 PLUG ADJUSTMENT If a plug valve leaks across the seats after injection of sufficient sealant into the valve:
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OMI-PB-CAN.0
- and the valve is easy to operate - and after checking that the plug is in the fully closed position. - and if installed, the end of travel stops of a gear or a power actuated valve are correctly set for 90o travel: The plug is probably out of adjustment and should be adjusted into the taper body seat. NOTE: damaged metal seats, debris in the line product, and solid residue from clay based sealants can create these symptoms. If a plug valve is hard to operate even after injection of sufficient sealant, the plug may have been forced too far into the tapered body seat and requires adjustment. PROCEDURE FOR PLUG ADJUSTMENT: This procedure may be carried out with the valve under pressure, but it is more easily performed when the valve is fully open and it has equal fluid pressure upstream and downstream. - Identify the lock nut or cap (see fig. 6) that protects the plug loading screw. The lock nut or cap is located in the centre of the valve cover. - Remove the nut / cap by unscrewing it to expose the plug loading screw. - Mark a line across the valve cover to identify the as-found position of the plug loading screw. - Use a correctly sized wrench to tighten the plug loading screw until it becomes significantly harder to turn. It should take no more than 1/4 turn to tighten the plug loading screw, unless the plug loading screw was previously slackened off. - Pump a sufficient quantity of sealant into the valve. - Cycle the valve several times and return it to its normal operating position. - Reinstall the lock nut or protector cap. Do not over tighten it. To adjust a seized or hard to turn plug out of the body seat, unscrew the plug loading screw by 1/4 turn. Inject sealant into the valve and cycle the valve several times, returning it to the as-found position. Reinstall the lock nut or protector cap, but do not over tighten it. If the valve is still hard to cycle, and it is fitted with a gear or a power actuator, it is recommended that the actuator should be inspected and/or overhauled. WARNING: Do not over tighten the plug loading screw - this may jam the plug into the body seat. WARNING: Do not remove the plug loading screw from the valve cover. This may cause an uncontrollable product leak.
Fig. 6
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9.4 DISASSEMBLY AND REASSEMBLY PROCEDURE
OMI-PB-CAN.0
WARNING: Only personnel authorized by GALLI & CASSINA should attempt to disassemble a GALLI & CASSINA valve. GALLI & CASSINA is not responsible for damage that may be caused by valve disassembly, and any valve guarantee will automatically become void. The following procedure must be read carefully before disassembling a GALLI & CASSINA plug valve. WARNING: Before removing the valve, ensure that: - There is no pressure in the line. - The valve is in the fully open or 1/2 open position. See page one of this manual for valve component identification: Unfasten and remove the valve operating device (wrench / gear / actuator). Remove the stem key (if any). Remove the cap screws connecting the gland plate to the body valve Carefully lift off the gland plate. Remove the cover nuts. Remove the cover and the lower thrust washer (the plug loading screw can be left screwed in the cover). Remove the 2 metal diaphragms (replace them if damaged), the bearing retainer and the ball. Remove the plug. Remove the Oldham coupling and the stem. In the case of a plain stem valve also remove the stem O-ring (replace it if damaged), the graphite ring (always replace with a new graphite ring) and the upper thrust washer. Remove valve fittings (stem seal and sealant injectors, check valve). After cleaning the metal components with a suitable degreaser visually check to see if any of the components have been damaged. Bolts, nuts & cap screws should be lubricated with industrial grease. The plug should only be lubricated with sealant recommended by GALLI & CASSINA. Re-assemble the valve in the reverse order of the above instructions. Tighten the plug loading screw as directed in Section 9.3. CAUTION: Maintenance operations other than those described in this manual should not be carried out on a valve that is under pressure, unless they have been authorized in writing by GALLI & CASSINA qualified personnel.
8/11
OMI-PB-CAN.0
APPENDIX A Most manual sealant injection guns are available in two sizes: 12 ounce (336 gram) capacity hydraulic handgun. 16 ounce (448 gram) capacity screw prime gun. Depending on the make, type and the condition of the handgun it will require approximately 25 to 33 strokes of the handle to pump 1 ounce (28 grams) of sealant into a valve. A useful rule of thumb for the approximate amount of sealant required for normal servicing of a plug valve is: 1/2 to 1 ounce (14 to 28 grams) per diameter inch of valve. The following table shows the approximate amount of sealant to use, and the approximate number of handgun handle strokes that would be required to inject the sealant, during normal plug valve servicing. Approximate Amount of Sealant Required for Normal Maintenance of Galli & Cassina Plug Valves (OUNCES) 2 3 4 6 8 10 12 14 16 20 24 30 1-2 1.5 - 3 2-4 3-6 4-8 5 - 10 6 - 12 7 - 14 8 - 16 10 - 20 12 - 24 15 - 30 (GRAMS) 28 - 56 42 - 84 56 - 112 84 - 168 112 - 224 140 - 280 168 - 336 196 - 392 224 - 448 280 - 560 336 - 672 420 - 840 Approx. Number of Screw Prime Handgun Handle Strokes 25 - 50 38 - 75 50 - 100 75 150 100 - 200 125 - 250 150 - 300 175 - 350 200 - 400 250 - 500 300 - 600 375 - 750 Approx. Number of Hydraulic Handgun Handle Strokes 33 - 66 50 - 99 66 - 132 99 - 198 132 - 264 165 - 330 198 - 396 231 - 462 264 - 528 330 - 660 396 - 792 495 - 990
Valve Size
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OMI-PB-CAN.0
APPENDIX B Galli & Cassina plug valves can use different types of Climax lubricants and sealants that are suitable for various services. The operating conditions should be specified at the enquiry stage in order to advise the end user which type of sealant is suitable. Products are packed in stick form and cartridges suitable for screw prime and hydraulic handguns.
Product Number 220 Temp. Range
o
Availability
Color
Principal Applications
Unsuitable For
Stick Bulk
White
-75 to +250
Liquid service. Very cold service for pipelines, compressor stations, gasoline plants and crude oil production fields. Same as above Gas service Acids and caustics General gas and water Sealant and general Hydrocarbons service Hydrocarbon and LPG service
Aromatics, Solvents
262 400 600
Stick Stick Bulk Stick Bulk
Translucent Red Cream Amber Blue
-85 to +250 -20 to +450 -20 to +500
LPG Liquid Hydrocarbons LPG
650
Stick Bulk
-40 to +500
Aromatics, Alkalies, Solvents 100% Benzene Aromatic, Alkalies Solvents Alkalies Alkalies
711 750
Stick Bulk Stick Bulk
Amber Black
+32 to +400 0 to +600
Aviation gasoline, Jet fuel, fuel blends of Alkylate. Asphalt, General hot oil service. Salt brine. Hot hydrocarbons and gases. Butane, Butadiene, Carbon Tetrachloride, Ethane, Propane. Natural gas, petrochemical plants, rubber plants and hot hydrocarbons service. Cold weather, hydrocarbon lubricant. Propylenes, Benzenes, Toluene, Butadiene, Xylene, Styrene, Cumenes. Liquid and gaseous Aliphatic hydrocarbon service (wet or dry natural gas)
800 900
White Black
-20 to +450 -20 to +650
901 950
Black Amber
-30 to +300 -40 to +300
Alkalies Alkalies
1034-MT
Stick Bulk
Cream
-20 to +400
Alcohols, Glycols
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APPENDIX C Trouble Shooting Guide for GALLI & CASSINA Plug Valves Problem
i. ii. Hard to Cycle iii. iii. iv. Does not cycle full open or closed Leakage across the seats Leakage through stem or operator Cover plate leakage i. ii. i. ii. iii. iv. i. i. ii. i. ii.
OMI-PB-CAN.0
Probable Cause
Lack of sealant. Dried out sealant. Cold ambient temperature Damaged valve operator. Plug forced too far into body. Operator end of stroke stops are incorrectly set. Debris. Lack of sealant. Incorrect sealant. Plug set incorrectly. Damaged seats. Leaking stem seal. Cover plate bolting loose. Possible damage to diaphragm seal Internal ball is not seated. Damaged buttonhead or internal check valve. Possible casting defect or internal corrosion/erosion Pressure gauge drops to zero after each stroke of the gun handle i. ii. iii. iii. iv. i. ii. i. ii. iii. iv. i. i. ii. ii. ii.
Solution
Inject sealant. Flush with valve cleaner. Consult GALLI & CASSINA for recommended valve cleaner. Inject sealant Check operator manufacturers manual. Reset plug. Adjust the operator end of stroke stops. Flush the piping. Inject sealant. Consult GALLI & CASSINA with service details. Adjust plug loading screw. Rotate plug 180o. Inject stem packing. Close the valve and tighten the cover plate bolts. If this does not stop the leak proceed to ii. Remove from service. Disassemble and inspect for cause of problem. Inject sealant to reseat ball. Isolate and depressurize valve. Cycle valve open. Remove and replace buttonhead fitting and check valve. Replace valve. Replace internal check valve. Consult manufacturers manual for instructions.
Leakage through buttonhead fitting. Leakage through valve body Problem with hydraulic handgun
i. i.
i. i.
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Galli Cassina Plug Valves: OMI-PB-CAN.0

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GALLI & CASSINA PLUG VALVES

OPERATING & MAINTENANCE MANUAL