Pro - Super - H - Assembly PDF

TM
Plug Valve
Super H Type
Best Assembly Practice
Super H - Best Assembly Practice
G Super H - Assembly Procedure
G Typical Types of Construction:

Threaded stems and
1/2” - 1” ANSI Class 150 - 2500
covers
Plain stems and bolted
1 1/2” - 4” ANSI Class150 - 600
covers
1 1/2” - 16” ANSI Class 900 - 1500

Threaded stems and
bolted covers
6” - 24” ANSI Class 150 - 600
Threaded stems and

1 1/2”- 8” ANSI Class 2500
covers
There are more specialised forms with different materials of

construction and methods of cover / base sealing
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G What are the benefits:

Certainty of Operation - freedom from seizure
Consistent torque (operation) over long periods
Freedom from regular maintenance
Assured sealing to atmosphere, facility to inject stem
packing compound
Downstream sealing
Fire tested performance
Increased overall reliability and safety for high integrity
systems
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G How these benefits are achieved?

– Pressure balance plug
– Super Lomu treatment on plug and stem
– Anti-Blowout stem
– Metal to Metal seats of large area that are fully protected
– Lapped taper surfaces for precise seat mating
– Firesafe graphite stem seal
– External emergency stem packing system
– External provision for plug sealant injection
– Precise control of plug loading on assembly
– Double D drive (wrench operated) for open and closed
positions
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G It is a`MISCONCEPTION` that….
Injecting Excess Sealant
Over-tightening pressure/thrust screw
G `Will Seal a leaking Valve` it Won`t

G Media under pressure will “Break Through” Taper match
problems causing leakage
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G Examination of components
G HENCE THE NEED TO CHECK THE

TAPER QUALITY
What body and plug taper problems attribute to seat

leakage?
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G Taper mating problems attributed to seat leak paths:-
– Geometry, shape, form or distortion

– Incorrect angle of taper
– sub-standard machining
– port edge damage
– circumferential scores, deep scratches, damage
– interference at small end of the taper, plug breaks through
into body sealant chamber
– narrow seat width
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G Methods of problem detection:-

Visual check
Feel ( fingers)
Vacuum test
Engineers blue applied to plug and rotated in the body
Taper-Lock Test
G For examination of the body and plug, what good practice

must be carried out before examination and assembly?
G What taper problems would you expect to detect by the

above methods?
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G Visual Method
Circumferential scores, scratches, etc

Damage
Un-lapped areas
G Feel (fingers) Method
Shape, form, geometry

Damage
Deep Scores
Sharp edges around port edges, ducts etc
Body lip, preventing plug break through into body chamber
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G Engineers Blue
Incorrect angle of taper
Shape, form, geometry, high and low spots
Ovality
G Taper Lock Test

Obstruction, preventing the plug taper to seat into the body
taper
– All plugs must be checked to make sure they will taper-lock
G Vacuum Method
Possible detection of all of the above
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Examination - Drive Train

Also known as
Valve Bore Sealing Mechanism

Also known as
Stem / Equaliser Ring / Plug
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G What characteristics should we check to ensure
The plug is allowed to move onto its seat when closed?
Adequate drive engagement?
Stand down position is not affected?
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G Checks include:
Tangs slide backwards and forwards easily in their slots
No excess play
Tangs fully engage
Plug / equaliser ring / stem fit - face to face
G ANY INTERFERENCE IS CAUSE FOR REJECTION!
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G What is the main and most common

assembly problem which causes seat
leakage?
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G What is the Definition of ‘Stand down’?
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G Stand down is the

clearance between
the cover seal face
and the bearing
pad etc.
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G Setting of the Plug Stand Down
What does Correct stand down ensure?
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Correct Stand Down ensures:-
– Plug is Seated Correctly
– Tight Shut-Off
– Good Valve Operation
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G We have Two Types of Stem, what are they?
G One may compromise the stand down, which

one and how?
G What is the solution?
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Screwed Stems
Check for adequate clearance which ensures

the plug is always seated in the open and
closed positions
Check and Re-Check Stand down
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G Methods of Checking the Stand Down
Check Body and Plug is Free of oils, debris etc.

Do Not fit the Stem or Equaliser Ring
Carefully lower the plug into the body
CHECK FOR TAPER LOCK
There are various types of assembly, therefore fit as required
– ball
– ball/bearing pad combination
– bearing pad
– spring disc
Check the stand down 0.3 - 1.0mm deep using gauge
Make a mental note of the Stand down position on the gauge
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G On Valve Assembly
Fit stem and equaliser ring
Small wad of plasticene to plug face - small end (not tang)
Lower clean plug into clean body
Tap plug onto seat
Check for taper- lock
Re-check with stand down gauge (remember mental note)
Remove plug and check clearance indicated by the plasticene
Minimum of 1 mm.
– This dimension does not change for plain stems
Screwed stems - clearance can be adjusted to ensure adequate

stem engagement
What does the 1.0 mm clearance guarantee?
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G Stand Down
Applicable to screwed stems only
What action is required if the reading is

greater?
What action is required if the reading is less?
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G ANTI-SEIZE 2667
G Do not underestimate its POWER!
G Must be applied liberally to:
Threads (studs, pressure & stem packing screws)
Stem thrust washer (Pampus Bearing)
Screwed stem packing groove
Stem Packing
Plug - large end, Ball, Bearing Pad, Spring Disc
Cover sealing face
Diaphragm
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G Assembly Plain Stem - Bearing
Pampus Bearing.
Glacier Bearing.
What is their main function?
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G Pampus Bearing function - Primary Stem Seal
G Ensure:
Body bearing face is of good finish and free from damage
Anti-Seize is applied to both sides of the Pampus Bearing
Pampus Bearing - Smooth Face to Body Bearing Face
Mesh Side to Stem Face
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G Glacier Bearing function - Primary Stem Seal
G Ensure:
Sealant is applied to both sides of the Glacier

Bearing
Black PTFE face to Body
Metal Face to Stem
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G Stem Packing Injection
Which type of valve is fully charged with

stem sealing compound (packing)?
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G Valves of Screwed Stem Design
Stem sealing compound is the Primary and

Only Stem Seal
Critical that this operation is correct
Fail = Serious leakage to atmosphere
Why?
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G Assembly Operation
Always apply Anti-Seize
– to each piece of Stem Packing
– to Injection Screw before each injection
Insert Stem Packing in Body Housing

Fit Packing Unit
Insert Stem Packing into Packing-Unit
It is difficult to inject sufficient stem packing
using a winding tool having a small radius.
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G Torque wrench/driver are the ideal tool because:
Sufficient leverage/torque output making injection easy
Can be set at the torque recommended to ensure

sufficient packing is injected to provide sealing
Recommended Torque's:-
3/8 UNC (M10) = 15 lbs ft

1/2 UNC (M12) = 25 lbs ft
3/4 UNC (M20) = 40 lbs ft
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Assembly Facility Development
G Tooling and Equipment
G Training
G Works Instructions
G Problem Solving
G Housekeeping
G General
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G Tooling and Equipment
Storage and Security

Colour Code to Assembly Unit
Location for Calibration
Immediate requirements:
– Torque wrenches
– Sockets
– Stud and Nut runners
– Drivers Hexagon type etc
– Visual Display for instructions
– Increase assembly benches
– Toolboxes
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G Training Program
Best Assembly Practice
Create greater awareness of the product
Identify training needs - New Product types etc.
Not Sure? ASK - One to One.
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G Works Instructions
Use of `N` Specs and Quality Plans

Access assembly procedures etc. VDU/Hard Copy
Valve Assembly Data at each work station:-
– Bolting torques
– tightening sequence
– method of setting torque guns
– pressure screw torques
– Check valve and packing Unit torques
– Stem packing injection torque
– Visual aids, assembly diagrams
– Nameplate instructions
– Test Pressure (Works Order)
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G Problem Feedback/Corrective Actions
Identify the cause and eliminate the problem
– Assembly
– Supplier
– Actuator Linkages
– Engineering Instructions
– Contract Instructions
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G Housekeeping
Identification of Batches - Works Order

Status Indicators
`HOLD` labels/Quarrantine Boards - RTV
Remove uncontrolled/unidentified components
Components and Tools on benches for current assembly only
Carousel - identification of components
Procedure:
– No uncontrolled copies
– Destroy procedures (hard copy) after job completion
– Controlled copies can be supplied for particular activities.
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G General
Check torque wrench setting using static torque meters
– when starting a new job
– daily basis for big batches
Stamping of the AK Numbers
Testers Stamps
45
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TM

G Super H - Assembly Procedure

G Typical Types of Construction:

1 1/2” - 16” ANSI Class 900 - 1500

Threaded stems and

There are more specialised forms with different materials of

G What are the benefits:

G How these benefits are achieved?

Over-tightening pressure/thrust screw

G `Will Seal a leaking Valve` it Won`t

G HENCE THE NEED TO CHECK THE

What body and plug taper problems attribute to seat

G Taper mating problems attributed to seat leak paths:-

– Geometry, shape, form or distortion

– narrow seat width

G Methods of problem detection:-

G For examination of the body and plug, what good practice

G What taper problems would you expect to detect by the

Circumferential scores, scratches, etc

G Feel (fingers) Method

Shape, form, geometry

G Taper Lock Test

Examination - Drive Train

Valve Bore Sealing Mechanism

Stem / Equaliser Ring / Plug

G What characteristics should we check to ensure

The plug is allowed to move onto its seat when closed?

Adequate drive engagement?

Stand down position is not affected?

Tangs slide backwards and forwards easily in their slots

Tangs fully engage

Plug / equaliser ring / stem fit - face to face

G ANY INTERFERENCE IS CAUSE FOR REJECTION!

G What is the main and most common

G What is the Definition of ‘Stand down’?

G Stand down is the

G Setting of the Plug Stand Down

What does Correct stand down ensure?

Correct Stand Down ensures:-

– Plug is Seated Correctly

– Good Valve Operation

G We have Two Types of Stem, what are they?

G One may compromise the stand down, which

G What is the solution?

Check for adequate clearance which ensures

Check and Re-Check Stand down

G Methods of Checking the Stand Down

Check Body and Plug is Free of oils, debris etc.

Screwed stems - clearance can be adjusted to ensure adequate

Applicable to screwed stems only

What action is required if the reading is

What action is required if the reading is less?

G Assembly Plain Stem - Bearing

What is their main function?

G Pampus Bearing function - Primary Stem Seal

Anti-Seize is applied to both sides of the Pampus Bearing

Pampus Bearing - Smooth Face to Body Bearing Face

Mesh Side to Stem Face

G Glacier Bearing function - Primary Stem Seal

Sealant is applied to both sides of the Glacier

Black PTFE face to Body

Metal Face to Stem

G Stem Packing Injection