APV API594 Manual de usuario

www.australianpipelinevalve.com.au

INSTALLATION, OPERATION & MAINTENANCE MANUAL

CHECK VALVES

SWING, TILTING DISC &

PISTON

API594/API6D/

BS1868/B16.34

API 6FD & ISO 10497

Firesafe Certied

(API 6D Version)

View our catalogues at www.australianpipelinevalve.com.au

AUSTRALIAN PIPELINE VALVE BRAND RANGE -CATALOGUES

APV FAMILY OF BRANDS RANGE - CATALOGUES

COMPLETE

PRODUCT LINE

“Australian Pipeline Valve

produces isolation,

control and ﬂow reversal

protection products for

severe and critical service

media in utility, steam,

pipelines, oil & gas

and process industries.

APV valves and pipeline

products form the most

competitive portfolio

in the market.”

Oilﬁeld Products

Valves & Wellheads

Gate, Globe & Check

Valves - Forged Steel

Plug Valves Lubricated,

Sleeved & Lined

Gate, Globe & Check

Valves - Cast Steel

Diamond Gear

Gearboxes

Flowturn Gate, Globe

& Check Valves

Flowturn

Instrument Valves

Flowturn Ball Valves

Multiway & Deadman

Flowturn Strainers

& Sight Glasses

Supercheck

Wafer Check Valves

Superseal

Butterﬂy Valves

Steamco

Steam Valves

Superseal

Industrial Ball Valves

TwinLok Tube Fittings Uniﬂo Check ValvesTorqturn Actuators

Ball Valves Floating

& Trunnion Mounted

Ball Valves

Floating Small Bore

Ball Valves

Special Service

Product Brochure

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual 1

Introduction 2

Safety Information 3

Valve Identification 4

1.0 Installation 5-7

1.1 Installation positions 5

1.2 Preparation for installation 6

1.3 End connections 6

1.4 Post-installation procedures 7

2.0 Operation 7

3.0 Maintenance 7

4.0 Repairs 7-11

4.1 Repair instructions 8

4.2 Disassembly & gasket replacement 8

4.3 Valve internals disassembly instruction and repair 8-9

4.4 Bolted bonnet swing/lift check valve reassembly 9-11

5.0 Troubleshooting 12

6.0 Warranty and Service 12-13

6.1 Valve warranty period 12

Appendix A - Body/bonnet bolting torques 14-17

Appendix B - Figure number system 18-19

Appendix C - Exploded B.O.M. 20-25

INDEX

Catalogues, photos, brochures and technical publications are the exclusive property of Australian Pipeline Valve.

Any unauthorised reproduction in total or in part, shall result in prosecution. Products and data sheets in this publication are subject

to change at anytime without notice. Australian Pipeline Valve reserves the right to carry out amendments to products and materials.

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual2

INTRODUCTION

The majority of this information is common knowledge to experienced valve users. When properly

installed in applications for which they were designed, Australian Pipeline Valve (APV) valves will give

long reliable service under normal conditions. This instruction manual is only a guide for installation and

operation on standard service and covers general maintenance and minor repairs. An APV approved valve

reconditioner should be used for reconditioning and major repairs.

Note

We recommend that this entire document be read prior to proceeding with any

installation or repair. Australian Pipeline Valve and it’s parent company take no

responsibility for damage or injury to people, property or equipment. It is the sole

responsibility of the user to ensure only specially trained valve repair experts

perform repairs under the supervision of a qualified supervisor.

RESPONSIBILITY FOR VALVE APPLICATION

The User is responsible for ordering the correct valves. The user is responsible for ensuring APV Valves are

selected and installed in conformance with the correct pressure rating and design temperature

requirements. Prior to installation, the valves and nameplates should be checked for proper identification

to ensure the valve is of the proper type, material and is of a suitable pressure class and temperature

rating to satisfy the applications requirements of the service application.

Do not use any valve in applications where either the pressure or temperature is

higher than the allowable working values. Also valves should not be used in service

media if not compatible with the valve material of construction, as this will cause

chemical attacks, leakage, valve failure.

RECEIVING INSPECTION AND HANDLING

Valves should be inspected upon receipt to ensure:

- Conformance with all purchase order requirements.

- Correct type, pressure class, size, body and trim materials and end connections.

- Any damage caused during shipping.

The User is advised that specifying an incorrect valve for the application may result

in injuries or property damage. Selecting the correct valve type, rating, material

and connections, in conformance with the particular performance requirements is

important for proper application and is the sole responsibility of the user.

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual 3

SAFETY INFORMATION

The following general safety information should be taken into account in addition to the specific warnings

and cautions specified in this manual. They are recommended precautions that must be understood and

applied during operation and maintenance of the equipment covered in this I.O.M.

To avoid injury, never attempt disassembly while there are pressures either

upstream or downstream. Even when replacing gaskets, caution is necessary to

avoid possible injury. Disassemble with caution in case all pressures are not relieved.

To prevent valve bending, damage, inefficient operation, or early maintenance

problems, support piping on each side of the valve. Warning, certain gases and

fluids could cause damage to human health, the environment or property hence the

necessary safety precautions to prevent risk should be taken.

This manual provides instructions for storing, general servicing, installation and removal of check valves.

APV and it’s resellers refuse any liability for damage to people, property or plant as well as loss of

production and loss of income under any circumstances but especially if caused by: Incorrect installation

or utilisation of the valve or if the valve installed is not fit for intended purpose. It is the sole

responsibility of the user to ensure the valve type and materials are correctly specified.

DURING OPERATION TAKE INTO ACCOUNT THE FOLLOWING WARNINGS:

a- Graphite body gaskets (where applicable) are very brittle, any compacting, twisting or bending should

be avoided.

b- The valve’s internal parts (disc/stem/hinge pin/seats/gaskets/seals, etc.) shall be handled with care

avoiding scratches or surface damage.

c- All tools and equipment for handling the internal parts shall be soft coated, or else take care.

d- Valves can be fitted with gaskets or seals in PTFE, Buna, Viton, etc., hence high temperatures and some

cleaning fluids may damage sealing components.

For all operations make reference to position number on part list of the applicable drawing.

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual4

VALVE IDENTIFICATION

Each APV valve is identified with a nameplate. Below is an example.

SIZE

CLASS

BODY

DISC

SEAT

ASME B16.34

150NB

150

WCB

CR13

150AP34XUN-GBW-FE

1096287-2

CR13+ST#6

ITEM DESCRIPTION

1APV valve gure number which delineates the as-built valve type, body, trim, features, packing,

NACE, etc. Refer Figure Number System Appendix C

2Shell material (e.g. body, bonnet)

3Closure member material

4Seat material

5Rated pressure class as per ASME B16.34. Section 2

6 Nominal pipe size

7Serial/batch number

When performing any work, ordering spare parts, or requesting technical support, please refer to this

tag. The serial number, the part number and numbers cast on the side of the valve body are keys to

proper valve identification.

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual 5

1.0 INSTALLATION

Piping should be properly aligned and supported to reduce mechanical loading on

the end connections.

1.1 INSTALLATION POSITIONS

Check valves are unidirectional and have the direction of flow indicated on the valve body. Australian

Pipeline Valve swing or tilting disc check valves may be installed in horizontal lines or vertical lines

where the direction of flow as indicated on the valve body is upwards.

Australian Pipeline Valve piston check valves are only for use in horizontal lines with bonnet facing up.

Check valves must be fitted in horizontal pipe runs with the cover facing vertically upward. Variance to

either side of the vertical axis must not exceed five (5) degrees. Swing-check valves and spring-loaded

check valve designs can be positioned in vertical pipe runs with upward flow.

Check valves must not be installed in a vertical down flow pipe run or in a

horizontal pipe run with the cover in the vertical down position. Always install

valves in the direction indicated by the flow arrow stamped on the body.

Note

Flow disturbances caused by the system components (e.g. pipe fittings, discharge of

pumps, etc.) can lead to valve chatter, which can cause rapid wear of seats and trim

and ultimately lea to valve malfunction. APV recommends that a sufficient distance

be maintained between the check valve and any component that can cause flow

disturbance as follows:

a) System components that create flow disturbance - examples are pumps, fittings and valves. When

installing a check valve near system components, APV recommends a minimum of 10 pipe diameters of

straight pipe between the upstream system components and the inlet of the check valve and a

minimum of 2 pipe diameters of straight pipe between the downstream system components and the

outlet of the check valve.

b) Pipe bends and transitions - examples are elbows, tees, branch connections and reducers. APV

recommends a minimum of 6 pipe diameters of straight pipe between the upstream system component

and the inlet of the check valve and a minimum of 3 pipe diameters of straight pipe between the

downstream component and the outlet of the check valve.

Spring loaded piston check valves are recommended for reciprocating compressor service in which a

history of noisy check valve operation has been experienced.

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual6

1.2 PREPARATION FOR INSTALLATION

• Remove protective end caps or plugs and inspect valve ends for damage to threads, socket weld bores

or flange faces.

• Thoroughly clean adjacent piping system to remove any foreign material that could cause damage to

seating surfaces during valve operation.

• Verify that the space available for installation is adequate to allow the valve to be installed.

1.3 END CONNECTIONS

1.3.1 Flanged Ends

Check to see that mating flanges are dimensionally compatible with the flanges on the valve body and

ensure sealing surfaces are free of debris.

Install the correct studs and nuts for the application and place the gasket between the flange facings.

Stud nuts should be tightened in an opposing criss-cross pattern in equal increments

to ensure even gasket compression. See Appendix A, Table A.

1.3.2 Buttweld Ends

Clean the weld ends as necessary and weld into the line using an approved weld procedure. Make sure

the pipe and valve body material given on the nameplate or valve body is compatible with the welding

procedure. (Refer compatibility cross reference chart at the APV website for equivalent pipe, valve &

fitting grades).

1.3.3 Valve Installation by Welding

Leave valves assembled during installation, welding and post-weld heat treatment. This will prevent the

valve seat from floating or distorting during the process. After welding completion, open the valve and

flush line to clean out any foreign matter.

Remove the bonnet and bonnet gasket and match mark each component during disassembly for proper

reassembly.

The responsibility for welding of the valves into piping systems is that of those performing the welding.

Refer to ASME B31.1, B31.3 etc. Written welding procedures covering all attributes of the process and

materials to be welded shall be in accordance with Section IX of the ASME Boiler and Pressure Vessel Code

and any additional requirements from the applicable piping code including any possible necessary

localised post weld heat treatment depending on material specifications.

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual 7

1.4 POST-INSTALLATION PROCEDURES

After installation, the line should be cleaned by flushing to remove any foreign material. When caustics

are to be used to flush the line, additional flushing with clean water is required. The valve should be

opened and closed after installation to ensure proper operating function.

With the line pressurised, check the valve end connections, body to bonnet/cover joints and external

plugs for leaks.

2.0 OPERATION

Refer to Appendix A, Table C, D, E, F to ensure the Cv is as required and there is enough cracking pressure

to open to disc.

The check valve operation is automatic and requires no assistance. When the flow exerts sufficient

pressure against the disc to overcome the disc’s weight, the disc allows the flow to continue through the

piping system. As pressure decreases, the disc lowers until it’s own weight forces it to seat. This prevents

the possibility of a reversal in the flow. Piston and ball check valves should not be used in applications

where rusting or rust particles are present or anticipated. Swing check valves are more tolerant for

applications of this nature.

Metal seated check valves (piston, lift, tilt and swing) are not zero leak devices and will “seep” in service.

This type of valve should always be backed up with an isolation valve (either gate or ball valve). Check

valves are designed to prevent reverse flow. Leakage rates for check valves with metal-to-metal seats

are dependant on the amount of back pressure and the viscosity of the flowing medium. Soft seat check

valves can offer improved leak tightness provided there is sufficient back pressure. However, soft seat

check valves should not be used in gas or low back pressure liquid applications if zero leakage is desired.

3.0 MAINTENANCE

No periodic maintenance is necessary unless special external accessories are fitted.

4.0 REPAIRS

Proper safety equipment and apparel should be worn when preparing to service a valve. Observe the

following general warnings:

CHECK VALVES - SWING, TILTING DISC & PISTON - API594/API6D/BS1868/B16.34

Australian Pipeline Valve - Installation, Operation and Maintenance Manual8

• A valve is a pressurised device containing energised fluids and should be handled

with care.

• Valve surface temperature may be dangerously too hot or too cold for skin

contact.

• Upon disassembling, attention should be paid to the possibility of releasing

dangerous and or ignitable fluids.

• Adequate ventilation should be available for service.

4.1 REPAIR INSTRUCTIONS

Due to the relatively low replacement cost of small diameter standard carbon steel valves especially

under 100 NB (4”), it is usually less expensive to replace the complete valve than to have maintenance

personnel effect repairs. Generally, the only viable repairs are replacement of bonnet gasket. However,

see Section 4.2 and 4.3 below for further extraordinary repairs.

Always replace the bonnet gasket whenever a valve is disassembled. Gasket seating surfaces should be

scraped clean (avoid radial marks). Bonnet bolts should be tightened in a diagonal pattern at several

different increasing torque settings in accordance with the recommended torque value (see table

Appendix A, Tables A & B).

4.2 DISASSEMBLY & GASKET REPLACEMENT

Before disassembling:

1. Check that the line is in a complete shut down phase, then remove the valve from pipeline.

2. Pre-order all necessary spare parts and joining gaskets.

3. Put identification markings on valve body, disc and bonnet. This helps to avoid mismatching of parts at

the time of re-assembly.

4. If the bolts and nuts are too tight, apply deep penetrating oil and then unscrew.

Disassembly:

1. Disassemble all cover bolts and nuts.

2. For check valves, lifting lugs are generally provided. Lift up the cover utilising lifting lugs. For smaller

and lower class valves the bonnet should be easy to remove without the aid of a mechanical lifting

device. In both cases gently break the seal with a lever, gradually lifting the bonnet flange at intervals

360° around the bonnet.

3. Clean gasket surface areas, replace gasket and refit bonnet as detailed in 4.1 above.

4. ‘Pressure seal’ valves use a proprietary graphite gasket.

4.3 VALVE INTERNALS DISASSEMBLY INSPECTION AND REPAIR

1. Check that the (where applicable) hinge, nut and pin are in good condition and firmly connected.

Replace damaged parts as necessary.

2. For swing and tilt check valves, remove the pin then lift and remove the disc hinge assembly. If

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