VCIOM-04586-EN 18/01© 2017 Emerson. All Rights Reserved.
VALVE STORAGE
Preparation and preservation for Shipment
All valves are properly packed in order
to protect the parts that are subject to
deterioration during transportation and storage
on site. In particular, the following precautions
should be taken:
1. The valves must be packed with the wedge
in the closed position.
2. The weld ends surface shall be protected
with suitable protective like Deoxaluminite.
The end shall be closed with plywood or
plastic disc fixed at the edge by strips.
3. All actuated valves must be carefully
securely palleted or crated, in order to
ensure that the parts of actuator (especially
pneumatic piping or accessories) do not
extend beyond the skid/crate.
4. The type of packing must be defined in the
customer’s order and shall be appropriate
to ensure safe transportation to final
destination and eventual conservation
before installation.
Installation and maintenance instructions
Handling requirements
A - Packed valves
Crates: Lifting and handling of the packed
valves in crates will be carried out
by a fork lift truck, bymeans of the
appropriate fork hitches.
Cases: The lifting of packed valves in cases
should be carried out in the lifting
points and at the center of gravity
position which have been marked. The
transportation of all packed material
must be carried out safely and
following the local safety regulations.
B - Unpacked valves
1. The lifting and the handling of these valves
has to be carried out by using appropriate
means and at respecting the carrying limits.
The handling must be carried out on pallets,
protecting the machined surfaces to avoid
any damage.
2. With valves of large dimensions, the sling
and the hooking of the load must be carried
out using the appropriate tools (brackets,
hook, fasteners, ropes) and load balancing
tools in order to prevent them from falling
or moving during the lifting and handling.
SEMPELL PRESSURE SEAL GATE VALVES - STYLE A
Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends
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2
SEMPELL PRESSURE SEAL GATE VALVES - STYLE A
Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends
Storage and preservation before installation
In case the valves have to be stored before
installation, the storage has to be carried out
in a controlled way, and has to be performed in
accordance with the following criteria:
1. The valves have to be stocked in a closed,
clean and dry storage room.
2. The wedge must be in the closed position,
and the end faces must be protected with
plastic or wooden discs fixed with straps. If
possible, keep the original protection.
3. Periodical checks have to be carried out
in the storage area to verify that the above
mentioned conditions are maintained.
For actuated valves, in addition to the above,
please refer to the warnings in the manual of
the actuator.
CAUTION
For valve handling and/or lifting, the lifting
equipment (fasteners, hooks, etc.) must be sized
and selected while taking into account the valve
weight indicated in the packing list and/or delivery
note. Lifting and handling must be made only by
qualified personnel.
Do not use the lifting points located on the
actuator, if any, to lift the valve. These lifting points
are for the actuator only.
Caution must be taken during the handling to
avoid that this equipment passes over the workers
or over any other place where a possible fall
could cause damage. In any case, the local safety
regulations must be respected.
INSTALLATION
Preparation before installation
1. Carefully remove the valve from the
shipping package (box or pallet) avoiding any
damage to the valve or, in case of automated
valves, to the electric or pneumatic/
hydraulic actuator or instrumentation.
2. The valves are shipped with the ends
protected by caps and coated with a
thin layer of protective grease. Before
installation, remove the caps of the ends
and the protective grease by cleaning them
completely with a solvent liquid. Clean the
inside of the valve using an air line. Ensure
that there are no solid objects such as
pieces of wood, plastic or packing materials
within the valve or on the valve seat.
3. Confirm that the materials of construction
listed on the valve nameplates (service and
temperature) are appropriate for the service
intended and are as specified.
4. Define the preferred mounting orientation
with respect to the system pressure.
If any (see arrow on the body), identify
the upstream side (high pressure) and
downstream side (low pressure).
NOTE
Storage in an open area for a limited period can be
considered only in case the valves have appropriate
packing (packed in cases lined with tarred paper, and
contents well protected with barrier sacks).
Do not place consignment packages directly on the
ground.
Do not expose consignment packages to the weather
or directly to the sun.
Check the packaging every two months.
WARNING
Verify that the direction of the flow in the line
corresponds to the arrow indicated on the valve
body. Valves without the arrow are bi-directional.
See the actuator user manual for the actuator
preparation.
VALVE SLINGING
FIGURE NO. 1
3
WARNING
Before welding, check that valve is completely
opened.
SEMPELL PRESSURE SEAL GATE VALVES - STYLE A
Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends
Installation instructions
Gate valves are normally installed in horizontal
pipe with vertical stem.
These valves can also be installed in vertical or
horizontal pipe with stem other than vertical,
but this may require special construction
depending on valve size, service condition,
material and type of operator.
For a correct operation, we recommend
that the valve shall be installed and oriented
following the indications of Fig. 2.
This can help minimize any problem associated
with solid particles present in the fluid that
otherwise could deposit in the lower part of the
body and be obstacle to the wedge complete
closure.
Install the valve with the wedges in closed
position unless otherwise stated. Thus, the
sealing surfaces will not be damaged during
installation.
Particular care should be taken with those
valves equipped with ‘fail-open’ actuators.
For operating temperatures above 200°C
(392°F) thermal insulation of the valve body is
recommended.
Handling and lifting of the valves during
installation MUST be performed following the
same criteria and instructions described in
previous points ‘Valve handling’ and ‘Storage
and Preservation before Installation’.
IMPORTANT
After the valves installation and before the
line testing, it is recommended to perform an
accurate cleaning of the lines to eliminate dirt
and any foreign objects that could seriously
jeopardize the tightness between seat/disc and
the correct operation of the valve. It is therefore
recommended to leave the valve in the open
position.
Buttweld valves
1. Open the valve.
2. Place the valve, check the alignment with
the pipe and weld in accordance with the
welding standard procedures as stated by
the Engineering Society.
IMPORTANT
If piping system is pressurized with water for
testing, and in case the piping system has been
shut down after testing for a long time, the
following recommendations should be adopted.
a. Use corrosion inhibitor with water to
pressurize the piping system
b. After testing, the piping system should be
depressurized and the test water completely
drained.
Valve verification before start up
1. Tighten the packing just enough to prevent
stem leakage. Over-tightening will decrease
packing life and increase operating torque.
The bolt torque figures for the packing bolts
can be calculated as indicated in Table I.
In the case that leaking from the packing
occurs during the start up, proceed as
follows:
- Tighten the nuts to the indicated torque
(see table), operate the valve and re-tight
the nuts to the indicated torque.
- Repeat the operation until the leakage
stops.
2. Check the operation of the valve by stroking
it to ‘full open’ and ‘full close’.
3. In case of electric actuated valves,
see paragraph for instructions on the
adjustment of the actuator.
Scheduled maintenance
1. Style A Series Gate Valves do not require
special care to work properly.
The following instructions will help provide a
satisfactory and long life service.
2. Make sure to perform periodic valve
verification as described in paragraph '
Adjustment of electric actuators'.
3. In case of actuated valves always follow the
specific instructions given by the actuator’s
manufacturer.
4. Never change the setting of torque and/or
limit switches which have been carefully set
during the final test at the manufacturing
plant.
FIGURE NO. 2
INSTALLATION POSITIONS RECOMMENDED
90° max.
4
⅜ 18 24,5
½ 37 50
⅝ 74 100
¾ 125 170
⅞ 207 280
1 310 420
1 ⅛ 443 600
1 ¼ 627 850
1 ⅜ 811 1100
22.2 0.64 1.15 1.65 2.14 2.65 3.13 3.64 4.15 4.62 5.11 5.59 6.06 5.25 5.65 6.04 7.99 8.98 9.94 10.91
25.4 0.71 1.28 1.84 2.38 2.95 3.49 4.05 4.61 5.14 5.68 6.21 6.74 5.84 6.28 6.72 8.89 9.98 11.06 12.13
28.6 1.03 1.85 2.65 3.43 4.25 5.02 5.84 6.65 7.41 8.19 8.96 9.71 8.42 9.05 9.68 12.81 14.39 15.93 17.48
31.8 1.11 1.99 2.86 3.71 4.59 5.42 6.30 7.18 8.00 8.84 9.67 10.48 9.09 9.77 10.45 13.82 15.53 17.20 18.87
34.9 1.21 2.17 3.10 4.02 4.98 5.89 6.85 7.80 8.68 9.60 10.50 11.39 9.87 10.61 11.35 15.01 16.87 18.68 20.50
38.1 1.60 2.87 4.12 5.34 6.61 7.82 9.09 10.35 11.53 12.74 13.94 15.12 13.11 14.09 15.07 19.93 22.39 24.80 27.21
41.3 1.72 3.09 4.42 5.74 7.10 8.40 9.76 11.12 12.38 13.68 14.97 16.23 14.07 15.13 16.18 21.40 24.04 26.63 29.22
44.5 1.82 3.26 4.67 6.06 7.50 8.87 10.31 11.74 13.08 14.45 15.81 17.15 14.87 15.98 17.09 22.61 25.40 28.13 30.86
47.6 1.93 3.47 4.97 6.45 7.98 9.44 10.97 12.49 13.91 15.37 16.82 18.25 15.82 17.00 18.18 24.06 27.02 29.93 32.84
50.8 2.43 4.37 6.26 8.12 10.05 11.88 13.81 15.73 17.52 19.36 21.18 22.97 19.91 21.40 22.89 30.28 34.02 37.68 41.34
54.0 2.56 4.59 6.58 8.54 10.57 12.49 14.52 16.54 18.42 20.36 22.27 24.16 20.94 22.51 24.08 31.85 35.78 39.63 43.47
57.2 3.14 5.64 8.09 10.49 12.98 15.35 17.84 20.32 22.63 25.01 27.36 29.68 25.73 27.65 29.58 39.13 43.95 48.68 53.41
60.3 3.28 5.89 8.45 10.95 13.55 16.03 18.64 21.22 23.64 26.12 28.57 30.99 26.87 28.88 30.89 40.86 45.90 50.84 55.78
63.5 3.43 6.15 8.82 11.43 14.15 16.73 19.45 22.15 24.67 27.26 29.83 32.35 28.05 30.15 32.24 42.65 47.91 53.07 58.22
69.8 3.71 6.66 9.55 12.38 15.32 18.12 21.06 23.98 26.71 29.52 32.29 35.03 30.37 32.64 34.91 46.18 51.88 57.46 63.04
73.0 3.85 6.92 9.92 12.86 15.91 18.82 21.88 24.91 27.75 30.66 33.54 36.38 31.54 33.91 36.26 47.97 53.89 59.68 65.48
76.2 4.62 8.29 11.89 15.41 19.07 22.56 26.22 29.86 33.26 36.75 40.21 43.61 37.81 40.64 43.47 57.50 64.59 71.54 78.49
79.4 4.14 7.44 10.66 13.82 17.10 20.22 23.51 26.77 29.82 32.95 36.05 39.10 33.90 36.44 38.97 51.55 57.91 64.14 70.37
82.5 5.08 9.12 13.07 16.95 20.97 24.80 28.83 32.83 36.57 40.41 44.21 47.95 41.57 44.69 47.79 63.22 71.02 78.66 86.30
85.7 4.94 8.87 12.72 16.49 20.41 24.13 28.06 31.95 35.58 39.32 43.02 46.66 40.45 43.48 46.50 61.52 69.11 76.54 83.98
88.9 5.10 9.16 13.13 17.02 21.06 24.91 28.96 32.97 36.73 40.58 44.40 48.16 41.75 44.88 48.00 63.50 71.33 79.00 86.67
95.3 5.57 10.00 14.34 18.59 23.01 27.20 31.63 36.01 40.11 44.33 48.49 52.60 45.60 49.02 52.42 69.35 77.91 86.29 94.67
98.5 6.48 11.65 16.69 21.64 26.78 31.67 36.82 41.93 46.70 51.61 56.46 61.24 53.10 57.07 61.04 80.75 90.71 100.46 110.22
101.6 6.71 12.05 17.27 22.39 27.71 32.76 38.09 43.37 48.31 53.38 58.40 63.35 54.92 59.03 63.13 83.52 93.82 103.92 114.01
108.0 7.02 12.61 18.08 23.44 29.01 34.30 39.88 45.41 50.58 55.89 61.15 66.33 57.50 61.81 66.10 87.45 98.23 108.80 119.36
111.1 8.22 14.77 21.17 27.45 33.98 40.18 46.71 53.19 59.24 65.46 71.62 77.68 67.35 72.39 77.42 102.42 115.06 127.43 139.81
SEMPELL PRESSURE SEAL GATE VALVES - STYLE A
Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends
TABLE I: BOLT TORQUE FIGURES FOR PACKING BOLTS
For system pressures < 2533psi For system pressures ≥ 2533psi
Torque (ft lbs) = (24.87) x (OD2 _ ID2) x (d) Torque (ft lbs) = (S.P./101.8) x (OD2 _ ID2) x (d)
Torque (Nm) = multiply Torque (ft lbs) x 1.3558
Where: OD = Stuffing Box Bore (ln.)
ID = Stem Diam (In.)
d = Gland Stud Diam (in.)
S.P. = System Pressure (psi)
This ‘Torque method’ may result in more or less than 30% compression.
TABLE II: BOLT TORQUE TO ENSURE TIGHTNESS OF PRESSURE SEAL GASKET
Position 31 for Gate valves
Stud Torque ft.lbs. Torque Nm
IMPORTANT
To ensure tightness of pressure seal gasket, pull
up bolts must be tightened when valve is under
fully hydrostatic test pressure.
TABLE III: CONSTANT FOR CALCULATION OF PACKING BOLT TORQUES
Stem Bolts gland diameter
diameter ⅛ ¼ ⅜ ½ ⅝ ¾ ⅞ 1 1 ⅛ 1 ¼ 1 ⅜ 1 ½ 1 ⅝ 1 ¾ 1 ⅞ 2 2 ¼ 2 ½ 2 ¾
NOTES
1. Select the constant according to both, stem diameter and bolts size.
2. In order to obtain the packing bolt torque in Nm, multiply the selected constant for the pressure in MPa.
Example:
Valve operating at 24MPa pressure with 44.5mm stem diameter and packing size of M16.
a. The constant is equal to 4.67
b. Packing bolt torque is equal to 4.67 x 24= 112.8Nm
5
TROUBLESHOOTING GUIDE
Symptom Possible cause Solution
Stem packing leaking 1. Gland flange nuts too loose 1. Check gland nuts torque
2. Packing damaged 2. Replace packing (See Page 6)
Body-Bonnet leaking 1. Gasket bolting loose (pos 31) 1. Tighten bolting (pos 31)
2. Gasket damaged 2. Replace the gasket
Valve leaking 1. Valve not fully closed 1. Close valve
2. Debris trapped in valve 2. Cycle and flush (with valve open) to
remove debris
3. Sealing surface damaged 3. Recondition the seat surface
Jerky operation 1. Packing is too tight 1. Loosen gland nuts, cycle the valve,
retighten
2. Air supply inadequate (for pneumatic act.) 2. Increase air supply pressure
Backseat leakage 1. Backseat damaged 1. Repair backseat surface
SEMPELL PRESSURE SEAL GATE VALVES - STYLE A
Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends
Periodic valve verification during service
A - Normal check
1. Verify monthly that there is no leakage from
packing or in the body/bonnet area.
In the case that a leakage from the packing
occurs, tighten the gland nuts (fig. 4, pos 16)
slowly and uniformly. Calculate torque value
as indicated in table I.
If the leakage does not stop, follow the
procedure for packing maintenance (page
6).
If the leakage has been detected from the
body/bonnet, tighten the nuts (pos. 31) as
indicated in Table II.
If the leakage does not stop, follow the
maintenance procedure for the replacement
of the body/bonnet gasket.
2. Every 3 / 6 months, depending on operating
frequency, verify the greasing of bearings
and stem thread.
3. For actuated valves, in addition to the above,
please refer also to the warnings in the
actuator manual.
WARNING
Do not modify the torque values and/or limit
switch settings. Default configurations have been
set up during final tests at our workshops.
B - Preventive actions
1. Every 3 months verify the tightness of gland
bolts.
2. Every 6 months on motorized valves and
every 8 months on hand operated valves,
grease stem and bearings.
3.
Every 4 years disassemble the critical
service valves and/or actuated valves,
verifying the sealing surfaces and lap them
again when necessary. Substitute the bonnet
gasket and the packing, grease the stem.
4. For the actuator, proceed as indicated in its
maintenance manual.
Adjustment of the electric actuators
Wegde gate valves must be set up with the
micro limit switch in open position and by
torque in close position.
Failure to do so may result in personal and/or
property damage.
6
WARNING
Before starting any maintenance, depressurize,
drain and vent the line; check that the valves are
not in temperature; disconnect any electrical
power supply.
Failure to do so may cause serious personal injury
and/or equipment damage.
SEMPELL PRESSURE SEAL GATE VALVES - STYLE A
Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends
MAINTENANCE
The Style A series valves have been designed to
require minimum maintenance.
This manual describes on site repairs as:
- Packing replacement
- Body/bonnet gasket replacement
All the other repairs should be performed by
Emerson or nominated service company.
Packing maintenance
If a leakage from the packing cannot be
stopped by tighten the gland nuts, replace the
packing as follows:
Please refer to Figure no.3 and 4.
1. Open completely the valve up to the
backseat position.
2. Remove the nuts (16) of the gland bolts (15)
3. Lift the gland flange (10) and the gland (9)
4. Remove the worm-out packing using a
hooking wire
5. For a better tightness, proceed to an
accurate cleaning of the stem and stuffing
box and make sure there are no scratches
or signs of seizing
6. The repacking shall be carried out by
placing one ring at a time around the stem,
inside the stuffing box and by making sure
that they are correctly oriented. Press it into
the bottom (refer to Figure no. 3).
7. When the stuffing box is filled, replace the
gland (9 figure no. 4) and gland flange (10
Figure no. 4) in their original position.
8.
Tighten gland nuts in accordance with Table I
(Bolt torque figures for packing bolts).
9. Cycle the valve.
10. Pressurize the line.
11. If a leakage is detected, tighten the gland
nuts slowly and evenly until the leakage
stops.
1 = Braided graphite
2 = Die formet graphite (5 or 6 ring)
3 = Metal ring
FIGURE NO. 3
FIGURE NO. 4
7
Bonnet gasket replacement
WARNING
Before starting any maintenance, depressurize,
drain and vent the line; check that the valves are
not in temperature; disconnect any electrical
power supply.
Failure to do so may cause serious personal injury
and/or equipment damage.
SEMPELL PRESSURE SEAL GATE VALVES - STYLE A
Cast Gate ValVes, wedGe & Parallel slide ConfiGuration, welded ends
VALVE REMOVAL
If the valve needs to be removed from the line
for some extraordinary reason, the user should
ensure the following:
1. The valve is depressurized, drained and vent.
2. The pipe shall be cut as far away from the
valve as possible.
GREASES AND SPECIAL TOOLS
Greases
To lubricate the bearings on manual and
gearbox operated valves, we suggest to use
the grease AGIP GRMUEP2 or an equivalent
product, as showed in the following table:
TABLE IV: GREASE AND LUBRICANT LIST
Manufacturer Grease
AGIP GRMUEP2
API PGX2
BP GREASE LTX2
ESSO BEACON 2
FINA FINAGREASE HP FINAGREASE EPL2
MOBIL MOBILUX EP2
Q8 REMBRANDT EP2
SHELL ALVANIA R2 SUPERGREASE A
TEXACO MULTIFAK EP2 GREASE L2
TOTAL MULTIS EP2 MULTIS 2
VISCOL SIGNAL ROLSFER 2
STATOIL UHIWAYLI LI G2
Special tools
No special tool required for the Maintenance
Operation described in this Manual.
Lifting lugs
For NPS 4 For NPS 3
Please refer to Figure no. 5.
1. Unscrew the body bonnet nuts (pos.12) and
the gland nuts (pos.16)
2. Lift up the yoke (pos.24) operating by the
handwheel or gearbox handwheel
3. When the stem nut is free from the stem
threads, lift up the yoke.
4. Unscrew the nuts (pos.31).
5. Remove the retaining ring (pos.311).
6. Remove the segment rings, push them out
from the body groove by using the body
holes placed radially on the top of the body.
7. Lift up the bonnet (pos.6) and pressure
seal body gasket (pos.5). Make sure not to
damage the packing. We suggest to replace
the packing when changing the body gasket.
8. Carefully clean all the gasket housing and
lubricate with suitable grease.
9. Replace the body gasket.
10. Reassemble all parts following backwards
the above mentioned steps.
CAUTION
The nuts (pos.31) need to be retightened after
valve first pressurization, as indicated in Table II.
WARNING
Before starting any operation, depressurize the
line with the valve in open position so no pressure
remains in the body cavity. Close the valve by way
and not by torque.
FIGURE NO. 5
For the lubrication of the stem thread, use the
grease SIGNAL CEP 30 produced by Viscol. As
an alternative you can utilize:
- CEPLATTYN 300 produced by REINER-FUCHS
- GRAFLOSCON produced by KLUBER
You can also use a grease having more than
25% pure graphite content (carbon 98%)
granulometry 5m, without any abrasive agent.
For the lubrication of the actuator, refer to the
relevant manual.
For NPS 6
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Sempell is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson
and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by
our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without
notice.
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