TANAP

TRANS ANATOLIAN NATURAL GAS PIPELINE

PROJECT
Project Rev Status
Doc.No. VPC-MAN-CST-GEN-001 P3-1 Re-IAA

VDR Code : P05 PO No.

TNP-TPG-BVPC-CNT-001
Document VPC ERECTION INSTALLATION COMMISSIONING OPERATION
Title : AND MAINTENANCE PROCEDURES FOR LUBRICATED PLUG
VALVES - INVERTED TYPE
Equipment BALL-PLUG VALVES
Description :
Tag Nos. ALL PLUG VALVES TAGS
Vendor: VALVITALIA S.p.A.
Vendor Doc.
No. MAN00-2017-A89 - ex MAN00-2010-Z22 Rev 1+CRS
Signature &
Date
C1 / APP - Reviewed & accepted. Manufacture may Proceed.For
documents status IFR\IFA, resubmit as IAA at next revision code.
For documents status IAA, no action required.
C2 / AWC - Reviewed & accepted as marked. Manufacture may
proceed. For documents status IFR\IFA, resubmit as IAA at next
revision code.
For documents status IAA, resubmit as Re-IAA at next revision code.
C3 / RWC - Reviewed & returned. Manufacture shall NOT
proceed.For documents status IFR\IFA, resubmit for review Re-
IFR\IFA at next revision code.
For documents status IAA, resubmit as IFA at next revision code.
C4 / IFI -Review not required. Manufacture may proceed
Resubmit for information as IFI at next Revision Code.
C5 / REJ - REJECTED Manufacture shall NOT proceed.
Revise document and resubmit for review.
Remarks:-
 VPC ERECTION INSTALLATION COMMISSIONING OPERATION
AND MAINTENANCE PROCEDURES FOR LUBRICATED PLUG VPC-MAN-CST-GEN-001
VALVES - INVERTED TYPE
Revision:P3-1 Status: Re-IAA Date: 16/01/18 Page 3 of 16

DOCUMENT REVISION HISTORY SHEET

Revision
Rev. Date Issued Update / Amendment Details
Description

P3-C IFR 16/12/2016 Issued for review

P3-0 IAA 07/08/17 Issued AS APPROVED

P3-1 Re-IAA 16/01/18 Re-Issued AS APPROVED

 VPC ERECTION, INSTALLATION,
COMMISSIONING, OPERATION AND
MAINTENANCE PROCEDURES FOR Doc. no. MAN00-2017-A89
LUBRICATED PLUG VALVES - INVERTED rev.1
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VPC ERECTION, INSTALLATION,

COMMISSIONING, OPERATION AND
MAINTENANCE PROCEDURES FOR
LUBRICATED PLUG VALVES -
INVERTED TYPE
Sheet 1 of 13
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REVISION SHEET

Rev. Date Prepared Verified Approved

0 12-01-17 P.Malchiodi L.Bariani P. Donini
1 15-01-18 P.Malchiodi L.Bariani P. Donini

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INDEX

REVISION SHEET ............................................................................................................................................................ 2

INDEX ................................................................................................................................................................................. 3
1. INTRODUCTION .................................................................................................................................................... 4
2. ERECTION............................................................................................................................................................... 4
3. INSTALLATION ..................................................................................................................................................... 6
4. COMMISIONING .................................................................................................................................................... 6
5. OPERATION ............................................................................................................................................................ 7
6. MAINTENANCE ..................................................................................................................................................... 7
7. SPARE PARTS & TOOLING ................................................................................................................................ 11
8. ASSEMBLY DRAWING ....................................................................................................................................... 12
APPENDIX........................................................................................................................................................................ 13

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1. INTRODUCTION

1.1. SCOPE:
The purpose of this manual is to furnish the right indications for the installation, use and maintenance of
lubricated plug valves manufactured for TANAP project.

1.2. REFERENCE DOCUEMNTS:

Use and maintenance manual for valves conformed to the follow specifications:
API 6D
Directive 97/23/CE (PED)

1.3. SUITABILITY:
This document is only for lubricated plug valves, installed in stations with operating conditions
described on chapter 3 to 6.

2. ERECTION

2.1. USE

The VALVITALIA’s lubricated plug valves are designed for services of flow control in the pipeline where the
valves are in fully open or fully close position. The valves must not be used to regulate the flow. Improper uses for
flow control may invalidate the guarantee.

The valve’s open and close operations shall be done using the instruments furnished and selected for the valve
(actuators). VALVITALIA refuses any responsibility for manoeuvre done with different operators.

2.2. SAFETY PRECAUTIONS

Protective clothing and equipment normally required when working with the involved fluid is recommended.
Depressurize the line and cycle the valve as follows:
Place the valve in the open position, cycle the valve to relieve residual pressure in the body cavity before removal
from the line; should the valve be seized in the open or closed position.
After removal and before any disassembly, cycle the valve again several times.
It is important to refer to the tag fastened on each valve for maximum pressure ratings and material description.

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2.3. NAME PLATE

The name plate is exposed on VALVITALIA’s valves in accordance to the European directive certificate, where
applicable.
Here below you can find an explanation table of what you will find on the name plates applied on the valves.

SIZE DN Nominal Diameter Serial N° Serial number

MONTH/ Production Month/Year CLASS Pressure Class
YEAR
TAG Valve tag number TYPE Type of valve
M.O.P./Tmin Maximum operating pressure M.O.P./Tmax Maximum operating pressure at
at minimum operating temp. maximum operating temp.
BODY Body material MODULE Not applicable.
BALL Plug material FLUID Fluid type
SEAT Not applicable QSL Quality safety level of the valve
STEM Stem material CATEGORY PED(97/23/EC)’s category.
FACE TO FACE / END TO END Face to face / end to end dimension
DBB, DIB-1, DIB-2 Not applicable

Table 1
The name plate also shows:
-Company logo and address:

Via Tortona 69
Rivanazzano(PV) ITALY

-API logo and license, CE logo(for European community only):

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2.4. ADDITIONAL NAMEPLATE

According to project requirement an additional nameplate, reporting all the data required by marking specification,
is fixed below the main nameplate described at point 6.1.
In the following table is possible to find all the fields included in the additional nameplate with a brief explanation.

P.O. Purchase order numberTAG N° Valve tag number

REQ.ITEM Customer item COMMODITY Valve commodity code
CODE
STEM Stem extension length from PUP PIECE Pup piece wall thickness in
EXTENSION valve centreline to actuator WALL [mm]
LENGHT flange in [mm]. THICKNESS
SEAL AND Stem PACKING MATERIAL DESIGN CODE Design code according to
PACKING customer data-sheet
MATERIALS
Table 2
Both the additional and the main nameplate are in double language English/Turkish as per project requirement.

3. INSTALLATION

Before the valve’s SET-UP, it should be carefully checked in order to verify that there are not evident damage due
to the shipping and handling. It’s very important verifying that the inside bore of the valve is free from any foreign
particles that might damage the seats and ball.

Use the appropriate lifting hooks to lift the valve; it is possible to use a sling rope around stem extension to raise
the valve(if shipped laid horizontally). During handling of the valve, lateral ports must be always close with
plywood covers and tape, in order to avoid entry of foreign materials and damage to the butt-welded ends.

The valve can be installed in both flow directions

Remove the end covers, clean the surfaces treated with antirust.

Ball valve with butt welded ends, welding connection to pipeline should be carefully carried out with ball in open
position and avoid an overheating of the body that can damage seals, gasket and seat ring (concerning to the
Interpass temperature, refer to the WPS/PQR).

4. COMMISIONING

After valve set-up, proceed to clear the pipeline to remove any foreign materials. Close and open the valve at least
three times and verify the correct operations.

No specific routine maintenance is necessary except operating the valve periodically, even if only
partially, to verify that the valve operation is satisfactory. If the valve shall stay in open position, it is
suggested to inject lubrication grease once a year.

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5. OPERATION

5.1. CHECKS OR REQUIREMENTS

Check there is no visible leak from the actuator, before the valve opening or closing. If any leak is detected,
further inspection shall be done to identify the reason of the leak, before removing the valve from service.
Check that the valve line and the body cavity are not under pressure before proceed with any dismounting
procedures.

Grease fitting could carried out also when the valve line is under pressure, due to the presence of security check
valves.

It’s required to have sealant and Sealant injection devices (guns or pumps) always available for maintenance or
operational purposes;

A batch of standard spare parts are always required for “routine”maintenance. If those particulars are not included
in the original scope of supply have to be requested to VALVITALIA through a service order.

6. MAINTENANCE

NOTE
During disassembly care must be taken to avoid damage to component surfaces. We
recommend components are placed on wood or similar surface and to avoid sharp metal
objects coming into contact with lapped surfaces of plug, stem and internal surface of valve
body. Similar procedures should be taken with gasket contact areas of flanges and clamp
connection areas.

6.1. DISASSEMBLY

6.1.1. Remove the valve from pipeline with plug in OPEN position, to avoid that any residual
pressure could bleed off fluid situated between plug and body cavities.
6.1.2. Remove valve actuator.
6.1.3. Unscrew the stem extension stud and nut.
6.1.4. Remove the stem extension assembly(107), pulling from the actuator flange.
6.1.5. Remove the inner drive pipe assembly(108), pulling from the upper spud using an eyebolt.
6.1.6. Unscrew gland plate screws (09) and Remove gland plate (05), then the graphite packing (54).
6.1.7. Rotate the valve 180° to access the cover.
6.1.8. Remove screw cap (131) and remove plug loading screw (68) and nuts (08).
6.1.9. Remove thrust seat (128) from the cover (02).
6.1.10. Remove the two diaphragms (134 & 135).
6.1.11. Remove the spherical bearing (127) from the plug (03)
6.1.12. Lift the plug (03) using an eyebolt.
6.1.13. Remove equalizer ring (67), and extract the stem (04) using an eyebolt.
6.1.14. Carefully remove the upper thrust washer (22) from stem (04).

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6.2. MAINTENANCE

6.2.1. Degrease and clean all components of the valve. Particular attention should be paid to the
cleanliness of the sealant grooves in the plug (03).
6.2.2. Clean and degrease the upper and lower chambers in the body (01) and visually check for signs
of damage or wear.
6.2.3. Visually examine the plug surfaces (03) and the contacting surfaces of the valve body for signs
of damage or wear.
6.2.4. Visually examine the stem (04) and equalizer ring (67) for damage or wear and the contacting
surfaces on valve body.
6.2.5. There should be no deformation or wear on cover (02).
6.2.6. Replace any worn or damaged parts such as: O-rings (12) packing (54) and the two diaphragms
(134 & 135).

6.3. ASSEMBLY

6.3.1. Place the upper thrust washer (22) and the O-rings (12) on the stem.
6.3.2. Carefully position the stem (04) in valve body and assemble the equalizer (67) onto the stem.
6.3.3. Position the plug (03) carefully into the valve body taking care not to damage the contacting
surfaces, and making sure the plug(03) and equalizer ring (67) are correctly aligned.
6.3.4. Position the support ball(127) into the plug (03).
6.3.5. Position the two diaphragms (134 & 135) in the body (01).
6.3.6. Position the support ball disc(128) into the cover (02a).
6.3.7. Screw stud bolts (07) into body (01) and place the cover (02) over valve assembly tightening
down the nuts (08).
6.3.8. Thread plug loading, register screw (68) and the screw cap (131) onto the cover (02).
6.3.9. Rotate the valve of 180°. To access the stem.
6.3.10. Install the graphite packing (54).
6.3.11. Place gland plate (05), and tighten down using the gland flange screws (09).
6.3.12. Position both the stem extension drive pipe(108) and stem extension pipe(107), on the top
body flange.
6.3.13. Screw the extension stud and nut.
6.3.14. Place the actuator over the extension flange.
6.3.15. Fix the actuator with pins its own screws and pins.

6.4. LUBRICATION

The functions of lubrication are 3:

- To protect the surface seal of the valve form corrosion and abrasion.
- To contribute to a good seal
- To contribute to an easy action.
Every metallic surface in contact with the plug during the ball movement should be lubricated.
The frequency of re-lubrication depends upon the operating conditions from the required mode of
sealing.

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The following table gives the frequency of re-lubrication according to the temperature range:

TEMPERATURE RANGE [°C] TIME INTERVAL

-50° a 0° 24 months
0° a 100° 16 months
Table 3
The quantity of grease for re-lubrication also depends on the operating conditions; however, the usual
amount is about 2 g/mm of passage.
The choice its lubricant should be according with the process medium and the service temperature
range (see lubrication table).

6.5. EMERGENCY SEALANT PROCEDURES

6.5.1. The emergency seal should be made using sealant type: “NORDSTROM (BTR) 555” or
equivalent.
6.5.2. The emergency seal should be carried out whenever a leakage is detected. The sealant injection
could stop the pressure leakage through body and stem. The injection points are shown in the
following figure and are provided with a giant button head nipple tapped with a female cap.
The injection is made by an high pressure pump(up to 10000psi). The sealant should be
injected inside the valve through the giant button head nipple, up to all the sealing area is
fulfilled. This happening when the sealant return in its path and close the check valve(not-
return) inside the nipple. This is the only way to ensure that all the gasket imperfections and
gaps are tapped with sealant.

Figure 1

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6.6. LUBRICATION PROCEDURES

The valve must be fully OPEN or fully CLOSED

Underground valves has the sealant injection points extended by tubing up to the actuator flange
VALVITALIA valves lubricated plug valves are designed to be lubricated using two different methods
– via built-in lubricant screw
– with hydraulic lever gun

- via built-in lubricant screw

6.6.1. remove lubricant screw and introduce grease stick into the stem reservoir. The check valve in
the reservoir eliminates the danger of any loss of grease during loading.
6.6.2. Re-fit the lubricant screw and tighten down to pressurize the grease which is forced past the
check valve into the upper chamber and then into the lower chamber via groove machined into
the plug. The grooves are positioned so that they are never exposed cannot be entrained by the
process fluid.
6.6.3. Rotate plug to evenly distribute lubricant.
6.6.4. If needed repeat procedure until lubricant is visible in inside valve.

- with hydraulic lever gun

6.6.5. Charge the lever gun following manufacturers instructions
6.6.6. Connect coupler of the lever gun to the universal button head of the grease injection (126-
126a)
6.6.7. Inject the grease by means of handgrip pumping.
6.6.8. Turn the plug for even distribution of lubricant.
6.6.9. Continue lubrication until lubricant is visible inside valve body.

Also note that:

6.6.10. The thrust washer (22) is auto-lubricated, so them not require any lubrication.
6.6.11. Lubricate the screw(07) thread with anti - frictional pick up.

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TYPES OF LUBRICANT AND SOLVENTS

TEMPERATUR
PRODUCTS RECOMMENDED FOR DO NOT USE
E
AUDCO ROCKWELL DL
Liquid and gaseous hydrocarbons, Aromatic
natural gas condense, natural gas solvents, strong
aggressive, sour gas, petroleum alkalis, aggressive
- 555 DL 55 -30°C ÷ 370°C products, chemical products, most chemical
hydrocarbon solvents, diluted acid products, warm
or alkaline solution, watery air
solutions
Acid, alkalis, alcohol, glycerine, Light
- - DL 21 0°C ÷ 343°C soap, water, hot gases, hot hydrocarbons
hydrocarbon vapours and gases aromatic solvent.
Natural gas transmission at Liquid
- - DL 62 -60°C ÷ 120°C subzero temperature hydrocarbon
solvent.
Stem Packing: / A non-asbestos plastic composition
Audco Rockwell DL containing graphitic filler for use in
sealing the stems of Hyperseal
Type Type Type valves. Designed for injection
through the packing injection
fittings on valve bodies. Colour:
H 909 - black Caution: for stem packing
only.
Table 4

Condition of the above table is only indicative; it is made in accordance with the actual service temperature.

LUBRICANT STICKS All stick lubricants are suitable for lubrication of plug valve

Stick diam. (mm) Box size No. of sticks per box

6 A 90
10 B 50
13 C 40
16 D 24
19 E 24
24 F 12
30 G 6
35 H 12
35 I 12
Table 5

7. SPARE PARTS & TOOLING

Please refer to documents VPC-SCH-OPR-GEN-004.

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8. ASSEMBLY DRAWING

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APPENDIX
APPENDIX A) ITEM LIST

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