Sempell Pressure Seal Gate Valves - Style A Owner's manual

Brand: Sempell

Model: Pressure Seal Gate Valves - Style A

Type: Owner's manual

Sempell Pressure Seal Gate Valves - Style A are cast gate valves with a wedge and parallel slide configuration and welded ends. They are used for controlling the flow of fluids in industrial and commercial applications. The valves are designed to be installed in horizontal or vertical pipes and can be used with a variety of fluids, including water, oil, gas, and chemicals. The valves are available in a range of sizes and pressure ratings, and they can be operated manually or with an actuator.

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, bymeans 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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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

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.

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 < 2533psi For system pressures ≥ 2533psi

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= 112.8Nm

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.

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.

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.

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

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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