Operation and Maintenance Manual: Turbine Inlet Butterfly Valves

Operation and Maintenance Manual
Turbine Inlet Butterfly Valves
GOMM-V0-2016
PMCES d.o.o.
Masarykova 37, BA-72000 Zenica
info@pmces.com
www.pmces.com
Operating and maintenance manual

GOMM; V0-2016
CONTENT:
1. General information
1.1 Construction and general data
1.2 Application / performance data / testing

2. Main structural units
2.1 Housing
2.2 Valve disc
2.3 Shaft bearing
2.4 Sealing elements
2.4.1 Main sealing disc sealing
2.4.2 Shaft sealing
3. Actuator
4. Material quality
5. Dimensions
6. Maintenance, inspections
7. Failure and troubleshooting
8. Certificates and documentation
9. Replacement of seals
9.1 Replacement of seals non drive shaft
9.2 Replacement of seals drive shaft
9.3 Replacement of main sealing
10. General and specific safety information

11. Mounting instructions
12. Storage and transportation
13. General safety instructions
Operation and maintenance manual
Page 2 of 16
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GOMM; V0-2016
1. General information
1.1.
Construction and general data
The butterfly valve is double flanged, double eccentric and fully welded construction.
Main applications this type is used are: as turbine-inlet valve, and pipe-burst valve for shut-off
service in water systems with temperature up to 80C. It is possible to use this type of valve for
higher temperatures of medium, but in that case suitable main sealing material has to be installed
(sandwich type (laminated) metal seal or VITON or PTFE), as well as to use for different mediums (air,
steam etc..).
The housing and valve disc as standard are made of carbon steel (S235 or S355), but other
grades are possible, as well as stainless steel. A special formed rubber profile gasket on the valve disc
ensures the leak-proof closing. The seal set in the disk is made of EPDM rubber profile seal
(optionally NBR, FPM, VITON, PU, or metal seal for high temperature). The shafts are non-corrodible,
two piece design, with special materials available on request.
The valve opens by applying hydraulic pressure to cylinder and closes by mass of a
counterweight. Between its open and closed positions the valve disc swivels by 90. The valve
operation is as a shut-off (open-close) valve. Regulating and throttling functions are not allowed and
can cause damage to sealing ring as well as seat ring on body. Open and closed positions are pre-set
in the factory.
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1.2.

GOMM; V0-2016
Application / performance data / testing
Medium:
water (other mediums on request)
Max. temperature:
80 C (higher temperature on request)
Working pressure:
according to technical documentation
Nominal pressure:
according to technical documentation
Pressure test:
EN12266-2
Test medium:
water
Leakage rate:
1 acc. to EN12266-2 (for soft seated valves only)
Test pressure
body strength test 1.5xPN

tightness test 1.1xPN
Permissible hydraulic oil pressure:
160 bar
Minimum hydraulic oil pressure:
80 bar
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GOMM; V0-2016
2. Main structural units:

2.1.
Housing
Carbon steel plate, bended (optionally stainless steel or other material), with the flange
dimensions according to EN 1092-1(2) form B (nominal pressure according to technical documents),
face to face according to EN 558-1 Series 14 (on request special face to face).
2.2.
Valve disc
Disc is made of carbon steel (optionally stainless steel or other material) and it is eccentric. Main
sealing gasket (rubber profile) is fixed on the valve disc by means of a clamping ring (normally
stainless steel), which is assembled on the disc with socket head bolts. These bolts admit a limited
correction of the opening- closing friction and tightness.
2.3.
Shaft bearing
Shafts are located with clearance fit in the disc and are secured by pins (keys when requested).
The bearing bushings are made of bronze with PTFE (or graphite) running surface; they are selflubricated and maintenance free. The bearings are located in the collar of the valve housing (see the
appendix). Optionally grease points can be added if requested.
2.4.
Sealing elements
2.4.1. Main sealing disc sealing

The valve disc carries an elastic profile ring which in its closed position is pressed to the seatring inside the housing, ensuring complete tightness of valve. It is fixed to the disc with a retaining
ring.
2.4.2. Shaft sealing

Shaft sealing elements ensures that there is no leakage through space between shafts and
bearing bushes. Sealing is achieved with combination of O-rings and nut-rings, providing several
layers of leak protection.
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GOMM; V0-2016
3. Actuator
The hydraulic cylinder serves as operating element. When the pressure rises in the cylinder, the
piston rod lifts the lever and this opens the valve. At the piston rod side, the returning inlet pipe is
closed with a filter screw, avoiding the entrance of impurities. The closure is helped by the medium
(eccentricity) and it is ensured by the counterweight. The hydraulic connection is available and
optionally throttle or flow regulating valve is provided - protecting the valve from slamming, in case
of hydraulic pipe damage.
Attention!
The hydraulic cylinders stroke is mechanically limited. The adjustment is
made at factory on cylinder and it is strictly forbidden to modify without
consultation and permission of the supplier!
The maximum allowed hydraulic oil pressure for the system is 120 bars!
Closing time adjustment not present for this project.
Two-step closing not present for this project.
Opening and closing time depends on the hydraulic power unit and hydraulic system. Operation
time can be influenced by using different diameter of hydraulic pipeline / hydraulic tube also the
length of pipeline and distance from power unit, capacity of the power unit.
Operating characteristics (as standard and optimal operation of turbine inlet valve, switches and
sensors connected properly to aggregates control unit).:
- The butterfly valve can be opened by means of oil pressure in the hydraulic.
- In the case of power failure, the butterfly valve will close automatically.
- The butterfly valve is provided with two position switches (on request additional switches
possible to install, e.g. intermediate position), which indicate (from bottom to top)
- closed position
- open position
4. Material quality
Used materials are according to customers requests. Please see details in parts list and material
certificates.
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GOMM; V0-2016
5. Dimensions
See the data sheets and drawings.
6. Maintenance, inspections
The butterfly valve is basically maintenance free as it is not provided with lubrication points,
unless specifically requested. The valve and hydraulic cylinder must be moved in a full operating
cycle (up down) every two month of a year. The annual complete inspection has to be performed
with an examination and routine trial operation. No leakage or corrosion is acceptable at the valve
parts or hydraulic drive.
7. Failure and troubleshooting

In case every connection has been installed as specified, the secure operation of the valve is
guaranteed. Failures may occur as a result of unforeseeable events (force major). Mechanical
problems: due to the high degree of safety taken in consideration at the design, mechanical
problems will occur only as a result of extreme operating errors or other unforeseeable events. If
such problems should occur, please contact and consult our company.
8. Certificates and documentation

The valve has been manufactured in and shipped from our factory according to the order and
our contract with the customer. The documentation in its content and extent are provided also
according to the order and our contract with the customer.
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GOMM; V0-2016
9. Replacement of seals
The seals do not need maintenance; in case of leakage they must be replaced.
9.1.
Replacement of seals non drive shaft
Depressurise the pipeline !!!

-
Remove the cover (red);

Exchange O-ring;
Put back the cover.
Number of bolts may be

different on actual valve!
Nut-ring is placed at inner part of the valve where shaft enters shaft tube, and does not require
dismantling of any parts and may be replaced without special tools.
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9.2.

GOMM; V0-2016
Replacement of seals drive shaft
Depressurise the pipeline !!!

-
Carefully support valve disc;

Remove the counterweight;
Remove the arrow (from shaft);
Remove the outer main plate, then hydraulic cylinder with lever, and finally inner main
plate;
Remove screws and set screws from sealing bush and take it out;
Replace sealing
Repeat everything in reverse order to assemble actuating mechanism.
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9.3.
-

GOMM; V0-2016
Replacement of main sealing

Depressurise the pipeline;
Discharge the pipeline and set the valve disc in its open position;
Mechanically secure the closing weight in its open position.;
ATTENTION!
THE WEIGHT HAS TO BE SUPPORTED WITH 100% SECURITY WHEN ANY
MAINTENANCE WORK IS CARRIED OUT INSIDE THE VALVE OR AT THE VALVE
DISC. ACCIDENTAL CLOSURE OF THE VALVE DISC IS EXTREMELY DANGEROUS!!!
Release the screws and the retaining ring;

Exchange the sealing;
Put Loctite 572 screw-thread protector successively on the screws;
Place the main sealing ring and tighten it by hand screws;
Close the valve disc.;
Tighten the sealing by tightening the transversal screw until proper resistance can be felt,
then tighten in the opposite direction with the grub screws.
Check if the sealing lays correctly on the inside of the seat ring.
WE STRONGLY RECOMMEND HAVING ALL REPAIRMENTS PERFORMED AT OUR

FACTORY OR BY OUR SKILLED PERSONNEL.
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GOMM; V0-2016
10. General and specific safety information

Operation of the valve is not dangerous under normal circumstances.
Nevertheless, it is necessary at all times to act with appropriate care and caution.
In and outside of the valve there are moving parts (lever, supporter,
counterweight, hydraulic, disc, shafts etc.)
-
Never loosen screws in pipelines under pressure.

Have repairs and/or maintenance performed only by skilled personnel.
Do not use force to loosen any screwed joint.
Never loosen hydraulic screws under pressure.
In case of reparation remove or support the counterweight.
Reparations on the disc are allowed only with counterweight removed.
It is absolutely important to inform all personnel of these operation and maintenance
instructions.
Please take special attention when standing close to valve! Every person in proximity of valve
has to be careful and should be aware that moving parts may suddenly start to move without any
warning!!!
Please take care of burning accidents. The valve and the components can be depending on
the operating condition and the purpose heating.
In case of every reparation it must be make ensured that the valve and the hydraulic are also
depressurised.
11. Mounting instructions

The butterfly valve will be delivered in almost ready for use condition. The installation process
is simple, please keep the following instructions in prior before assembly:
-
Unpack valve and equipment then check condition of all parts. Do not install valve if you recognized
any damaged or missing parts!
Make sure that pipeline is clear and free from impurities and metal chips. Those can damage valve
sealing and other parts.
Before installation check if there is enough space for valve, operation device and to have free
access all around the valve.
Keep in priority the correct flow direction.
Clean the valve sealing surfaces.
Use correct sealing material for flanges according to applicable medium and temperature.
Tighten connecting bolts evenly and crosswise.
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GOMM; V0-2016
12. Storage and transportation

During storage period the valve has to be protected against impurities, direct sunlight, rain,
frost and other weather elements.
On site the valve must be stored so as to be protected against mechanical damage and/or
corrosion. The preferable storage condition is in dry closed room with ambient temperature and low
humidity. Flanges or weld ends can be sealed using plugs, lids, plastic caps or oil paper.
Internal surfaces can be treated with preservatives or moisture absorbers.
The protective packaging we provide must be left intact during storage and removed prior to
installation or operation respectively.
If valve is stored for longer than twelve months, it is necessary to replace sealing elements and
gaskets in the valve.
If valve is going to be kept in stock for a time leave the valve disc in a slightly open position and
apply lubricant all around of main seal ring (e.g. silicon oil).
If valve is going to be stored sitting on its flange connection, make sure that valve is stored on a
wooden pallet to protect flange surface against mechanical damages.
Never lift valve using actuator mechanism as an anchor. This may cause serious
damage to actuation mechanism and the valve, and it is extremely dangerous for persons
around the valve.
Dont lift the valve using the lever or the other operation device. To lift the valve, hook up it by
the lifting eye and at least additional 3 sports on valve housing or flange holes. In all cases never drag
the valve along the floor. During handling and moving avoid any damages of the valve and take care
of personal safety.
When loading or unloading ensure that the valves are not thrown or subjected to sudden
knocks. Large valves should be handled with hemp or synthetic ropes slung to the yoke arms or the
bonnet flange. Valves with actuators should be slung using a three-point suspension at the main
connection nozzle and the yoke arms or yoke head (note centre of gravity). Special eyebolts must be
used when supplied with heavy valves.
In and outside of valve there are moving parts (lever, supporter, counterweight,
actuator, hydraulic, disc, shafts etc.). Because of it, every person in valve proximity
has to be careful and should be aware that those parts may suddenly start to
move without any warning. Be careful of burn injuries; the valve may be hot
due to medium inside. Some parts may have significantly higher temperature
than others (i.e. body). Before starting ANY maintenance or reparation
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GOMM; V0-2016
operation, parts such as hydraulic and pipeline itself MUST NOT be pressurized and all
actuation must be disabled, so emergency closing or/and opening functions cannot
be started.
Valve should not be installed in area which is permanently accessible by
personnel OR area without clearly displayed warnings for dangerous moving
objects!!!
Any repairing has to be performed by skilled personnel.
Never loosen bolts and screws in pressurized pipeline, the same applies for any existing hydraulic or
actuation devices.
In case of disc repairing, it has to be supported and fixed to avoid any possible movements.
Before any maintenance read this operation and maintenance manual.
Page 13 of 16
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GOMM; V0-2016
13. General Safety Instructions

The valve is to be used exclusively for the application according to our order confirmation. Any
other application is considered as not conforming and the user is fully responsible for any damage
that may result from this.
Every other use than intended is not considered, and the supplier is not responsible for
damaging occurring due to false use.
Design, manufacture and testing of these valves were carried out on condition that the valves
are operated under normal operating conditions. Normal operating conditions contain for example
the following:
operation with liquid or gaseous media, without special corrosive, chemical or abrasive
influences;
frequency of temperature-change of app. 3C 6C per minute;
usual flow rates, depending on the kind of medium and the range of application of the valve;
operation without additional outer influences like pipeline-forces, vibrations, wind load
stressing, earthquake, corrosive environment, fire, operation load stressing, disintegration
pressure of unstable fluid, etc.
If the purchaser expects stresses deviating from the normal operating conditions, he has to
indicate these requirements unambiguously and completely in the inquiry as well as in the order.
This would allow us, as the valve manufacturer, to work out corresponding measures and to suggest
them to the customer. These measures could be for example:
special selection of the body material;
higher wall-thickness;
protection of areas which are endangered by wear;
special gaskets and bolt connections;
special operation instructions depending on the medium and the kind of operation;
special coatings;
additional equipment to avoid excessive overpressure;
special design for control operation, etc.
During planning and installation of the pipeline the customer should take measures which
minimize additional dangers and pressures on the valves, on the piping system and on the
environment, for example by:
installation of vibration dampers;
consideration of a security final position in case of breakdown of energy
taking measures to ensure the safe drainage of dangerous media in case of leakage, etc.
We consider the uses of the outside mounted moving parts are in a safe area. Otherwise
protective device must be installed.
Unauthorized modifications or the use of spare parts other than original spare parts exclude our
liability for damages that may result from this. In this case, the user is bearing the full responsibility.
Maintenance and repair of the valve must be carried out only by qualified personnel, and it is
important to follow the corresponding rules and regulations for pressure vessels and steam boilers.
Page 14 of 16
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The actuators produce high positioning forces. Mounting and starting up must be carried out
under careful consideration of the safety instructions.
Before starting any maintenance works, it is important to ensure and well note the following:
drainage of the pipeline;

get complete information on the possible dangers, which can occur through
remainders of the flow medium and take suitable measures (safety gloves, safety
glasses, etc.);
let the valve cool down, if required;
make sure that no third person can put the plant into operation;
remove any pressure, which might build up in a shut-off pipeline.
Qualified Personnel
Warning
In the sense of the operating instructions are persons who are familiar with the mounting,
starting up, and operation of this product and who have the corresponding qualification for such
works, e.g.
Education or training according to the actual safety standards for maintenance and use of
adequate safety equipment.
First aid training
For plants with explosion hazards: Special training or instructions, or the authorization
respectively to carry out works in plants with explosive hazards.
Additional Instructions for Installation

Installation
As a general rule the direction of flow is marked by arrows in assembly drawing. In case of
doubt contact supplier.
Always allow for adequate access clearance in the planning and installation phase for easy
assembly and disassembly of internal valve parts.
Valves should never be taken as fixed reference points within pipe systems, and substantial pipe
loadings on valves should therefore be avoided. Exceptions to this rule are subject to our specific
approval for each individual case. It has to be on a case-by-case basis because the forces resulting,
for example, from shear, bending and torsional stresses as well as temperature gradients vary
according to duty and installation, and occur in a variety of combinations. We are therefore not able
to make any generalizations.
Before fitting the valve in position, remove the flange- or butt weld end protectors and moisture
absorbers, if provided. The valve must be free from foreign matter of any nature.
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GOMM; V0-2016
Cleanliness is the cardinal rule when fitting valves. If the pipe ends require machining, chips and
other foreign matter must be carefully removed. The pipe ends must be properly aligned so as to
prevent the valve being subjected to unnecessary strain.
Bricklaying or painting should not be carried out in the vicinity of installed valves until stuffing
boxes, spindles and valve position indicators (if fitted) have been properly protected against soiling.
Valves are despatched from our works with clean internal parts. This is a quality feature that can
only be maintained if care is taken during installation and subsequent operation to prevent the
ingress of foreign matter into the valve and hence damage to seats and other areas.
Flanged Valves
The sealing faces of flanged valves must be clean and in good condition. Before bolting-down,
flanges must be correctly aligned. When bolting-down, all flange boreholes must be used at all times.
For initial fitting, threads can be smeared with graphite or molybdenumdisulphide to stop seizure do not use oils or greases. Never use damaged parts such as bolts, nuts or washers. Make sure that
materials are suitable and correct for the job.
Tighten bolts evenly and in cross-sequence using the correct tools to the correct torques. In
case of any doubt please ask the supplier.
Valves with Butt Weld Ends

The piping contractor is responsible for welding the valves into the pipeline and any necessary
heat treatment. To prevent effects of thermal stress, we suggest that valves are opened before being
welded in.
Never attach the welding cable (opposite pole) to the bonnet, spindle or any other places on the
valve assembly!
This could cause spots of arcing on the spindle or seat faces. The weld cable should be attached
to a bright area on the valve body or, even better, to the pipe itself. For valves with socket weld ends,
the socket depth of the pipe ends should be selected in accordance with codes of practice, and
unacceptable weld seam stresses prevented by leaving a gap between pipe end and socket seat.
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Operation and Maintenance Manual: Turbine Inlet Butterfly Valves

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Operation and Maintenance Manual

Turbine Inlet Butterfly Valves

Operating and maintenance manual

1.2 Application / performance data / testing

10. General and specific safety information