Valves Principles – Valve Automation Specialist Contents...

Valves Principles – Valve Automation Specialist

INSTALLATION ANDOPERATION

MANUAL

DPCM-594-000Issued 07/2015

COPYRIGHT © 2015 FCVALTECH

MANUFACTURING DIVISIONNo.16, Jinting Road, Shuige Industry, Lishui City, Zhejiang Province, 323000 ChinaE-mail: [email protected]

INTERNATIONAL HEAD QUARTER SALES OFFICEFLOW CONTROL GROUP HOLDING LTDRoom 102, No. 17 Lane 618, Huting North, Songjiang, Shanghai, 201615 ChinaMobile Contact: 86-13959376762 E-mail: [email protected] Website: www.fcvaltech.com

SOUTH EAST ASIA REGIONAL SALES OFFICEOIL-TECH ENGINEERING PTE LTD48, Toh Guan Road East, #05-148, Enterprise Hub Singapore 608586Phone: 65-6515 1684 Fax: 65-6896 8056 E-mail: [email protected] Website: www.oiltech-eng.com

FCDPCM-594-000-EN-01/2015

Dual Plate CheckValves API 594

Contents I. RECEIVING AND PREPARATION FOR INSTALLATION 1.1 Receiving Inspection 1.2 Storage 1.3 Special Instructions

Il. WARNINGS

Ill. GENERAL MAINTENANCE 3.1 Trouble Shooting 3.2 General Assembly Information

IV. INFORMATION PERTINENT TO DUAL PLATE CHECK VALVES 4.1 Detailed Maintenance 4.1.1 Seat Leakage, General 4.1.2 Seat Repairs 4.1.3 Disc Repairs 4.1.4 Fitting of Repaired Parts

V. TYPES OF DUAL PLATE CHECK VALVES 5.1 Dual Plate Check Valves 5.2 Lug Type Dual Plate Check Valves 5.3 Double Flange Dual Plate Check Valves 5.4 Disassembly 5.5 Assembly 5.6 Replaceable Seat, Dual Plate Check Valves (Double Flange View) 5.6.1 Disassembly 5.6.2 Assembly 5.7 With Retainer, Dual Plate Check Valves 5.7.1 Disassembly 5.7.2 Assembly

Vl. SPARE PARTS 6.1 Dual Plate Check Valves

ADDENDUM 1: Recommended Check Valve Installation Practice

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FCDPCM-594-000-EN-01/2015 Dual Plate Check Valves API 594

COPYRIGHT © 2015 FCVALTECH 2

1.1 Receiving inSPecTiOn

All valves must be examined for signs of damage that may have occurred during transportation. Serious damage should be reported to your local representative or to Customer Service so that a suitable arrangement for repairs can be made without delay.

1.2 STORAgeValves should be stored in a suitably sheltered place to prevent contamination by weather, dirt or dampness.

1.3 SPeciAL inSTRUcTiOnS

Dual Plate Check Valves must be installed with the arrow in the direction of the normal flow. This must be checked carefully before installing the valve. Placing a check valve in the opposite direction to the flow will prevent the disc from operating in the intended manner.

The preferred orientation is vertical upward flow or horizontal. The valve may be installed in other orientations, but any deviation from vertical or horizontal is a compromise to the design of the valve. Installation upside-down is not recommended. If installed horizontal, pins MUST be vertical.

NOTE: Before installation remove the rust preventive coating with any hyrdo-carbon solvent, such as kerosene, varsol etc.

NOTE: All check valves should be installed at least ten pipe diameters away from upstream pumps, elbows, fittings or equipment. If closer installation is required, please consult the Customer Service Manager.

FOR SAFETY REASONS, IT IS IMPORTANT TO TAKE THESE PRECAUTIONS.

► Personnel making any adjustments on the valves should wear safety equipment normally used to work with fluid in the line where the valve is installed.

► Depressurize, drain and vent the line, before removing the valve from the line.

► Valve standards, such as API and MSS, caution users of the successful completion of removing a valve from a line.

WARNINg ON NACE CONvERSIONSIt is extremely important to ensure that valves, when converted to NACE trims in the field are done by authorized service shops.Unauthorized conversions can result in failure to carry out post-weld heat treatment and result in severe stress cracks in nonstress relieved areas.

ill. geneRAL MAinTenAnce

3.1 TROUBLe SHOOTing

• Damaged Seat Faces• Seat repair (optional information

available upon request)• Disc movement restricted• Disassembly and reassembly of check

valve• Body damage• Check for leakage through the body

wall

i. Receiving And PRePARATiOn fOR inSTALLATiOn

il. WARningS



3.2 geneRAL ASSeMBLY infORMATiOn

1. The most important fact to be considered is the cleanliness of all parts.

2. Visually inspect all parts to ensure no damage.

3. Repaired or replacement parts must be checked to see if all repair procedures have been done and that all replacement parts have been checked for size so that they will fit into the valve you are servicing.

4. All orientation marks assigned during disassembly must be observed so that correct orientation is maintained.

iv. infORMATiOn PeRTinenT TO dUAL PLATe cHecK vALveS

4.1 deTAiLed MAinTenAnce

4.1.1 Seat Leakage, generalAn indication of a valve leak is a pressure loss in Excessive leaks can develop from failure of a valve to close tightly, due to possible foreign particulate matter lodged between the seat and disc or the seating surfaces may have become damaged. Leaky valves should be repaired as quickly as possible to prevent greater damage.

NOTE: Dual Plate Check Valves have a permitted seat leakage as defined by API 598.

4.1.2 Seat Repairs1. Disassemble the valve and

inspect the bodyseat for any damage.

2. Damages no deeper that 0.005” (0.12 mm) can be removed by lapping using original disc. If defects cannot be corrected by lapping, the seat should be machine ground. Maximum of 0.040” (1.0 mm) can be removed.

NOTE: FC Valtech recommends the use of “clover” lapping compound silicon carbide grade “E” medium course for minor imperfections and grade “C” fine grit compound for finishing.

4.1.3 disc Repairs

1. Disassemble valve and inspect the disc for scratches or damage.

2. If the seating faces are scratched, the disc must be lapped. Slight pitting, grooving or indentations no deeper than 0.005” (0.12 mm) can be removed by lapping. If defects cannot be corrected by lapping, the disc should be machine ground, maximum of 0.040” (1.0 mm) can be removed.

3. For the lapping, a flat plate, preferably cast iron, should be used and an abrasive lapping compound mixed with olive oil should be evenly distributed over the plate. Only light, even pressure should be applied to the plate, lifting the disc as often as possible to prevent accumulation of particles in one area and to allow for proper distribution of the lapping compound.

• The part should be lapped until seating faces are smooth. FC Valtech recommends the use of Clover Compound (silicone carbide) Grade E or C, or an approved equivalent.

4. Thoroughly clean off the lapping compound with a suitable cleaning fluid such as acetone or alcohol. Do not use solvents containing chloride or fluoride.

4.1.4 fitting of Repaired Parts1. After the seating faces of the discs

have been relapped and cleaned, a ‘blue ink’ test is recommended before reassembly. A blue ink should be distributed smoothly and equally over the full surface of both discs.



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This view is rotated 90º to show actualoperation position of the valve. The pinsmust be vertical for horizontal flow.

PARTS DESCRIPTION QTY1 Body 12 Body seat3* Disc 24 Disc seat5* Holder 26* Spring 17* Hinge pin 18* Stop pin 19* Retainer pin 2

10* Lock washer 211* Lock pin 2

*Recommended Spare Parts

Figure 1: Dual Plate Check Valves

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To suit ASME/ANSI B16.5 FlangesAPI 594 face to face, minimum wallthickness is to API 594.

175 AARH Both Sides

• Slowly lower the part into the body and find the correct mating point of the faces.

2. If a part cannot be repaired, new parts must be fitted and installed. The valve serial number must be given to FC Valtech in order to be supplied with the correct new parts.

3. Ensure there is clearance between the discs and the holder (also known as keeper) components. A functional test is the best method for verifying there is no binding between the discs and holders.

v. TYPeS Of dUAL PLATe cHecK vALveS5.1 dUAL PLATe cHecK vALveS

• Check the clearance with a filler gauge at either end of the assembled discs. Ideally, the clearance at both ends should be the same, however, a minimum clearance of 0.005” at either end must be maintained.

4. The stop pin must be able to slide down the slot in the holder and rotate freely. Be sure to remove any burrs or gouges that may impede the fit-up of the stop pin.



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Figure 2: Lug-type Dual Plate Check Valve

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This view is rotated 90º to show actualoperation position of the valve. The pins mustbe vertical for horizontal flow.

To suit ASME/ANSI B16.5 FlangesAPI 594 face to face, minimumwall thickness is to API 594.

175 AARH Both Sides

Figure 3: Double Flange Dual Plate Check Valves

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This view is rotated 90º to show actualoperation position of the valve. The pins mustbe vertical for horizontal flow.

To suit ASME/ANSI B16.5Flanges, 2 – 24” to suitASME/ANSI B16.47 SeriesA Flanges, 26” & larger,API 594 face to face,minimum wall thickness isto API 594.

175 AARH Both Sides

5.2 LUg TYPe dUAL PLATe cHecK vALveS

5.3 dOUBLe fLAnge dUAL PLATe cHecK vALveS



5.4 diSASSeMBLY

1. For large valves 10” and up, it is recommended that two technicians be utilized for assembly or disassembly of a valve.

2. Bend the ‘tabs’ of the Lock Washer (10), off-from the Holders (5).

3. If a Lock Pin (11) is present (used on valves 4” (100 mm) and smaller, slide it from the Holder (5).

4. Rotate the Stop Pin (8) 90° and remove from the Holder (5) and place on a flat clean surface.

5. While holding the top of the Holders, lift the internal assembly from the valve Body seat and place on a flat clean surface.

6. Remove the Holders (5) from the Hinge Pin (7).

7. While holding the Spring (6) down so there is clearance between the Spring and Hinge Pin (7), slide the Hinge Pin from the Disc lugs (3).

8. Slowly remove pressure from the Spring (6) and remove from the Disc (3) surface.

5.5 ASSeMBLY1. Clean all parts with varsol or other

similar solvent/degreaser. Ensure the Body and Disc seating surfaces are clean and free from any nicks, burrs or scratches.

2. Place the Body (1) in the horizontal position onto a flat clean surface so that the outlet bore (Flow arrow) is pointing upwards. Be careful NOT to scratch or damage in any way the seat face or the gasket seal faces on the body.

v. TYPeS Of dUAL PLATe cHecK vALveS

3. Place the Discs (3) in the horizontal position onto a flat clean surface with the seat faces down. Assemble the discs into position so that the lugs are brought together. The holes in the Disc lugs should now be in-line. Be careful NOT to scratch or damage in any way the lapped surfaces of the seats.

4. At this time, one of the technicians will be required to “pre-torque” the Spring (6) approximately 1/4 turn and place it into position between the lugs of the assembled Discs (3). The spring is “pre-torqued” by turning the 2 spring legs approximately 1/4 turn in the same direction as the spring is wound. The spring legs should be approximately 180° apart at this point and the hole in the Spring should be held inline with the holes in the Disc lugs

5. At the same time, another technician must be ready to insert the Hinge Pin (7) through the 1st set of Disc lug holes, through the Spring which is being held in position and through the 2nd set of Disc lug holes. At this point the Spring can be released so that the 2 legs are now resting on the surface of the Discs (3).

6. Function test the Discs at this point by lifting and releasing to ensure proper positioning of components. Be careful not to damage the seal seats.

7. Install a Holder (5) onto each end of the Hinge Pin (7) using the bottom-elongated hole in the Holder. The counter bored holes on the Holder should be facing each other and positioned above the Hinge Pin.

8. The Disc assembly is now ready to be installed into the Body bore. Carefully lift the Disc assembly, complete with Holders, and gently guide into the Body bore. The solid round pegs on the bottom of each Holder must be aligned so that they sit inside the 2 holes on the bottom seat face of the Body.



9. Install the Retainer Pins (9) through the counter bored holes in the Holders (5) and into the side holes in the Body bore. Function test the Discs at this point to ensure proper positioning of all components. Be careful not to damage the seal seats.

10. Install the Lock clips (10) onto the ends of the Stop Pin (8). Slide the flats on the Stop Pin, with clips in place, into the slot on the Holder (5) and ensure the Stop Pin fits snugly in between the Retainer Pins (9). Rotate the Stop Pin so that the flats are 90° to the slot and adjust the clip so that the tabs can be bent around the Holder edges.

5.6.1 disassembly1. For large valves 10” and up, it is

recommended that two technicians be utilized for assembly or disassembly of a valve.

2. Un-screw the Seat Retainer (8) and along with the Retainer Seal (11), place on a flat clean surface.

3. Remove the Set Screws from the Pin Keepers (5).

11. On valves 6” (150 mm) and larger, a “flat” Lock Pin (11) is to be inserted into the Holder (5) above the flat on the Stop Pin prior to bending the Lock Clip tabs. The Lock Pin acts as a secondary safety feature.

12. Function test the Discs at this point to ensure proper positioning of all components. Be careful not to damage the seal seats.

5.6 RePLAceABLe SeAT, dUAL PLATe cHecK vALveS (dOUBLe fLAnge vieW)

Figure 4: Replaceable seat, Dual Plate Check Valves (double flange view)

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175 AARH Both EndsPARTS DESCRIPTION QTY

1 Body 12* Disc 2

Disc seat3* Hinge pin 14* Spring 15* Pin keeper 26* Stop pin 17* Seat ring 18* Seat retainer 19* Hinge bearing (opt.) 2

10 Body seat11* Retainer seal 1


4. Holding the Stop Pin (6), lift the internal cartridge from the valve Body and place on a flat clean surface.

5. A gentle tap with a rubber mallet, knock the Pin Keepers (5) from the Seat Ring (7).

6. Place the Pin Keepers and Stop Pin on a clean flat surface.

7. While holding the Spring (4) down so there is clearance between the Spring and Hinge Pin (3), slide the Hinge Pin from the Disc lugs (2).



8. Slowly remove pressure from the Spring and remove from the Disc surface.

5.6.2 Assembly1. Clean all parts with varsol or other

similar solvent/degreaser. Ensure the body and disc seating surfaces are clean & free from any nicks, burrs and/or scratches.

2. Place the Body (1) in the horizontal position onto a flat clean surface so that the outlet bore is pointing upwards. Be careful NOT to scratch or damage in any way the seat face or the gasket seal faces on the body.

3. All of the internal parts are assembled together, outside of the body to form a ‘sub-assembly’ or ‘cartridge’. The cartridge is then inserted into the body where it is secured by a threaded ring.

4. Place the Seat Ring (7) onto a flat clean surface so that the seating surface is facing up.

5. Place the Pin Keepers (5) onto each end of the Seat Ring.

6. Place the Discs (2) in the horizontal position onto the Seat Ring, with the seat faces down. Assemble the Discs into position so that the lugs are brought together. The holes in the Disc lugs should now be in-line with the elongated slots of the Pin Keepers (5). Be careful NOT to scratch or damage in any way the lapped surfaces of the seats.

7. At this time, one of the technicians will be required to “pre-torque” the Spring (4) approximately 1/4” turn and place it into position between the lugs of the assembled Discs. The Spring is “pre-torqued” by turning the 2 spring legs approximately 1/4” turn in the same direction as the spring is wound. The spring legs should be approximately 180° apart at this point and the hole in the spring should be held inline with the holes in the Disc lugs.

8. At the same time, another technician must be ready to insert the Hinge Pin (3) through one elongated Pin Keeper slot (5), in the 1st set of Disc lug holes (2), through the Spring (4) which is being held in position, through the 2nd set of Disc lug holes, and through the opposite elongated Pin Keeper (5) slot. At this point the Spring (4) can be released so that the 2 legs are now resting on the surface of the Discs.

9. Function test the Discs at this point by lifting and releasing to ensure proper positioning of components. Be careful not to damage the seal seats.

10. The ‘cartridge’ assembly is now ready to be installed. Gently guide the ‘cartridge’ into the bore of the body.

11. Function test the Discs at this point to ensure proper positioning of all components. Be careful not to damage the seal seats.

12. The ‘cartridge’ is ready to be secured to the valve Body.

5.7 WiTH ReTAineR, dUAL PLATe cHecK vALveS

5.7.1 disassembly1. For large valves 10” and up . it is

recommended that two technicians be utilized for assembly or disassembly of a valve.

2. Remove the Pin Retainers (8) and place on to a flat clean surface.

3. Slide the Stop Pin (6) from the valve.4. While holding the Spring down so there

is clearance between the Spring (4) and Hinge Pin (3), slide the Hinge Pin from the valve.

5. Slowly remove pressure from the Spring (4) and remove from the valve.

6. Lift the Discs (2) from the body seat and place onto the flat surface.

7. Remove the Hinge Pin Bushings (5) from the valve.



Figure 5: With retainers, Dual Plate Check Valves

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PARTS DESCRIPTION QTY1 Body 12* Disc 2

Disc seat3* Hinge pin 14* Spring 15* Hinge pin bushing 26 Stop pin 17 Hinge pin retainer 28 Stop pin retainer 29 Body seat


5.7.2 Assembly1. Clean all parts with a solvent/

degreaser. Ensure the Body (1) and Disc (2) seating surfaces are clean and free from any nicks, burrs or scratches.

2. Place the Body (1) in the horizontal position onto a flat clean surface so that the outlet bore is pointing upwards (see the Flow arrow). Be careful NOT to scratch or damage seat face or gasket seal faces.

3. Place the Hinge Pin Bushings (5) into the Body (1). A gentle tap with a rubber mallet may be required to ensure a tight seal.

4. Place the discs (2) onto Body seat (9), with the seat faces down. The disc lugs should be brought together, and the disc lugs should now be in-line with the Hinge Pin Bushing (5).

5. At this time, one technician will “pre-torque” the Spring (4) approximately 1/4” turn and place it into position between the lugs of the assembled discs. The Spring is “pre-torqued” by turning the 2 spring legs approximately 1/4” turn in the same direction as the spring is wound. The spring legs should be approximately 180° apart at this point and the hole in the spring should be held inline with the holes in the disc lugs.

6. At the same time, the other technician must be ready to insert the Hinge Pin (3) through one end of the valve Body, through the Hinge Pin Bushing (5), through the Spring (4), which is being held in position, through the 2nd Hinge Pin Bushing and finally through the opposite side of the valve Body. At this point the spring can be released so that the 2 legs are now resting on the surface of the discs.

7. Slide the Stop Pin (6) into the valve body (1) and tighten the Pin Retainers (8). Wrap Teflon tape around the Pin Retainer threads before tightening.

8. Function test the discs at this point by lifting and releasing to ensure proper positioning/clearance of components. Be careful not to damage the body seat.

9. For long-term storage, ensure the valve is clean and free from any foreign matter. Apply rust preservative to carbon steel surfaces and reattach gasket face protectors in order to protect the internals and the gasket sealing faces. Store valve in a clean and stable environment.



vl. SPARe PARTS

All parts on any Dual Plate Check Valve can be ordered.

When ordering spare parts, correctly determine which parts are required. After this is done, present FC Valtech with some of the following information:

1. FC Valtech order number.2. FC Valtech item number (if more than

one item).3. FC Valtech size, rating and figure

number, available from the nameplate.4. Customer order number.5. Customer item number

OR6. Valve size, type, pressure class and

materials of construction.

6.1 SPeciAL TOOLS

1. Dip a clean rag into a hydrocarbon solvent, such as kerosene or varsol, to remove any rust preservative on carbon steel valves and components.

2. Applicable lifting eyebolt for valves weighing approximately 30 lbs. or greater.

3. Apply rust preservative, such as “Rust Ban” or equivalent, to any carbon steel valve that is removed from service and put into storage.

4. No special tools are required for installation and disassembly purposes



AddendUM 1: RecOMMended cHecK vALve inSTALLATiOn PRAcTice

1. Recommended Installation PracticesRefer to Figure 1 of this addendum for viewing distances to various piping configurations.

1.1 Discharge of Compressors and PumpsIt is recommended that our Check valve be positioned 10 pipe diameters from the discharge of a compressor or pump.

1.2 Elbows or 90 Degree BendsIt is recommended that our Check valve be positioned 5 pipe diameters from an elbow or 90 degree bend.

1.3 Reducers and EnlargersIt is recommended that our Check valve be positioned 5 pipe diameters from a reducer or enlarger.

Header Valve Reducer CompressorDischarge

Figure 1: Recommended Distance From Discontinuities For Check Valve Installation

Elbow

3d Pipe 5d Pipe

5d Pipe

10d Pipe

Flow

Valves Principles – Valve Automation Specialist

INSTALLATION ANDOPERATION

MANUAL

DPCM-594-000Issued 07/2015

COPYRIGHT © 2015 FCVALTECH

MANUFACTURING DIVISIONNo.16, Jinting Road, Shuige Industry, Lishui City, Zhejiang Province, 323000 ChinaE-mail: [email protected]

INTERNATIONAL HEAD QUARTER SALES OFFICEFLOW CONTROL GROUP HOLDING LTDRoom 102, No. 17 Lane 618, Huting North, Songjiang, Shanghai, 201615 ChinaMobile Contact: 86-13959376762 E-mail: [email protected] Website: www.fcvaltech.com

SOUTH EAST ASIA REGIONAL SALES OFFICEOIL-TECH ENGINEERING PTE LTD48, Toh Guan Road East, #05-148, Enterprise Hub Singapore 608586Phone: 65-6515 1684 Fax: 65-6896 8056 E-mail: [email protected] Website: www.oiltech-eng.com

FCDPCM-594-000-EN-01/2015

Dual Plate CheckValves API 594

Contents I. RECEIVING AND PREPARATION FOR INSTALLATION 1.1 Receiving Inspection 1.2 Storage 1.3 Special Instructions

Il. WARNINGS

Ill. GENERAL MAINTENANCE 3.1 Trouble Shooting 3.2 General Assembly Information

IV. INFORMATION PERTINENT TO DUAL PLATE CHECK VALVES 4.1 Detailed Maintenance 4.1.1 Seat Leakage, General 4.1.2 Seat Repairs 4.1.3 Disc Repairs 4.1.4 Fitting of Repaired Parts

V. TYPES OF DUAL PLATE CHECK VALVES 5.1 Dual Plate Check Valves 5.2 Lug Type Dual Plate Check Valves 5.3 Double Flange Dual Plate Check Valves 5.4 Disassembly 5.5 Assembly 5.6 Replaceable Seat, Dual Plate Check Valves (Double Flange View) 5.6.1 Disassembly 5.6.2 Assembly 5.7 With Retainer, Dual Plate Check Valves 5.7.1 Disassembly 5.7.2 Assembly

Vl. SPARE PARTS 6.1 Dual Plate Check Valves

ADDENDUM 1: Recommended Check Valve Installation Practice

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