Kerotest MODEL-1 Manual de usuario

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

1 OF 30

KEROTEST CUSTOMER MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Table of Contents

1SCOPE .........................................................................................................................................................................................3

2PRODUCT DESCRIPTION AND FEATURES .....................................................................................................................................3

3CAUTIONS AND WARNINGS ........................................................................................................................................................4

4VALVE IDENTIFICATION...............................................................................................................................................................4

5VALVE COMPONENTS .................................................................................................................................................................4

6ACCESSORIES ..............................................................................................................................................................................6

6.1 HANDWHEEL ......................................................................................................................................................................................6

6.2 LOCKING DEVICE .................................................................................................................................................................................6

6.3 COATING ...........................................................................................................................................................................................7

7FACTORY TESTING.......................................................................................................................................................................8

8STORAGE, HANDLING, AND INSTALLATION.................................................................................................................................9

8.1 STORAGE ...........................................................................................................................................................................................9

8.2 HANDLING .........................................................................................................................................................................................9

8.3 INSTALLATION.....................................................................................................................................................................................9

8.3.1 General Notes on Installation ............................................................................................................................................... 9

8.3.2 Screwed End Valves...............................................................................................................................................................9

8.3.3 Socket Weld End Valves ...................................................................................................................................................... 10

8.3.4 Flanged End Valves ............................................................................................................................................................. 10

8.3.5 Butt Weld End Valves..........................................................................................................................................................11

8.3.6 Butt Weld End X Flange End Valves ....................................................................................................................................11

9OPERATION...............................................................................................................................................................................12

9.1 GENERAL VALVE OPERATION ...............................................................................................................................................................12

9.2 OPERATING TORQUE..........................................................................................................................................................................12

9.3 CRITICAL TORQUE..............................................................................................................................................................................12

9.4 PRESSURE DROP................................................................................................................................................................................13

10 REPAIR SERVICE ........................................................................................................................................................................13

10.1 SHUT-OFF OR SEAT LEAK ....................................................................................................................................................................13

10.1.1 Clearing Internal Debris..................................................................................................................................................13

10.1.2 Body and Wedge Seating ...............................................................................................................................................13

10.2 EXTERNAL STEM PACKING LEAK............................................................................................................................................................14

10.2.1 Packing Shim Installation Under Pressure......................................................................................................................14

10.2.2 Repacking a Valve with Zero Pressure............................................................................................................................15

10.3 EXTERNAL BONNET SEAL LEAK .............................................................................................................................................................18

10.3.1 Sealing a Bonnet Leak with Zero Pressure......................................................................................................................18

10.3.2 Sealing a Bonnet Leak Under Pressure ...........................................................................................................................18

10.4 BROKEN STEMS.................................................................................................................................................................................22

10.4.1 Valve Operation with Broken Stem ................................................................................................................................22

10.4.2 Stem Repair .................................................................................................................................................................... 22

10.5 SERVICE PARTS ORDERING PROCEDURE .................................................................................................................................................23

APPENDIX A: BROKEN BOLT REMOVAL ..............................................................................................................................................24

INFORMATION AND BACKGROUND .................................................................................................................................................................24

MODEL-1 BOLT REMOVAL PROCEDURE ..........................................................................................................................................................24

APPENDIX B: BONNET SCREW TIGHTENING PROCEDURE ...................................................................................................................26

INCREMENTAL TIGHTENING PROCEDURE:.........................................................................................................................................................26

CROSS-PATTERN TIGHTENING SEQUENCES:......................................................................................................................................................26

APPENDIX C: MODEL-1 –NPS 1 AND 1 ¼ BOLT REPLACEMENT FIXTURE FOR FIELD SERVICE REPAIR ..................................................28

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

2 OF 30

Table of Tables

Table 1: Valve Specifications ................................................................................................................................................................5

Table 2: Handwheel Options ................................................................................................................................................................6

Table 3: Minimum Test Parameters .....................................................................................................................................................8

Table 4: Valve Torque Values .............................................................................................................................................................12

Table 5: Pressure Drop and Cv............................................................................................................................................................13

Table 6: Gland Cap Screw Torque Values............................................................................................................................................16

Table 7: Packing Repair Part Numbers................................................................................................................................................16

Table 8: Packing Repair All-Thread Studs ...........................................................................................................................................17

Table 9: Bolt Replacement Support Clamps........................................................................................................................................19

Table 10: Bonnet Cap Screw Torque Values .......................................................................................................................................19

Table 11: Bonnet Gaskets...................................................................................................................................................................21

Table 12: Bonnet Cap Screws .............................................................................................................................................................21

Table 13: Broken Stem Repair Kit Part Numbers ................................................................................................................................23

Table 14: Bonnet Bolt Removal Chart.................................................................................................................................................25

Table 15: 72631146 Repair Kit Components.......................................................................................................................................25

Table 16: Cross-Pattern Tightening Sequences...................................................................................................................................26

Table of Figures

Figure 1: Model 1 Pressure-Temperature Chart....................................................................................................................................3

Figure 2: Valve Components.................................................................................................................................................................5

Figure 3: Design Changes......................................................................................................................................................................5

Figure 4: Locking Device .......................................................................................................................................................................7

Figure 5: Bolt Torquing Pattern Examples ..........................................................................................................................................11

Figure 6: Valve Packing Components..................................................................................................................................................17

Figure 7: Support Clamp Installations.................................................................................................................................................19

Figure 8: Teflon Rope Installation Diagram ........................................................................................................................................20

Figure 9: All-Thread Installation Diagram ...........................................................................................................................................20

Figure 10: Broken Stem Repair...........................................................................................................................................................23

Figure 11: Bonnet Broken Bolt Diagram .............................................................................................................................................24

Figure 12: Example Pattern for 12-Bolt Tightening Sequence.............................................................................................................27

Figure 13: Bolt Replacement Instructions (1 of 2)...............................................................................................................................28

Figure 14: Bolt Replacement Instructions (2 of 2)...............................................................................................................................29

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

3 OF 30

1 SCOPE

This operations manual defines for gas utility customers the procedures for proper use and

common repairs on the Model 1 line of metal seat gate valves.

2 PRODUCT DESCRIPTION AND FEATURES

Below are some of the features of the Kerotest Model-1 steel gate valves:

Maintenance free

No gland tightening

No lubrication required

Low operating torque

Field repairable

Dual integral angled seats and wedge

Bidirectional installation and operation

The intent of this manual is to acquaint our customers with installation, operation, and

maintenance/service repair techniques for Model-1 Gate Valves. Model-1 Gate Valves are cast

steel valves used in natural/fuel gas distribution pipelines and are available in NPS 1 through NPS

16, in ASME/ANSI Pressure Classes 150 and 300 and intermediate pressure rating of 500 WOG

Maximum Operating Pressure (MOP, psi). The valve end connections are welded, flanged, weld-

by-flange, and some threaded and socket ended. Temperature limits of the valves are -20°F to

250°F with allowable pressures as shown in Figure 1.

Figure 1: Model 1 Pressure-Temperature Chart

Class 300

500 WOG

Class 150

100

200

300

400

500

600

700

800

-20

100

120

140

160

180

200

220

240

Maximum Operating Pressure (psig)

Operating Temperature (°F)

Model 1 - Pressure Temperature Chart

Class 300

500 WOG

Class 150

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

4 OF 30

3 CAUTIONS AND WARNINGS

Within this document, you will see the following symbols;

General Advisory Marking - for information or operational procedures, order of

operation, etc.

Caution Marking –note designates an action or step that may result in personal injury

or death or equipment/property damage. Personnel performing activities should be

fully aware of the hazards and take necessary steps to prevent any injuries, damage,

or unsafe operating/repair conditions.

4 VALVE IDENTIFICATION

Each valve will have an identification nameplate attached with the following information:

Manufacturing company

ASME/ANSI pressure class, or intermediate pressure rating (such as 500 WOG)

Temperature and pressure ratings

Body and stem materials

Serial number

Date of manufacture

Name of the product line

5 VALVE COMPONENTS

Model-1 Valves are divided into 2 basic designs: (1) Prior to 1988 production date and (2) after

1988 production date. Valves produced after 1988 contain a weather seal O-ring. Figure 3 shows

the part differences between the two versions.

Serialization marking on tags began September 2014. As of February 2018, the serial number is also

stamped directly on the body of the valve

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

5 OF 30

Figure 2: Valve Components

Figure 3: Design Changes

Table 1: Valve Specifications

Valve

Size

NPS

C/L to

Top

(in)

Number of

Turns to

Open/Close

7.25

5.5

1-1/4

7.25

5.5

8.75

7.3

10.43

10.3

12.68

13.3

16.43

19.8

20.25

26.3

27.00

21.8

30.75

25.8

41.37

69.0

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

6 OF 30

6 ACCESSORIES

6.1 Handwheel

If required, the 2” operating square may be removed and replaced with a handwheel.

Table 2: Handwheel Options

Valve

Size NPS

Handwheel Diameters (inches)

1-1/4

72530140

72530165

72530173

72530181

72530199

72537699

6.2 Locking Device

Model-1 valves can be ordered with a locking device installed or it may be installed by

customers. This locking device prevents unauthorized users from changing the valve

state (open or close) with a customer supplied lock. When installed, the lock and/or the

cap may turn, but no torque is applied to the stem. To install this device, perform the

following (see Figure 4);

1. Remove nut which holds operating square in place and replace with swivel assembly

(1). Keep the lock washer (2) on the assembly.

2. Place cap (3) on swivel assembly (1).

3. Attach a padlock (not furnished) to swivel assembly to complete locking device

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

7 OF 30

Figure 4: Locking Device

6.3 Coating

The Model-1 valve is ordered with either a zinc chromate gray primer coating or a two-

component, high solids green epoxy coating. The gray primer will provide a limited indoor

non-exposed protection against corrosion. It is the responsibility of the customer to

provide long duration corrosion protection coverings or systems once installed per CFR

192 Subpart I.

The two component, high solids epoxy coating is generally applied 4 to 8 mils dry film

thickness (DFT) unless specified by the customer.

If a valve appears corroded prior to installation, particularly on the internal components,

contact Kerotest to determine if the valve can be installed.

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

8 OF 30

7 FACTORY TESTING

To be certain that all valves shipped from the factory are bubble tight, they are subjected to the

following tests.

Table 3: Minimum Test Parameters

Table 3a: Hydrostatic Shell Test

Valve Size

NPS

Class 150 (285 MOP)

500 WOG

Class 300 (740 MOP)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

1 –4

450

875

1125

6 –8

450

875

1125

450

1125

12 –16

450

1125

Table 3b: Hydrostatic Seat Test

Valve Size

NPS

Class 150 (285 MOP)

500 WOG

Class 300 (740 MOP)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

2 –4

315

550

815

6 –10

315

5**

550

815

12 –16

315

815

* Time Listed Per Each Side

** 10” Not Applicable

Table 3c: Air Shell Test

Valve Size

NPS

Class 150 (285 MOP)

500 WOG

Class 300 (740 MOP)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

1 –4

150

6 –10

150

12 –16

150

Table 3d: Air Seat Test

Valve Size

NPS

Class 150 (285 MOP)

500 WOG

Class 300 (740 MOP)

Time

(seconds)

Pressure

(psig)

Time

(seconds)

Pressure

(psig)

Time

(seconds)

Pressure

(psig)

1 –8

80 –100

10 –16

80 –100

* Time Listed Per Each Side

The above tests equal or exceed those valve tests required by API 6D.

Note: valves built before changes to US CFR in July 2006 were rated as follows:

Class 150 –275 MOP

Class 300 –720 MOP

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

9 OF 30

8 STORAGE, HANDLING, AND INSTALLATION

8.1 Storage

Store the valve carefully before installation, preferably in a well-ventilated, dry place, on a

shelf or a wooden grid/pallet, preferably in the original packaging, to protect it from

ground water and moisture. Leave flange and port protectors in place to provide limited

internal corrosion and contamination protection.

Protect the valve from sand, dust, and water when storing or transporting.

When properly stored, the Model-1 has a shelf life greater than 10 years.

8.2 Handling

CAUTION: For heavy large valves, use rated lifting slings or straps. The valve or valve

assembly must not be lifted by the operating square or handwheel. Most Model-1 valves

with the operating square facing up are top-heavy and can shift or rotate in the sling.

Dropping or incorrect lifting of the valve can result in personal injury or damage to nearby

equipment or property.

If pressure testing is performed prior to pipeline installation, exercise extreme caution

with methods, tools, and procedures for capping and securing the valve.

8.3 Installation

8.3.1 General Notes on Installation

CAUTION: Incorrect installation may result in serious personal injury or damage to

nearby equipment or property. These instructions must therefore be followed

carefully when installing the valve.

NOTE: The valve must only be installed in intended applications. Valves should be

installed with the wedge in the closed position

Prior to installation, remove port and flange protectors and check that the inside of

the valve is clean and free of corrosion.

For valves located at the end of a pipeline, it is recommended to install a short

pipe pup with pressure rated cap to the valve outlet to reduce potential corrosion

issues. Following installation, the pup and cap section should be pressurized to

match the main pipeline.

8.3.2 Screwed End Valves

Screwed End Valves are only available on 2” valves, 500 WOG or Class 300.

Valve ends have NPT pipe threads machined per ASME B1.20.1

Apply a suitable threading compound to the threads on the pipe. The threading

compound should be applied sparingly.

By hand, thread the fitting onto the mating component until hand-tight, being

careful not to cross thread.

KEROTEST CUSTOMER

MODEL-1 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1464

REV.:

DATE:

06/26/2018

PAGE:

10 OF 30

The wrench used for installing these valves should be applied to the end of the

valve next to the pipe to which it is being connected

Tighten fitting about 4-5 turns past hand-tight.

8.3.3 Socket Weld End Valves

NOTE: in order that the valve seats are not affected during the welding operation,

the wedge should be in the closed position

Socket Weld End Valves are only available on 1” valves, Class 300

Valve ends are machined per ASME B16.11

Valves should be installed using either the electric arc or oxy-acetylene welding

methods by welders and welding procedures qualified under Section IX of the

ASME Boiler and Pressure Vessel Code or an equivalent requirement

Valve bodies are carbon steel (ASTM A216, GR WCB). Type 7018 Welding

Rod is suggested for welding these valves in the pipeline.

8.3.4 Flanged End Valves

End flanged dimensions conform to ASME B16.5

The length of the valve must be the same as the distance between the flanges

in the pipe line, taking into consideration the gasket.

Standard end flange facing is 1/16" raised face with phonographic finish. Some

valves may be ordered with a flat face finish. Contact Kerotest or your

distributor for further information and availability of flat face finished valves. Flat

face finished valves are slightly shorter than standard faced valves, as allowed

per ASME B16.10.

Bolting and gasketing practice conforming to ASME B16.5 is suggested. The

bolts and gaskets used on installation must be selected to match operating

conditions, temperature, pressure and medium. Gasket dimensions must be

compatible with sealing faces of the flanges.

End flange bolts should not be fastened in consecutive order. Each one

tightened should be 180° opposite the previous one (see Figure 5). Two

passes should be made. Once pass for half tightness and final pass for full

tightness. ASME PCC-1 can provide guidelines for assembly of bolted flanges.

NPS sizes 10, 12, and 16 Class 150 valves conform to Class 300 flange thickness and flange outside

diameter requiring longer bolts.

Otros manuales para MODEL-1

Tabla de contenidos

Otros manuales de Unidad de control de Kerotest

Kerotest

Kerotest WELDBALL Manual de usuario

Kerotest

Kerotest MODEL-1 Manual de usuario

Kerotest

Kerotest EV-11 Manual de usuario

Manuales populares de Unidad de control de otras marcas

Festo

Festo Compact Performance CP-FB6-E Manual de lista de piezas

Elo TouchSystems

Elo TouchSystems DMS-SA19P-EXTME Manual de usuario

JS Automation

JS Automation MPC3034A Manual de usuario

JAUDT

JAUDT SW GII 6406 Series Guía rápida

Spektrum

Spektrum Air Module System Manual de usuario

BOC Edwards

BOC Edwards Q Series Manual de usuario

KHADAS

KHADAS BT Magic Manual de usuario

Etherma

Etherma eNEXHO-IL Manual de usuario

PMFoundations

PMFoundations Attenuverter Manual de usuario

GEA

GEA VARIVENT Manual de usuario

Walther Systemtechnik

Walther Systemtechnik VMS-05 Manual de usuario

Altronix

Altronix LINQ8PD Instrucciones de montaje

Eaton

Eaton Powerware Series Manual de usuario

WAGO

WAGO 750-407/040-000 Manual de usuario

Sony

Sony CCU-590 Manual de usuario

Graco

Graco 25D614 Manual de usuario

Task Force Tips

Task Force Tips YE-RF-900 Manual de programación

Shini

Shini SPV-U Series Manual de usuario