01 - 11056-INS-415 Installation Procedure For Blow-Off Valve of Turbine

North Oil
Document Title: Company

Installation Procedure for Kirkuk- Iraq
Control Links Engineering
Blow-off Valve
Page 1 of 15 Document No. 11056-INS-415 Client Ref. No.xxxx
Project Filing Code: K2.6 / Installation &
Project No. 11056 REV. A
Commissioning Documents
Project Title: Mechanical Rehabilitation & Controls Upgrade of EM85 Water Injection Gas Turbine Units
CLIENT:
North Oil Company (NOC),

Kirkuk – Iraq.
PROJECT TITLE:
Mechanical Rehabilitation & Controls Upgrade of EM85 Water

Injection Gas Turbine Units
VENDOR:

Co.,
P.O. Box 2773, Amman11953,
Jordan
DOCUMENT TITLE:
Installation Procedure for Blow-off Valve
DESIGNED CHECKED APPROVED

REV DATE DESCRIPTION
BY BY BY
A 21/05/2013 For Information S.K M.O A.Y
For Engineering Use by NOC:

System Integration, Solution Provider
Amman, Jordan
Confidential Document:- These documents contain Engineering information which is the sole property of Control Links and its
distribution to any third party without the express written consent of Control Links is prohibited
North Oil
Blow-off Valve
Document Code No. Code Description

A WORK MAY PROCEED. NO MORE SUBMISSION FOR REVIEW IS REQUIRED.
REVISE AND RESUBMIT. WORK MAY PROCEED SUBJECT TO
B INCORPORATION OF THE CHANGES INDICATED.
C REVISE AND RESUBMIT. WORK MAY NOT PROCEED.
FOR INFORMATION/ REFERENCE. REVIEW NOT REQUIRED. WORK MAY
D PROCEED.
Reviewing Engineer’s Name (IN BLOCK LETTERS), Sign and Date
Name: Sign: Date:
Revision history
Rev Date Description of Change
A 21/05/2013 For Information
B
C

Amman, Jordan
North Oil
Blow-off Valve
Table of Contents
1. INTRODUCTION........................................................................................................................... 4
2. WARNING SAFETY NOTICE ....................................................................................................... 4
3. PRELIMINARY PRECAUTIONS ................................................................................................... 4
4. INSPECTION ................................................................................................................................ 5
5. TOOL REQUIREMENT ................................................................................................................. 6
6. TRANSPORT & STORAGE .......................................................................................................... 6
7. INSTALLATION............................................................................................................................. 7
8. INSTALLATION STEPS .............................................................................................................. 10
9. FLANGE CONNECTING AND BOLTING ................................................................................... 14
10. REMOVAL PROCEDURE........................................................................................................... 15
11. BILL OF MATERIAL FOR BLOW-OFF VALVES ........................................................................ 15
12. ANNEXURE-1 (GA & 3D DRAWINGS) ...................................................................................... 16
13. ANNEXURE-2 (MANUALS) ........................................................................................................ 16

Amman, Jordan
North Oil
Blow-off Valve
1. INTRODUCTION
1. The information in this document covers the following topics of GT1,GT2,GT3,GT4, and GT5
Blow-off valves:
• Installation considerations,
• Installation plan,
• General Arrangement,
• Schematic Drawings.
2. This document manual should be kept by a person who is actually using and maintain the
valves.
3. After reading this manual, keep it at a place easier to access
2. WARNING SAFETY NOTICE
PRIOR TO STARTING WORK

Prior to installation and initial use of the valve, it is essential that the following actions are taken.
The following information and instructions are important for perfect installation and safe
operation of the valve.
This Installation manual is read and understood.
Check that the system is safe to work on. That the system has been isolated and all
pressure removed from the system prior to items being removed or worked on.
Prior to starting any work, permits should be taken out and safety locks placed in position
by the operative.
3. PRELIMINARY PRECAUTIONS
For Safety, Follow these Cautions before installing, removing or disassembling the
Valve.
Must know what media is in the pipeline.
Make sure the line is depressurized.

Amman, Jordan
North Oil
Blow-off Valve
Use Protective Clothing and equipment to avoid injury. Keep hands and other body parts
out of the valve.
Always ensure the valve is in the fully closed position before installation, Removal or
Disassembly.
Ensure that flanges faces are clean before installation in pipeline.
4. INSPECTION
Before installation of the valve into the piping system, visually inspect the valve to
determine if any damage has occurred during shipping. Particularly, inspect the actuator,
shaft, valve interior, valve body and flanges. For proper operation of the valves, the seat
and disc seal must be undamaged and free of foreign material. If other than superficial
damage is discovered, contact vendor immediately, indicating the location and extent of
the damage found.
If it is necessary to clean the valve, use a soft cloth and mineral spirits, or an equivalent
solvent. All rust preventive should be removed before installing your valve.
Prior to start up or commissioning of the equipment, ensure that all works and
Outstanding actions have been completed and it is safe to start up.
Check that no personnel are working on the unit prior to removal of final permit and safety
locks.
The triple offset butterfly valve series is installed between pipeline flanges acc. to ANSI
B16.5.
It should be taken into account, that a valve which is designed for a particular flange
standard cannot be normally used for other flanges. If pipeline flanges are to be used
which are not in accordance with the specifications of the order, the manufacturer is to
be consulted.
Pipelines always have to be run in such a way that damaging shear and bending stresses
cannot act on the valve body.
The surfaces of the pipeline flanges between which the valve is installed have to be
parallel to one another, the sealing surfaces must be clean and without damage. No
cross marks may be visible.
Do not carry out welding work on the flanges and pipelines when the triple offset butterfly
valve has been installed, as this could cause damage to the valve.
The triple offset butterfly valve is clamped between two pipeline flanges using two
suitable seals.

Amman, Jordan
North Oil
Blow-off Valve
Pipes, Bolts, nuts and seals are not included in the scope of supply, special square
flanges for Turbine 2,3 & 4 will be supplied by NOC
All the usual 8’’ flange seals can be used.
The "clearance" of the mating flanges - including inner coating - has to be sufficient to
allow the disc to be fully opened without touching (ØDi ≥ ØL + 6 mm). This must be
checked before the valve is installed and compared with the space necessary for the
valve.
5. TOOL REQUIREMENT
There are no special tools required for installation and maintenance. Any lifting devices
used to move the valve into a desired position shall be of sufficient size to support the
weight of the valve and actuator assembly. Nylon slings secured around the valve bearing
areas are recommended to reduce the possibility of mechanical damage occurring to the
valve body and actuator.
Figure 1

Amman, Jordan
North Oil
Blow-off Valve
6. TRANSPORT AND STORAGE

When the valve is not put into immediate service, it is required that the valve be stored in a
heated building that is fire resistant, weather tight and well ventilated. Storage area shall be
situated and constructed so that it will not be subject to flooding or the presence of any
corrosive chemicals. All valve actuators be cycled approximately every 60 days or as
required by the manufacturer of the actuation system. Any spare parts for the valve shall be
stored in the original packaging and under the same conditions as the valve will be stored.
For storage greater than 4 months, the storage container should be inspected every four (4)
months to ensure it is in good condition, and any additional protective coverings or materials
are in working order. Ensure all parts are plugged, and bare metal is covered with a suitable
rust inhibitor.
The valve must be transported and stored dry and clean. In humid rooms, a drying material
or heating must be used to avoid condensation.
The transport packaging protects the valve against soiling and damage. Impact and
vibrations must be avoided.
If the valves are painted (coated) on the outside, this coating must remain without damage
otherwise the faulty spots must be repaired immediately.
The factory-adjusted basic setting (position of the disc at delivery) must not be changed.
7. INSTALLATION
The valve must be installed so that pipeline stresses are not transmitted to the valve body.
Despite its solid manufacture, such stress may affect valve operation. If pipeline stresses
are severe, they should be cushioned by expansion joints or compensators. If supports are
necessary for the valve, they should only support the dead weight of the valve and should
not serve as base points for the pipeline. NOC has to prepare the necessary mechanical
support for the piping & valves.
In Gas Turbine -1 install the Blow-off Valve directly in the existing flanges, refer to (Fig.2)
for exact location and Annixture-1 for dimensional details.
In Gas Turbine – 2, 3 & 4 require special flanges on the compressor side (Fig.4), NOC will
provide the special flanges with spool piece, in addition of the remaining pipe fabrication
works & materials to install the Blow-off Valve. Refer to (Fig.3) for exact location and GT-
2, 3 & 4 Installation drawings for dimensional details.
In Gas Turbine -5 install the Blow-off Valve directly in the existing flanges, refer to (Fig.5)
for exact location and Annixture-1 for dimensional details.

Amman, Jordan
North Oil
Blow-off Valve
Figure 2: GT1-Blow-off Valve Mounting Location
Figure 3:GT-2, 3 & 4 Blow-off Valve Mounting Location.

Amman, Jordan
North Oil
Blow-off Valve
Figure 4: GT-2, 3 & 4 Special Flanges
Figure 5:GT-1 Blow-off Valve Mounting Location

Amman, Jordan
North Oil
Blow-off Valve
8. INSTALLATION STEPS
The valve must be installed so that pipeline stresses are not transmitted to the valve body.
Despite its solid manufacture, such stress may affect valve operation. If pipeline stresses
are severe, they should be cushioned by expansion joints or compensators. If supports are
necessary for the valve, they should only support the dead weight of the valve and should
not serve as base points for the pipeline.
All valves must be in full closed position during installation or removal. It is not necessary to torque seat the
valve, but the disc travel must be restricted to prevent damage.
Please be sure there is no foreign material and that it is clean inside of the pipe and valve.
The shaft side of the disc is considered the high-pressure side of the valve, (as indicated on the drawings
by a flow arrow) meaning the best closure performance is obtained on this side of the valve, and a
determination as to the best installation should be made, to utilize this feature. This may not necessarily be
the normal flow direction of the system. (Fig.6).
Please install the valve stem horizontally as (Fig.7), thus could prevent sand and some chips from collecting
around bottom bushing and seat. Such reside could damage the valve.
Install valve and gaskets into pipeline as (Fig.8).
Make sure that the valve is installed concentrically between the flanges in order to could prevent the disc
from being damaged by interference with the flange and pipeline (Fig.9)

Amman, Jordan
North Oil
Blow-off Valve
Figure 6
Figure 7

Amman, Jordan
North Oil
Blow-off Valve
Figure 8
Figure 9

Amman, Jordan
North Oil
Blow-off Valve
9. FLANGE CONNECTING & BOLTING

Keep valve protection boards until installation.
Make sure the material and size of gaskets could be suitable for the service. Ensure that the faces of flange
and valve are smooth and flat. Sandpaper the faces if there are any defects.
Check that all the bolts and nuts are in good condition.
Apply lubricant such as Molybdenum to all the bolts and nuts before fixing them.
The pipe support(s) may now be required to be partially disengaged. A determination as to pipe flange
alignment and space between the pipe flange and the valve face must be made at this time. The optimum
spacing would be such as to only allow the flange gasket to be installed, at the maximum, and the flange
bolt holes would be concentric.
The opposite connecting pipe flange face may not be more than 1/4 inch away from the valve flange face.
Alternate methods of alignment, other than using the flange bolts, must be utilized to conform with this
requirement.
Install all studs, maintaining uniform clearance between the studs and the mating bolt holes. Additionally
the studs spanning the valve assembly should not contact the valve body.
Seat the flange by alternate tightening of four equally-spaced flange bolts no more than 1/4 turn per bolt,
until the flange faces seat. During this operation, it is advisable to continually check the relative distance
between the flange faces. Torque the bolts to approximately 25% of the final torque value (see table 1).
Inspect the remaining bolts and assure correct alignment. Tighten to the same level as the first four bolts.
Complete the tightening of all flanges bolting in a minimum of four increments to the final determined torque
value.
Test cycle the valve to be sure that there is no interference or binding.
Maximum Torque of Flange Bolt (Table-1)

Amman, Jordan
North Oil
Blow-off Valve
Note: Actual torque shall depend on gasket type, consult gasket manufacturer.
10. REMOVAL PROCEDURE

To remove your valve from the pipeline, please follow these simple steps:
Ensure that the valve is in the closed position.
Ensure that the line is depressurized.
Use protective clothing and equipment to prevent injury.
If your valve is equipped with a fail-open actuator, manually close the valve or disconnect the actuator then
close the valve before removal.
Attach nylon slings to the body shoulders of the valve and around the body of the actuator.
Remove the bolts holding the valve to the pipeline flanges.
11. Bill of material for Blow-off valves

Sr.No Material Supplied by
1 Butterfly Valves C.L
2 Actuators C.L
3 Pressure regulator for Blow-off Valves C.L
4 Instrument air tubes till Blow-off valve pressure regulators NOC
5 Valve supports for GT1,GT2,GT3,GT4,GT5 NOC
6 Special square flanges for GT2,3,4 NOC
7 Pipes with supports from air inlet to air exhaust for GT2,3,4 NOC
8 Pipes, Bolts, nuts and seals NOC

Amman, Jordan
North Oil
Blow-off Valve
12. ANNEXURE
ANNEXURE-01
Gas Turbine - 1 General Arrangement Drawings
Gas Turbine - 1 Three Dimensional Drawings
ANNEXURE-02
Flowserve TX Butterfly Valves Literature
Assembly Manual RG Series Pneumatic Actuators
Flowserve TX Butterfly Valves Technical Bulletin
RG Series Pneumatic Actuators User Instructions

Amman, Jordan

01 - 11056-INS-415 Installation Procedure For Blow-Off Valve of Turbine

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North Oil

Document Title: Company

North Oil Company (NOC),

Mechanical Rehabilitation & Controls Upgrade of EM85 Water

Control Links Engineering

Installation Procedure for Blow-off Valve

DESIGNED CHECKED APPROVED

For Engineering Use by NOC:

Control Links Engineering

Document Code No. Code Description

Reviewing Engineer’s Name (IN BLOCK LETTERS), Sign and Date

Name: Sign: Date:

Control Links Engineering

Control Links Engineering

2. WARNING SAFETY NOTICE

PRIOR TO STARTING WORK

Must know what media is in the pipeline.

Make sure the line is depressurized.

Control Links Engineering

Ensure that flanges faces are clean before installation in pipeline.

Control Links Engineering

Control Links Engineering

6. TRANSPORT AND STORAGE

Control Links Engineering

Figure 2: GT1-Blow-off Valve Mounting Location

Figure 3:GT-2, 3 & 4 Blow-off Valve Mounting Location.

Control Links Engineering

Figure 4: GT-2, 3 & 4 Special Flanges

Figure 5:GT-1 Blow-off Valve Mounting Location

Control Links Engineering

Install valve and gaskets into pipeline as (Fig.8).

Control Links Engineering

Control Links Engineering

Control Links Engineering

9. FLANGE CONNECTING & BOLTING

Test cycle the valve to be sure that there is no interference or binding.

Maximum Torque of Flange Bolt (Table-1)

Control Links Engineering

10. REMOVAL PROCEDURE

Ensure that the valve is in the closed position.

Ensure that the line is depressurized.

Use protective clothing and equipment to prevent injury.

Remove the bolts holding the valve to the pipeline flanges.

11. Bill of material for Blow-off valves

1 Butterfly Valves C.L

3 Pressure regulator for Blow-off Valves C.L

4 Instrument air tubes till Blow-off valve pressure regulators NOC

5 Valve supports for GT1,GT2,GT3,GT4,GT5 NOC

6 Special square flanges for GT2,3,4 NOC

8 Pipes, Bolts, nuts and seals NOC

Control Links Engineering

Gas Turbine - 1 General Arrangement Drawings

Gas Turbine - 1 Three Dimensional Drawings

Gas Turbine - 2 General Arrangement Drawings

Gas Turbine - 2 Three Dimensional Drawings

Gas Turbine - 3 General Arrangement Drawings

Gas Turbine - 3 Three Dimensional Drawings

Gas Turbine - 4 General Arrangement Drawings

Gas Turbine - 4 Three Dimensional Drawings

Gas Turbine - 5 General Arrangement Drawings

Gas Turbine - 5 Three Dimensional Drawings

Flowserve TX Butterfly Valves Literature