Assured Automation ESOV Handbuch

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

263 Cox Street

Roselle, New Jersey 07203 ESOV(EMERGENCY SHUTOFF VALVES)

1800 899-0553 sales@aa-fs.com www.assuredautomation.com

Doc No.IOM 2010 Rev

FOREWORD

The following instructions are offered as a reference to aid the valve user when installing,

maintaining or operating ESOV (Emergency Shutoff Valves). This document, consisting

of basic information, should be of interest to the layman as well as the experienced

valve user; however, it does not replace the need for an understanding of the

particular application, and is not intended to be a complete instruction for the

inexperienced valve user.

1. RECEIVING & HANDLING

A. Upon receipt of valves, they should be inspected for shipping damage. The areas

to inspect are the pressure retaining shell, valve ends, and valve operating

mechanisms such as handwheel, actuator, stem, etc.

B. If valves show no sign of shipping damage, they should be stored in a sheltered

area to protect them from weather, dirt and damage. Materials attached to protect

valves during shipment should not be removed until time of installation in the line.

C. Each valve should behandled only with apparatus that will safely support the valve

assembly weight. Slings should never be placed around the handwheel, stem or

gland adjustment parts. Protect valve ends by leaving end protectors in place until

their removal is necessary. Valves are shipped in the open or closed position,

depending on the valve type, to protect seating surfaces and should be left in these

positions, if possible, until completion of installation. Check valves will be shipped

with material blocking the disc from swinging during transit.

2. VALVE TRANSPORTATION / STORAGE

A. Check the packaging of valve before transportation according to standard. If the

packaging is damaged, repair it so that the valve can be safely stored and

transported.

B. The paint, the nameplate and the sealing face of flange shall be protected during

transportation. No part of the valve can be dragged on the ground, and the valve

must be adequately protected from abrasion and impact during transport.

C. The valve shall be stored at a safe location to protect against rain and dust if it will

not be installed immediately. Valve shall be stored in ventilated and dry storehouse

for protection. It is not permitted to store the valve outdoors. Valve end flanges

shall be covered.

D. If the valve is electrically triggered, care shall be taken to protect the electrical

components from moisture.

E. Check and clean the valve if the it has been stored over six months, and pressure

test before using the valve if the valve has been stored over twelve months.

3. PREPARATION FOR INSTALLATION

A. Prior to installing the valve, clean out any dirt or foreign matter from inside the

piping system. Wherever possible, the line should be blown out with clean

compressed air or flushed out with water to remove any dirt and grit. The valve

should be cleaned in a similar manner.

B. Check for adequate clearance around the valve to ensure that it may be operated

properly and that enough free space is available for maintenance of the valve.

4. INSTALLATION

Precautions: The valve body is a rugged structure, but is not intended to be a

means of aligning improperly fitted pipe. Care must be taken to ensure that any

stresses caused by improper pipe alignment are relieved elsewhere in the piping

system. Piping should be supported by hangers placed on either side of the valve

and large heavy valves should be independently supported.

A. The following general rules should be followed when installing the valve in the pipe

line:

1. Keep pipe ends free of dirt, spatter and grit.

2. Install the valve with flow in the proper direction with regard to valve internals

and flow indicators on the valve body.

3. Handle valve only with apparatus that will adequately support it, using a safe

and proper technique.

4. Install the valve using good piping practices as governed by the applicable

code or specification.

5. ESOVsare usually shipped with disc blocked to prevent damage in shipping.

Remove blocking before installation in the line.

6. Flanged End Valves

a. Check and align pipe flanges before valve installation.

b. Use proper type and size gaskets.

c. Clean debris, dirt and other particles off the surface of the flanges.

d. Do not attempt to fit two flanges that are not alike together. Plain face with

plain face or raised face with raised face is the proper procedure.

e. Do NOT TIGHTEN BOLTS IN ROTATION: they must be tightened in a

crossover or star pattern to load the bolts evenly.

7. Butt-Weld End Valves

a. Valve, pipe and weld rod must all be of materials that are mutually

compatible.

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

263 Cox Street

Roselle, New Jersey 07203 ESOV(EMERGENCY SHUTOFF VALVES)

1800 899-0553 sales@aa-fs.com www.assuredautomation.com Doc No.IOM 2010 Rev

b. Make certain valve is in the open position before applying heat. Check

valves may be in the closed position.

c. Welding should be performed by a qualified welder using the correct

welding equipment and following an acceptable procedure.

d. After completion of the weld, it should be stress relieved if required by the

welding procedure and subjected to a pressure test to ensure a sound

weld.

5. POST INSTALLATION

A. After installation of the valve, the line should be flushed or blown out to remove dirt

and foreign objects.

B. Check for tightness of body/bonnet joint.

C. Pressure test the joint to prove quality of flange bolting, welding, etc.

Note: Use of caustics or other chemical agents to flush pipe and valve may

require the removal of the valve packing and gasket based on compatibility

of flushing agent, gasket and packing material.

6. MAINTENANCE & TROUBLE SHOOTING

Valves do not need much attention, but to assure the best operating life and a lower

incidence of maintenance, a program for periodic inspection should be established.

Items to check on a periodic basis are:

A. Glands should be kept tight to prevent leakage. Avoid over-tightening stuffing nuts

or stuffing box packing. This excessively compresses the packing, which

considerably shortens its life and increases operating torque. The gland should

be only as tight as is necessary to seal.

B. Observe valve for leakage taking special note of the body/bonnet joint area, the

end connections and the pressure retaining shell. If leakage at the body/bonnet

joint is evident, check tightness of bolts.

If leakage is at the end connections, check the tightness of the flange bolts in a

flanged valve or the weld in a welded valve.

After determination of joint tightness and leakage is still evident, the joint must be

disassembled and the gasket replaced and/or sealing surfaces repaired.

C. Ensure integrity and cleanliness of fusible link and exposed hinge pins as well as

ensuring that the spring is unobstructed and correctly operating.

Note: Use of a tacky lubricant can pick up abrasive particles. Dry film lubricants

are preferred.

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

263 Cox Street

Roselle, New Jersey 07203 ESOV(EMERGENCY SHUTOFF VALVES)

1800 899-0553 sales@aa-fs.com www.assuredautomation.com Doc No.IOM 2010 Rev

D. Open and close valve to check for possible obstruction to travel.

E. Check tightness of packing gland on the hinge pin.

7. REPAIRS

The following general instructions are offered to make limited repairs to the valve.

For major repairs, contact an authorized WILLIAM E. WILLIAMS VALVE

CORPORATION Distributer for special instructions. Always give the

information shown on the identification plate affixed to the valve.

A. When holding a valve in a vise to work on it, always put the valve ends against the

vise jaws. Never hold the valve with the vise jaws pressing against the valve body

since this will cause distortion.

B. Replacing Bonnet Gasket –

1. Isolate and de-pressurize valve prior to attempting to disassemble valve.

2. Mark the body and bonnet flanges so they may be mated in the same position

when reassembled.

3. Valves having large or heavy top works will require the use of a hoist or crane

to support and lift the top works away from the valve body.

4. Loosen the bonnet joint and lift the bonnet and top works away from the body

in a direct straight line.

5. Reassemble in reverse order of above instructions.

6. Prior to re-pressurizing the valve, recheck the tightness of the body/bonnet

joint.

C. No periodic maintenance is necessary besides routine inspections. If gasket leaks

are detected, correct using the following procedure:

1. Disassemble all cover bolts and nuts.

2. Check that the hinge, nut, and pin are in good condition and firmly connected.

Replace damaged parts as necessary.

3. Lift and remove the disc-hinge assembly. Movement should be free and not

hindered by any malfunction of the hinge pin. Where disc travel is not

sufficiently smooth, remove plugs or blind flanges and then remove hinge pin.

Check surface for seizure marks. If marks are less than 0.8 mm (1/32”); re-

machine hinge pin and re-assemble, if marks are greater than 0.8 mm (1/32”)

a new hinge pin is necessary. When reassembling hinge pin, it is

recommended that the disc be removed by loosening nut.

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

263 Cox Street

Roselle, New Jersey 07203 ESOV(EMERGENCY SHUTOFF VALVES)

1800 899-0553 sales@aa-fs.com www.assuredautomation.com Doc No.IOM 2010 Rev

D. When leakage is due to deterioration of seal surfaces caused by corrosion or

foreign substances, it must be determined whether the disc or seat seal are the

cause.

1. Deterioration of disc surfaces - Disassemble disc by removing nut and

washer. Repair surface by grinding and lapping using fine grain abrasive

paste.

2. Deterioration of seat seal surfaces - When seal surfaces are damaged and

defects are confined to a small are but are not deeper than 0.8 mm (1/32”),

the seal surface can be repaired. The recommended method is to use a cast

iron strap with an outside diameter matching the valve’s raceway. Then

using a fine grain abrasive paste between the strap and raceway, it is rotated

on the seat to restore original tightness. When defects are deeper than 0.8

mm (1/32”) and found on the entire seal surface, a new seat is required. To

replace the seat, use preferably a pneumatic tool with a shape to match the

dimensions of the valve seat. It is recommended that an anti-seizing

compound be used when installing the replacement seat to make threading it

in to the body easier

CAUTION: Always be sure that the valve is de-pressurized and isolated prior to

performing any maintenance work.

8. TOOLS & EQUIPMENT

Standard wrenches and tools are generally suitable for servicing

Valves. They are:

A. One set box, open end or socket wrenches.

B. One set Allen-type hex key wrenches.

C. Combination oilstone, coarse and fine grit, to polish disc and seat ring faces.

D. Hammer and punches to drive out pins.

E. Hoist to lift large or heavy items.

INSTALLATION, OPERATION AND

MAINTENANCE MANUAL

263 Cox Street

Roselle, New Jersey 07203 ESOV(EMERGENCY SHUTOFF VALVES)

1800 899-0553 sales@aa-fs.com www.assuredautomation.com Doc No.IOM 2010 Rev

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