Metso D Series Manuel utilisateur

1 D 71 en • 12/2010

BALL VALVE

Series D

Installation, Maintenance and

Operating Instructions

21 D 71 en

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about safe handling and operation of the valve.

If you require additional assistance, please contact the manufacturer or manufacturer's representative.

Addresses and phone numbers are printed on the back cover.

SAVE THESE INSTRUCTIONS!

Subject to change without notice.

All trademarks are property of their respective owners.

Table of Contents

1 GENERAL........................................................ 3

1.1 Scope of the manual.............................. 3

1.2 Valve description.................................... 3

1.3 Valve markings ...................................... 3

1.4 Technical specifications......................... 3

1.5 CE marking............................................ 4

1.6 Recycling and disposal.......................... 4

1.7 Safety precautions................................. 4

2 TRANSPORT, RECEPTION AND STORAGE .. 5

3 MOUNTING AND COMMISSIONING.............. 5

3.1 General.................................................. 5

3.2 Mounting the valve in the pipeline.......... 5

3.3 Actuator.................................................. 5

3.4 Commissioning ...................................... 6

4 MAINTENANCE............................................... 6

4.1 General.................................................. 6

4.2 Maintenance of a mounted valve........... 6

4.3 Removing the actuator from the valve... 6

4.4 Removing the valve from the pipeline.... 6

4.5 Dismantling the valve............................. 7

4.6 Removing and inspecting the valve parts. 7

4.7 Reassembling the valve......................... 7

5 TESTING THE VALVE .................................. 11

6 MOUNTING THE ACTUATOR ...................... 11

6.1 General................................................ 11

6.2 M actuator............................................ 11

6.3 B1C actuator........................................ 12

6.4 B1J actuator......................................... 12

6.5 Mounting actuators of

other manufacturers............................. 12

7 MALFUNCTIONS .......................................... 13

8 TOOLS........................................................... 13

9 ORDERING SPARE PARTS ......................... 13

10 EXPLODED VIEWS AND LISTS OF PARTS ... 14

10.1 D2 valves, T and S constructions........ 14

10.2 D2 valves, H construction.................... 15

10.3 D1F valves........................................... 16

11 DIMENSIONS AND WEIGHTS...................... 17

12 TYPE CODE .................................................. 22

1 D 71 en 3

1 GENERAL

1.1 Scope of the manual

This manual provides the essential information about

the use of series D ball valves. For more information on

actuators and other equipment, which are covered only

briefly, please refer to the separate manuals on their

installation, use and maintenance.

1.2 Valve description

Series D valves are flanged ball valves. The body con-

sists of two symmetrical parts which are attached to

each other with screws. The ball and stem are of one

piece. Large low-friction bearings ensure reliability and

long maintenance intervals. The valves have spring-

loaded seats which are either soft or made of metal.

The valves can be used for shut-off and control appli-

cations.

1.3 Valve markings

The body markings are cast or stamped on the body

side. The identification plate (Fig. 2) is attached to the

valve flange.

The identification plate has the following markings:

1. Body material

2. Ball material

3. Stem material

4. Seat material

5. Maximum operating temperature

6. Minimum operating temperature

7. Maximum shut-off pressure differential

8. Type code

9. Number of the list of valve manufacturing parts

10. Pressure class

1.4 Technical specifications

Face-to-face length: ASME B 16.10, API 6D

Body ratings: ASME Class 150, 300 and 600

Maximum pressure differential:

see Figures 3 and 4

Temperature range: see Figures 3 and 4

Flow direction: single-seated:

upstream

double-seated:

flow direction free

Leakage rate:

metal-seated ASME Classe V

ISO 5208 leakage rate D, C,

or B

soft-seated API-598 (1970)

Dimensions: see Section 11

Weight: see Section 11

NOTE:

As use of the valve is application-specific, a number

of factors should be taken into account when select-

ing the application. Thus, some of the situations in

which the valves are used are outside the scope of

this manual.

If you have any questions concerning the use or appli-

cation of the valve, contact Metso’s Automation busi-

ness for more information.

Fig. 1 Construction of the D series valve

Fig. 2 Identification plate

BODY

TRIM

SHAFT

SEAT

TYPE

RATING

No.

t max.

t min.

ATTENTION: READ INSTRUCTIONS BEFORE INSTALLATION OR SERVICING. CONTACT METSO AUTOMATION FOR COPY.

MADE BY METSO AUTOMATION

XXXX

(1) (3) (5) (6) (8) (9)

(2)

(4)

(7) (10)

41 D 71 en

1.5 CE marking

The valve meets the requirements of the European

Directive 97/23/EC relating to pressure equipment, and

has been marked according to the Directive.

1.6 Recycling and disposal

Most valve parts can be recycled if sorted according to

material. Most parts have material marking. A material list is

supplied with the valve. In addition, separate recycling and

disposal instructions are available from the manufacturer. A

valve can also be returned to the manufacturer for recycling

and disposal against a fee.

1.7 Safety precautions

Fig. 3 Pressure/temperature curves of the valve body,

material ASTM A216 gr. WCB

Fig. 4 Pressure/temperature curves of the valve body,

material ASTM A351 gr. CF8M

Temperature (°C)

Temperature (°F)

p(bar) p(psi)

38 50 100 150 200 250 300 350 375 400 425

100

120

200

400

600

800

1000

1200

1400

1600

#600

#300

#150

100 122 212 302 392 482 572 662 707 752 797

Temperature (°C)

Temperature (°F)

p(bar) p(psi)

38 50 150 250 350 400 450 500 550 600

100

120

200

400

600

800

1000

1200

1400

1600

#600

#300

#150

100122 302 482 662 752 842 932 1022 1112

CAUTION:

Do not exceed the performance limitations!

Exceeding the performance limitations marked on the

valve may result in valve damage or even in uncon-

trolled pressure release. Damage or personal injury

may result.

CAUTION:

Do not remove or dismantle a pressurized valve!

Removing or dismantling a pressurized valve will cause

an uncontrolled pressure release. Always shut off the

pipeline, release the pressure and remove the

medium before removing or dismantling the valve.

Identify the medium, protect yourself and the environ-

ment against any harmful or poisonous substances.

Prevent the medium from entering the pipes during

maintenance.

Failure to do this may result in damage or personal

injury.

CAUTION:

Beware of the cutting movement of the ball!

Keep hands, other parts of your body, tools and other

objects out of the open flow port. Also make sure that no

foreign objects enter the pipeline. Close and detach the

actuator pressure supply for maintenance.

Failure to do this may result in damage or personal injury.

CAUTION:

Protect yourself against noise!

The valve may produce noise in the pipeline. Its level

depends on the application and can measured or cal-

culated using the Metso Nelprof computer program.

Occupational safety regulations on noise levels

should be observed.

CAUTION:

Beware of extreme temperatures!

The valve body may be very hot or very cold. Protect

people against frostbites and burns.

CAUTION:

When handling the valve or the valve package,

remember its weight!

Do not lift the valve or the valve package from the

actuator, positioner, limit switch or their pipes. When

lifting the valve, place the lifting ropes around the

valve body. See Figure 5.

Damage or personal injury may result from falling

parts.

Valve weights are listed in Section 11.

CAUTION:

Follow the proper procedures when handling and

servicing oxygen valves.

1 D 71 en 5

2 TRANSPORT, RECEPTION AND

STORAGE

Check the valve and the associated equipment for any

transport damage.

Before mounting the valve, store it indoors in a suitable

place.

Do not take the valve to the intended location or remove

the flow port protectors until just before the mounting.

The valve is supplied in an open position.

Do not lift the valve or the valve package from the actu-

ator, positioner, limit switch or their pipes.

When lifting the valve, place the lifting ropes around the

valve body. See Figure 5.

3 MOUNTING AND COMMISSIONING

3.1 General

Remove the flow port protectors and check the valve for

dirt that may have entered it during transportation and

storage.

3.2 Mounting the valve in the pipeline

Clean the pipes by flushing or blowing before mounting

the valve. Keep the valve in fully open position during

flushing. Any impurities such as sand or pieces of weld-

ing electrode may damage the seats and tightening

surfaces of the ball.

The functioning of the valve, actuator or the positioner is

not affected by the flow direction or the valve position.

Do not, however, install the valve with the stem pointing

downwards. This may allow impurities at the bottom of

the pipeline to enter the space between the stem and

the body and damage the gland packing.

Sufficient support for the pipeline reduces stress due to

pipeline vibration. Low vibration also ensures reliable

positioner operation.

An unsupported valve is easier to maintain. Neverthe-

less you can support the valve by its body with stand-

ard pipe clamps and supports. Do not fasten the

supports to the flange bolts or the actuator.

3.2.1 Valve insulation

If necessary, the valve may be insulated. Insulation

must not continue above the upper level of the valve

body, see Figure 6.

3.3 Actuator

The closed position of the ball is indicated as follows:

❑by an indicator on the actuator or

❑by a groove at the end of the ball stem (parallel to

the flow opening).

If you are not sure about the indicator, check the flow

direction by the groove.

If possible, mount the valve so that it can remain in

place even if the actuator is removed.

Mount the actuator cylinder should be mounted in an

upright position.

The actuator should not touch the pipeline as pipeline

vibration may damage it or affect its performance.

3.4 Commissioning

Before commissioning, check the valve and the pipe-

line for any impurities or foreign objects. Flush the pipe-

line carefully and keep the valve in fully open position

during the flushing.

Check all joints, pipings and cables.

Check the adjustments of the actuator, positioner and

the limit switch. For actuator adjustment, see Section 6.

For other devices, consult their individual manuals.

If necessary, tighten the gland packing.

Fig. 5 Lifting the valve package

CAUTION:

The valve and valve package are heavy. Remem-

ber this when handling them.

NOTE:

Always use the appropriate flange gaskets. Check to

see what gaskets are used elsewhere in the pipeline.

NOTE:

Do not try to correct pipeline misalignments with

flange bolts.

CORRECT

WRONG

Fig. 6 Insulation of the valve

NOTE:

When mounting the actuator, check that the valve

package functions properly. For more information

about the mounting of the actuator, see Section 6 or

the separate actuator instructions.

Insulation limit

61 D 71 en

4 MAINTENANCE

4.1 General

Although the valve does not require any regular mainte-

nance, you should check the tightness of the gland

packing from time to time and, if necessary, take a few

simple maintenance measures. This chapter outlines

the measures the valve user can take.

The numbers in brackets referto the exploded view and

the lists of parts in Section 10.

4.2 Maintenance of a mounted valve

4.2.1 Gland packing

Replace the gland packing (69) if the tightening of the

nuts does not stop leakage.

Ensure that the valve is unpressurized and remove the

actuator. Then remove the existing gland packing using

a tool that does not damage the tightening surfaces.

Install the new gland packing as instructed in Sections

4.7.4 and 4.7.5.

4.2.2 Body and bonnet joint

Should the body joint leak tighten the nuts as indicated

by the torques in Section 4.7.3.

4.2.3 Turning the ball

If the ball’s tightening surface is so badly damaged that

the valve leaks in closed position, turn the ball 180

degrees. Note the effect of the measure on the orienta-

tion of the actuator. Should the leaking continue, send

the ball to the manufacturer for repairs.

Do not turn a ball with a Q attenuator. For further

instructions, contact the manufacturer.

4.3 Removing the actuator from the

valve

It is usually easiest to remove the actuator and its sup-

port equipment before removing the valve from the

pipeline. If the package is small or not easily accessi-

ble, it is better to remove the entire package at one go.

❑Close and detach the actuator pressure supply

and remove the control cables and pipes from

their couplers.

❑Loosen the bracket screws.

❑Remove the actuator from the valve with an

extractorthat can be ordered from the manufac-

turer (See Chapter ’Tools’). See Figure 7.

❑Remove the bracket and any coupling.

4.4 Removing the valve from the

pipeline

❑Make sure that the pipeline is empty and unpres-

surized and that there is no medium flowing into

the pipeline while the valve is not in its normal

position.

❑Carefully attach the ropes, loosen the pipe flange

screws and lift the valve using the ropes. Make

sure that you lift the valve correctly. See also Fig-

ure 5.

CAUTION:

Familiarize yourself with the safety precautions in Sec-

tion 1.7 before any maintenance operations!

CAUTION:

The valve and valve package are heavy. Remem-

ber this when handling them.

NOTE:

Always use original spare parts to ensure proper

valve functioning.

NOTE:

A valve sent to the manufacturer for servicing should not

be dismantled. Clean the valve carefully from inside and

outside and, to ensure safety, inform the manufacturer of

the type of medium involved.

CAUTION:

The valve package is heavy. Remember this when

handling it.

NOTE:

To ensure proper reassembly, observe the position of the

actuator and the positioner/limit switch with respect to the

valve before removing the actuator.

Fig. 7 Removing the actuator with the extractor

CAUTION:

Do not remove or dismantle a pressurized valve!

1 D 71 en 7

4.5 Dismantling the valve

❑Place the valve on its flange on a clean, level sur-

face made of wood, hardboard or plastic. If nec-

essary, support the actuator so that it cannot

overturn as the mounting bolts are being

removed.

❑Remove the actuator if it is still attached to the

valve.

❑Remove the mounting brackets of the valve.

❑Tap loose the key at the end of the ball stem.

❑Remove any burrs from the keyway edges.

❑Loosen the gland packing nuts and the bonnet’s

fastening bolts and pull the bonnet away from the

ball stem.

❑Remove the bolts keeping the body halves

together and lift the upper body half on its flange.

4.6 Removing and inspecting the valve

parts

4.6.1 Ball

To make carrying and inspection easier, the balls

>DN300 (12") have a threaded hole at the end of the

stem for an eyebolt.

❑Lift the ball from the body on a soft surface and

clean it.

❑Check the sealing and bearing surfaces of the

ball stem.

❑Remove any minor scratches and impurities

using an emery cloth.

❑File off any burrs from the stem keyway.

❑If the ball has deep scratches on its sealing and

bearing surfaces or if it is not fully spherical, it

should be sent to the manufacturer for repairs.

4.6.2 Bearings

❑Check the bearings. In PTFE bearings, the stain-

less steel net should not be visible.

4.6.3 Seats

❑Turn the body upside down and detach the seat

by tapping at it through the flow opening with a

rubber or plastic mallet.

❑Clean and check the tightening surfaces.

4.6.4 Body and bonnet

❑Always replace the body and bonnet gaskets

during maintenance.

❑Remove existing gaskets from all sealing sur-

faces and clean the surfaces carefully.

❑Do not round the sharp edges at the conver-

gence point of the body joint and bonnet sealing

surfaces, as this could cause leaks. See

Figure 8.

❑Remove the gasket from the bonnet, for example

with a screwdriver.

4.6.5 Other parts

❑Clean all parts carefully, including the studs and

nuts.

❑After cleaning and checking all parts, keep them

in a protected place until reassembly. Handle the

ball, its seats and the body joint surfaces with

particular care.

❑If necessary, send the valve to the manufacturer

for repairs.

4.7 Reassembling the valve

❑Reassemble the valve by placing the female

body half on a level surface in an upright position

with the body joint pointing upwards.

❑Then put the parts in their place in the following

order:

1. Seats

2. Ball with its bearings

3. Body joint between body halves and bonnet

4. Gland packing

4.7.1 Fitting the seats

T and S seats

❑Check the sealing surfaces.

❑Place the back seals (63) into their position to the

body grooves. See Figure 9.

❑Place the back-up rings (64) made of PTFE strips at

the side of the O-ring. To ensure that the seam

becomes flexible, the strip must have slanted ends.

❑For easier assembly, lubricate the O-ring and

back-up ring surfaces facing the seats with sili-

cone grease or another suitable substance.

❑Place the spring (62) into the groove in the seat

(7). Connect the ends of the spring.

❑Place the seats into the body by hand or if nec-

essary, using a plastic mallet. The seat is in cor-

rect position when the spring touches the body

shoulder.

Fig. 8 Sealing surfaces

The edges must remain sharp

81 D 71 en

D and R seats

❑Check the sealing surfaces.

❑Place the back seals (63) into their position to the

body grooves. See Figure 10.

❑Place the back-up rings (64) made of PTFE strips

at the side of the O-ring. To ensure that the seam

becomes flexible, the strip must have slanted

ends.

❑For easier assembly, lubricate the O-ring and

back-up ring surfaces facing the seats with sili-

cone grease or another suitable substance.

❑Place the graphite backseal (129) carefully into

the seat. Make sure the backseal is installed in

correct direction.

❑Place the set ring (130) against the backseal.

❑Place the spring (62) into the groove in the seat

(7). Connect the ends of the spring.

❑Place the seats into the body by hand or if nec-

essary, using a plastic mallet. The seat is in cor-

rect position when the spring touches the body

shoulder.

E seats

❑Check the sealing surfaces.

❑Place the back seals (63, 75) into their place in

the body grooves. See Figure 11.

❑Place the back-up rings (64, 76) made of PTFE

strips on both sides of the back seal (63) and

beside the back seal (75). To ensure that the

seam becomes flexible, the strips must have

slanted ends.

❑For easier assembly, lubricate the O-ring and

back-up ring surfaces facing the seats with sili-

cone grease or another suitable substance.

❑Place the spring (62) into the groove in the seat

(7). Connect the ends of the spring.

❑Place the seats into the body by hand and make

sure that the pin (78) in the body, which prevents

the seat from rotating, goes into the hole in the

seat. Note that the bore through the seat is an

ejector hole. If necessary, use a plastic mallet.

❑The seat is in the correct position when the

spring touches the body shoulder.

B seats (for D2)

❑Check the sealing surfaces.

❑Place the spring (62) onto the back-up ring (35).

❑Place the ring (130) and the graphite back seal

(129) into their place. The slanted side of the

back seal should face the ring. See Figure 12.

❑Push the assembled parts inside the seat (7).

❑Place the seat package into the body.

H seats

❑Check the sealing surfaces.

❑Lap the opposing surfaces of the seat and bel-

lows and of the bellows and body with diamond

paste before you fit the seat.

❑Then clean the parts carefully using a suitable

solvent and emery paper (500 or finer).

❑Place the seat into the body.

Fig. 9 T and S seats

Fig. 10 D and R seats

62 7 63 64

62 130 129 7 63 64

Fig. 11 E seat

Fig. 12 B seat

75 76 62 78 764 63

35 62 7130 129

1 D 71 en 9

C seats

❑Check the sealing surfaces.

❑Place graphite backseal (129) carefully into the

seat. Make sure the backseal is installed in cor-

rect direction.

❑Make sure there are not any sharp edges in the

seat cavity of valve body to damage the back-

seal.

❑Place the seat into the body.

4.7.2 Bearings and ball

PTFE bearings

❑Place the bearings (60,61) onto the thrust and

trunnion bearings so that the PTFE surface

touches the stem. See Figure 15.

❑Push the bearing (60) into the thrust bearing (4).

❑Turn the bearing (61) so that it fits inside the trun-

nion bearing (5). Push the bearing until the lip is

flush with the flange groove. Then release the

bearing and push the lip into the groove.

❑When you install the thrust bearing (89), make

sure that the PTFE surface is against the ball

shoulder.

❑Push the bearings onto the stem and the trun-

nion.

Heat-resisting bearings

High-tolerance cobolt alloy bushings are used as bear-

ings.

❑Place the bearing (4) onto the stem so that the

shoulder faces the ball.

❑Place the trunnion bearing (5) in its place.

Ball

❑Lower the ball (3) carefully to the female body

half (2). The bearings will ensure that the ball

goes into the correct position inside the body

half.

4.7.3 Body Joint

Depending on the valve application, the body joint gas-

ket (65) is of either PTFE or graphite.

❑Place the PTFE gasket into the outer circumfer-

ence of the groove of the female body half. See

Figure 17.

Fig. 13 H seat

Fig. 14 C seats

62 7

129 7

Fig. 15 PTFE bearings

Fig. 16 Fitting and cutting the graphite gasket

Fig. 17 Fitting the PTFE gasket strip

D1F D2

D1F

10 1 D 71 en

Tightening the body joint bolts

❑After fitting the ball and the body gasket, lift the

male body half (1) and the seat (7) onto the ball.

See Section 4.7.1.

❑Check the correct alignment of the bonnet bore

with the body joint. Push the bonnet (8) onto the

stem.

❑Lubricate the flange, neck and bonnet bolts and

screw them into position. If hexagon bolts are

used as flange bolts, it is easier to tighten them if

they are inserted from below so that the nuts can

be tightened from above the body joint flange.

❑Put the bonnet (8) into its place. After tightening

the flange bolts loosen the bonnet bolts and

remove the bonnet.

❑Tighten the flange bolts as indicated in Figure

18. Start from opposite the stem and first tighten

the bolts to torques that are 10 % of the values in

Table 1. Then tighten them to their final torques in

the same sequence.

❑In valves up to DN 100 mm (4"), insert the neck

bolts before mounting the body halves. Center

them so that the distance from the nut’s outer

side to the bolt’s shoulder is equal at both ends.

Tighten the neck bolts after tightening the flange

bolts.

Tightening the bonnet bolts

❑Remove any excessive body gasket from the

gland surface, for example with a screwdriver.

❑Place the ring-shaped bonnet gasket (66) into

the bonnet shoulder. You can attach the gasket to

the bonnet for the duration of the installation with

small amounts of silicon grease.

❑Place the bonnet onto the stem.

❑Tighten the bonnet bolts as indicated by the tor-

ques in Table 1.

4.7.4 Gland packing, D2, D1F

❑Install the new gaskets one by one by using the

gland. PTFE rings should be mounted so that the

breaks are at a 45 angle with respect to the flow

opening and at a 90 angle with respect to each

other. Graphite rings should be put into place

from the end of the stem. Make sure that there is

no burrs in the keyway, as it could damage the

gland packing.

❑Put the gland into place.

❑Turn the hexagon nuts on the studs and tighten

the gland packings while the valve is still unpres-

surized.

❑Re-tighten the nuts as needed.

4.7.5 Gland packing, D1F_G

❑Make sure the valve is not pressurized.

❑Unfasten the nuts (25) and remove the disc spring

(TA-Luft) kits (43), the gland (9a), the retainer ring

(42) and the compression ring (9b).

❑Remove old packing rings (20). Do not damage the

surfaces of the packing ring counterbore and shaft.

❑Clean the gland and packing ring counterbore.

Install new set of packings. Slip the rings onto the

shaft. Ensure that there are no burrs in the key-

way groove which could damage the packing.

Position the cut ends of the graphite rings at a

90° angle to each other.

❑Mount the compression ring.

❑Slip the retainer ring on the shaft and push it

against the compression ring, see Fig. 19.

❑Install the gland.

❑Mount the disc spring kits.

❑Place the nuts on the studs.

❑Pre-compress the gland packing by tightening

the nuts with a tool until the disc springs have

Fig. 18 Tightening the body joint bolts

Table 1 Tightening torques

Thread Torque, Nm

5/16 UNC 25

3/8 UNC 45

1/2 UNC 100

5/8 UNC 200

3/4 UNC 350

7/8 UNC 500

1 UNC 700

1 1/4 8UN 1300

1 1/2 8UN 1600

1 3/4 8UN 1600

2 8UN 2500

2 1/4 8UN 3500

2 1/2 8UN 5000

2 3/4 8UN 6300

3 8UN 8400

NOTE: Tightening torques are for guideline only.

Consult with valve manufacturer.

Fig. 19. Mounting the retainer ring

Ce manuel convient aux modèles suivants

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