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    6.1.4 Three way valve (TCV)

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    6 views15 pages

    6.1.4 Three Way Valve (TCV)

    Uploaded by

    jairo mahecha

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    CONTROL VALVES = DIVISION “TRV ee va INSTRUCTION MANUAL MANTRV01E.doc.DOC. TRVE-TRV2Z_3-way Control Valves Applicability ‘This instruction manual is applleable for TRV and TRV S-way contol valves, diverting an mixing REVISIONS: REV. |__DATE | PREPARED | VERIFIED | APPROVED 0 [Settembre 2010| CAROSELLI_ | PISTORE [__MURONI 1 | 2 | 3 4 5 6 7 8 9 MANTRVO1E.doc.D0C Page 2 TRVI-TRV2 3-way Control Valves SAFEGUARDS Instructions “These instructions provide insabatn, operaton and maininance infemation far VALVITALIA TRV Ssvay contol valves, This ocument should be made avalabe fo personal respensie fr Insataton, eperalon, ané manfenance ef these valve teres ‘Gualfed stat ony must be used to operate onthe valve. The Company elects any responsibly fr personnel ius and damages to ‘equpmentimputable to improper cperaton, use of nan eign spare parts or pats executed by unauthoriaod sta Safety Messages Safety messages in there instruction and on labels) onthe valve axe fanged with one ofthe words Caution, Warning or Dangor. ‘Those messages must be carefuly reed and followed to avoid personal Inuy andlor equipment damage. Ifa safely label Becomes cit 0 see or ead, o label has been remeved, pease cotat Valitaa 8.9 A, for abe) replacement WARNING! Personnel involved in the installation or maintenance of valves should be constantly alert to potential emission of process fluid and take appropriate safety precautions. Always wear suitable protection when dealing with hazardous fluids. Handle valves which have been removed from service taking into account the risk of entrapped hazardous fluid inside the valve. Inspection Vaiviaa valves nave been packaged to provide protection dung shipmont, however, i sil can be damaged in transport. Carefuly ‘inspect the unit for damage upon arrival. If damage is detected, immediately file a damage claim with the carrier. Storage Units shouldbe stored in clean, ool and dy location, and shoul be protected trom dr. chips, dust end otter contaminants. For ng tom storage, the seating aoa shouldbe protected ftom direct simi Replacement Parts Consult factory for recommended spare pts, read drawings and instruction fr thelr corect use Naise In partelar condlions the valve may generale igh noise levels. n such cases I Is tharefore necessary to take the necessary precautions, according othe regulon i force. MANTRVO1E.dos.DOC Page 3 TRVI-TRV2 3-way Control Valves Temperature 'ncase that Nt fhids Now vough he valve, he operate must pay alterion ont Insulated pats Lifting & Handling Ling the vale improperly may damage 8 Ut the valve wh sings, chains or cables fastened around the valve body or fastened ta baler rode Uvough bet les in he lange. A De not stenting devices othe actuator assem! Maintenance ‘To cence tis valve you should havea fl se of combination wrenches, et Ypped serenvers, Alen wrenches, @ torque wrench, Socket, erisls,» naked toa fer removing the pacing and a ded bow han. Perea ubrcaion it nol necessary wih the basle valve. See te acualr and accessory hituens for any icatlon requremens these ensembles may have Stuffing Box DANGER! Packing must not be released or replaced whon the valve Is under pressure. Sealing Surfaces Take caro of body soaling surfacos which must not be damaged during handling. Use wooden blocks or cloth strips to lay down tho valve during assomblingidisassombling or general maintenance, Removing Actuator WARNING! DO NOT remove actuator from the valve assembly while pipeline is still under pressure. Depressurize pipeline before any operation on the valve assembly. MANTRVOTE.dos.DOC Page 4 TRVI- TRV2 3-way Control Valves Table of Contents LUMITATION OF USE... ‘BENERAL INSTALLATION TP ‘VALVE INSTALLATION ‘VALVE REMOVAL . ‘VALVE DISASSEMBLY VALVE DISASSEMBLY ‘VALVE ASSEMBLY. ‘PACKING ADJUSTMENT. PACKING REPLACEMENT MANTRVO1E.doc.D0C Page 6 TRVI-TRV2 3-way Eontral Valves Limitation of use Residual Hazerds according to Essential Safely Requirements ( Annex I) Pressure Equipment Directive 97/23/CE 4—MAXIMUM OPERATING PRESSURE AND ‘TEMPERATURE Before placing the valve in pipe line make sure that maximum working pressure and temperature are within the limits of body rating and lower than allowable ‘maximum values indicated on valve serial plate. 2.= MINIMUM OPERATING TEMPERATURE Remember that control valves made of carbon steel material (SA-105 or SA216 WCB) are suitable for a ‘minimum fluid working temperature up to ~29°C. 3~PIPING STRESSES In generat itis not necessary to perform any check and calculation if pipe size is no larger than 1,5 tmes valve ‘body size (2 times for valve body size up to 3"), As the cconirol valve has not to be used as a fixed point, inlet ‘and cutlet pipe sizes are different, it should be considered the smaller one as itis essential for the piping design. 4= VIBRATIONS When the control valve is coreely sied and selcted important wrations caused by the vale eel shoud not cocur Howver on. severe senicas, smal Govitons ‘rom original process concilens may caine vibration phenomena of high lrlensily.whish cen damage tim and actielor accessories (positoner, Imi Sutches et) n this case ts necessary ta estore the original service condons or olnerwge to change the keen ype. 5~ SEISMIC STRESSES Valitala globe control are not significantly affected by ssolsmis accelerations up to 0.59. When control valves are equipped with large actuators and installed in a seismic region, it is necessary to perform appropriate calculations 10 check the yoke resistance, 6 FLASHING AND CAVITATION When flashing or cavitation occur, itis advisable to use body materials such as CrMo alloy steels or stainless steel. Also body oversizing and increased rating are recommended. 7 = EXTERNAL FIRE Valvitalia control valves usually are not designed to withstand external fire, ‘8 — OVERPRESSURES 8.4 ~ Safety valves discharge Valvital contro! valves have to be protected against overpressures above the maximum allowable rated pressure, Shor time pressure peaks are allowable during safety valve discharge, up to 10% over the maximum allowable working pressure, 8.2—Water hammer Especially when incompressible fluids are handled, itis essential to not quickly close the valves to avoid hydraulic shock waves which cause uncontrolled overpressure and damages to piping and associated equipments 9 ABRASIVE FLUIDS Abrasive sold particles carried by the fuid are the main cause of erosion and can cause a possible reduction of wall thickness of pressure containing parts 10-CORROSION For corrosion service Valvitalia LTG control valves are designed taking into account an allowance of body wall Cf 1mm for forged bodies and 2 mm for casted ones, up toa maximum wall thickness of 30 mm. In case of intergranuler corrosion itis possible to precict the lifetime of valve , while for local corrosions such as pitting, interstitial corrosion and stress corrosion, Is very difficult to get any realistic prediction of lifetime, In these case itis essential to properly select the material of valve body, 14 -LIFTING Lift valve with slings, chains or cables using eyebolts on valve body, fastened directly around the vaive body or fastened to bolts or rods through bolt holes in the flanges. Failure to lit the valve propery may cause damage during handling and instalation, 12 DEAD-END PIPING DESIGN Vaivitalia LTG3 control valves are not designed to perform deacend piping closure under a pressure greater the max one specified in the technical book in the closed position. Consult engineering department for any information MANTRVO1E.doe.D0C Page 6 TRVI-TRV2_3-way Control Valves General Installation Tips The LTG3 contro! valve can be easily insted in most piping systems. To ensure the valve is properly installed, make sure the following requirements are mat ORIENTATION Even if valves are normally installed in vertical position with upward oriented actuator, TRV series valves may be installed and properly operale in any position. However, vertical shaft orientation with downward actuator i's not recommended dus to solid particles hold by fluid which may head up in the packing FLOW DIRECTION The flow direction is marked on the body or on the valve plate. TRV! (diverting) are assembled in the way that the fluid goes between the two ‘seats, for avoid stress to the follower and in general, for a Detter stability of plug. For TRV2 (mixing), the fuid goes between side and bottom entry and exit mixed {rom the other side way. PIPING LAYOUT To reduce the effect of downstream disturbance, a minimum straight pipe 6 ON long must be installed upstream the valve. Also a straight pipe 3 DN length (including reducers) must be installed downstream. Very low fuid velocities may allow upstream and downstream straight pipe lenght reduction. Reducers are allowed only if tapered and concentric. The observance of those requirements are necessary to the valve to operate properly according to the design pattern, with regard to sizing, ncise generation, plug stabity and so on. Before installing the vaive in the line, especially the new ones, clean piping and valves from all foreign materials, such as welding chips, scale, ol, grease or dirt. VALVE TRAVEL ‘The actuator is adjusted at the factory not to interfere with the proper closed and ‘open positon, LUBRICATION Periodic lubrication normally fs not necessary with the standard valve. See the actuator and accessory instructions for any lubrication requirements these assemblies may have. MANTRVO1E.dos.DOC Page 7 TRVI-TRV2 3-way Coniral Valves Tani 1, VALVE INSTALLATION FOREWARD 2G Before instalng the LTG3 series valve, i's necessary to verily thal process operating pressure and temperature do not exceed the body rating. 1.1. Before instalation remove all foreign material such as weld spatter, oll, grease ‘and dirt from the valve, flanges and pipeline. 41.2 Follow piping layout and other installation tips (see pag.7 of this manual for details) 41.3 Check piping connection distance, coaxialty and parallelsm to avoid tensile and bending stresses which could oczur when the valve is fastened to piping. WARNING! Ensure that the valve, the pipeline and the mating connections are properly aligned before tightening the pipeline bolts. Do not use the valve to force the pipeline into position. 1.4 Toit the valve use appropriate eye bolts or olher devices fitted on the valve. Don't lif the valve keeping it from the actuator 4.5 In case of welding connections, it is recommended to avoid valve body overheating. Ifthe valve plug is provided by a piastic inset it's suggested to lit the plug over the seat during welding process. if excessive body heating is ‘expected, the body temperature should be kept under control: the outside surface temperature should not exceed 100°C at 100 mm from the welding bead. In case of doubt, with plastic insert plugs, tis beter fo remove the tim from valve body before welding process 1.6 Flange gasket is required. Tighten the bolts evenly, in a crisscross figure. MANTRVO1E.doc.DOC Page 8 re TRVI-TRV2 3-way Control Valves Fig! TRV part list diverting type -way contral valve TRV1 — Part list ren PART NAME 1 BODY 2 ‘BONNET 3 ‘STEM 4 STUD, 3 NUT & BODY GASKET 7 PIN 8 PLUS 0 SEAT RING @ (GUIDE BUSHING 78_|__ PACKING FLANGE 1% PACKING STUD, 16 PACKING NUT 16_|_ PACKING FOLLOWER 17] BOTTOM FLANGE 25 PACKING BOX 26_| LOCKING WASHER a NUT Fig2~TRV2 part ist mining type 3-woy control valve TRV2 — Part list TEM PART NAME: 1 BODY 2 BONNET a STEM 4 ‘STUD a NUT 6 BODY GASKET 7 PIN 2 PLUS 0 ‘SEAT RING 2 GUIDE BUSHING 13_| PACKING FLANGE 4 PACKING STUD 5 PACKING NUT. 76_| PACKING FOLLOWER 17_| _ BOTTOM FLANGE 25 PACKING BOX MANTRVO1E.doc.DOC Page 9 ea TRVI-TRV2 3-way Eontral Valves 2. VALVE REMOVAL FROM PIPELINE To safely remove the valve from the pipeline carefully folow these steps. 2.1. Discontinue pipeline flow and relieve pipeline pressures in the portion ofthe flow system where the valve is located. WARNING! Pipeline pressure can propel the loose flange bolts and flanges, and can cause personal injury or equipment damage. Relieve pipeline pressure before removing flange bolts and flanges. 2.2 Be careful to potential emission of pipeline material and take appropriate safety precautions. Always wear suitable protection when dealing with hazardous pipeline materials. Handle valves which have been removed from service taking Into account the risk of entrapped hazardous fuid inside the valve, 2.3 Support the valve assembly, then remove the flange bolls or mechanical joint connectors. 2.4 Carefully lift the valve from the pipeline as described in ‘Lifting & Handling” section (pag.4) and remove the valve from pipeline. Feilure to lift the valve properly may cause demage during handling and installation, 2.8 Lay down the valve on wooden surface or cloth strips to prevent machined surfaces from damages MANTRVO1E.doc.D0C Page 10 TRVL-TRV2_3-way Control Valves 3. VALVE DISASSEMBLY 4, STEM and PLUG REPLACEMENT 3.1 Remove the valve from the pipeline as described in the “Valve Removal From Pipeline” section 3.2 Remove the actuator from the valve as described in the Actuator Instructions. 3.3 For disassembly the plug, in case of TRV (diverting), remove bottom flange (17) screws with a sutable hex driver (6). To push completely stem and plug for ‘unscrewing nut and lock nut (27). Plug can be stopped from 2 spanner stuck on the plans proceeds an the stem between the two caps. For TRV2 (mixing), after remove bottom flange (17) with seat (10), to take off cage and stem, from bottom, 3.4 Before removing the packing assembly from the bonnet, please read “Packing Replacement’ section 3,5 Remove the gasket from the body - bottom flange and between bonnet - body (6) Ifproblems occur, it must be replaced with VALVITALIA original spares. 36 Ifdamaged, unscrewed the seat and changed. ‘Stem and plug are two diferent pieces coupled with a serewed part and a pin. 4.1. Remove the pin by pushing it outwith a punch. 4.2 It is recommended fo use an original new stem (not dilled), The plug may be used again 4.3 Screw the new stem into the plug paying attention to not damage machined surfaces, 4.4 Dril the stem driving the too! in the existing hole in the plug 48 Remove dril burs. 4.6 Put some grease on a new pin and stip it into the hole. 4.7. Check stem and plug alignment on a lathe. If necessary straighten them with 2 plastic rubber hammer ®pin 2 3 4 55 0 o a 0 @rote | 2 402 | 3 401 | 4 +022 | 5,5 40,22 MANTRVO1E.doe,DOC Page 11 TRVI-TRV2 3-way Control Valves 5, VALVE ASSEMBLY 6. PACKING ADJUSTMENT 5 82 53 84 585 56 et 62 Use original spares only Carefully clean the seat surfaces of the static gaskets (6). Insert seats into the body. In case of TRV1, with stom completely down, assembly stem and plug for ssrewing nut and lock nut (27). Plug can be stopped from @ spanner stuck on the plans proceeds on the stom between the two caps. Screwing bottom flange (17) witha suitable hex driver (6) For TRV2, put from the bottom stem with plug, ‘Screwing bottom flange (17) with a suitable hex driver (8) Screw studs in the body threaded holes then put the bonnet on the top of the valve body by fastening relevant nuts. Follows packing replacement end aclualor mounting instructions to complete valve assembly. If leakage through the packing occurs, tighten the packing nuts just enough to stop the leakage. ‘Overtightening wil cause excessive operating force, high friction and premature packing wear. If packing leakage cannot be stopped by tightnening the packing nuts, the packing must be replaced. Read the relevant section on this manuel to replace packing, MANTRVO1E.doc.DOC Page 12 TRVL-TRV2_3-way Control Valves 7. PACKING REPLACEMENT aA 72 73 74 15 78 77 78 19 710 712 7.43 714 Removing packing while the pipeline is under pressure can cause personal injury or equipment damage. Relieve pipeline pressure before removing the valve packing. WARNING! Close the vaive and relieve pipeline pressure, Ifthe actuator is powered, disconnect and lock out the pneumatic, hydraulic, or electrical ower to prevent accidental operation ofthe actuator. Remove the actuator from the valve following related instructions, Remove the actuator adaptor from the top ofthe valve. ‘Take out screws that hold the packing gland and slide land off the valve shaft. Packing replacement: 7.6.1 Remove all the old packing rings from packing chamber with a hooked tool, 7.8.2 Apply @ light fim of grease to the inside and outside clameters of the new Packing, then install the packing one right ata time. 7.6.3 Push the packing fimly in place (don't use sharp or pointed tools). Slide the packing gland (7) down the shaft untilit just contacts the packing, Screw the packing gland screws into the body. Fasten the actuator mounting bracket to the top of the valve, Install the actuator on the valve following related instructions. If the actuator is powered, reconnect the pneumatic, hydraulic ar electrical power. ‘Affor the valve is pressurized, check for packing leaks. Ifpacking leaks, tighten the packing gland screws just uni the leak stops. Caution: Do not overtighten packing nuts. MANTRV01E.doc. DOC Page 13, EEE | pia coma fon 3 | [Ponta = maveravnmor __ OATASHEET Noa 3 ue ao 7 ec vo nae Socin TT) [ester = 7] rr Wakitatn Modal POA TST Z| fae 7 se] freee digg 1 plan [CPS] [recannams 7 Proucian P ete Pes 2] [Sve ceo. ceposes I~ doubt set 1 aa ] [tien tr. BF a a max | [a0] face 308m “Etech wes re ] [oat onan 7s a] fea om ©] essere ov 3 see 8 fom 7] [eset es ov soon Fae oe | & [Poems SAS w]e = [Peehason Fam 7 eo ws] [Rreomiee aa 10] fosonarsnce tong [eames Efe] tr tor eet pats me 14] g [lina Chass = 87] Sircking time = 72] 3 [rcs Tanne 6] [cies Tepe 73] [area con Tom Er a 1 7] [ro] fare oT 7] Fe A 38] & [Flow Rate 2 i 72 _|umscro| [72] [Straight way osem at aA 2] § tonsa 5 a feo Tank ial Pras ena Tae [cas [a [ me Tagen Taint wo] [onsen [oe [|e fecae e r 720] § [rat conir ot = ign 76] & [meats HPT? Eeare Web 21] 8 owes wa Tae [re Dior | Lr] ieommine Fb omom 22 & [Crist preseure Pe bore 78] [Redecton othe Teed R Exio(t) TNA 7a [Nesey won [ao | aan | | [7] [eonmaicain i fot FT Pome TNA] 2] ce ia [taf el = a ; | [Somretyaar oe a1] § acne PnP peaeny Pee 25] [uote mi 2 [= | ware [2B [smring pr awed T= etmvel Teper a7] laraors am [ WA] mae | HAM] tog [es] [eons ope Te seor PoroT ze] Pomrinazaiin ——Toenaiot penbwoo Tov [20] 8 ecxtonatiss ea [ecm 1” Sieawe 20] [Airfare pasion TP open ACW open Biot _ I holt 85] [Assembly 1 extemal I bultin r se] fiat 7 [ «| [ef] pr ea 3], wear ane a 22] [ttn cor 7 CO | 35] 3 [oailaed minor [fot [aes el z 3a] ° [aan ee Tam_| aes | aa | aoe | [0] 8 et ersten ec | _[fesastcdpemte [ane Lene Lo Lea) [at] feast = 33] [rR ‘Vaivalia Teds TRV a2]? Recon ota Tse Te 7 Saeses a] Rowdee : 28

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