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Summary of Contents for APV SAPM
- Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL LUBRICATED PLUG VALVES SAPM/SAPL www.australianpipelinevalve.com.au...
- Page 2 Valves - Cast Steel Valves - Forged Steel Sleeved & Lined Valves & Wellheads APV valves and pipeline products form the most APV FAMILY OF BRANDS RANGE - CATALOGUES competitive portfolio in the market.” Diamond Gear Flowturn Ball Valves Flowturn Plug, Globe...
- Page 3 LUBRICATED PLUG VALVES - SAPM/SAPL I N D E X Introduction Safety Information 1.0 Storage Temporary storage Long term storage Preparation 2.0 Operation 8-11 Manual operation Wrench operation Gearbox operation Lock device Throttling service Pressure surge 10-11 3.0 Installation 11-14...
- Page 4 LUBRICATED PLUG VALVES - SAPM/SAPL I N D E X Disassembly Inspection & repair 19-20 6.0 Gearbox Re-lubrication Appendix A - Range & types Appendix B - Sample drawing Appendix C - Standard design Appendix D - Typical main material types...
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Page 5: Responsibility For Valve Application
RESPONSIBILITY FOR VALVE APPLICATION The User is responsible for ordering the correct valves. APV Valves are to be installed in the observance of the pressure rating and design temperature. Prior to installation, the valves and nameplates should be checked for proper identification to be sure the valve is of the proper type, material and is of a suitable pressure class and temperature limit to satisfy the applications requirements. -
Page 6: Material Compatibility
This manual provides instructions for storing, general servicing, installation and removal of plug valves. APV refuses any liability for damage to people, property or plant as well as loss of production and loss of income under any circumstances but especially if caused by: Incorrect installation or utilisation of the valve or if the valve installed is not fit for intended purpose. -
Page 7: Fire Safety
LUBRICATED PLUG VALVES - SAPM/SAPL FIRE SAFETY The term “firesafe” is nebulous and should not be used without an accompanying specification of what exactly may be required. For example there may be a requirement for a specific test, or for limitations on the failure mode of the valve to be identified. - Page 8 The valve wrenches are only intended for valve operation and must not be used to carry them. Failure to comply could result in operator injury. APV should be consulted prior to equipment intended for installation in areas which may be subject to seismic activity or extreme climatic conditions.
- Page 9 ‘lethal service’. All products for such service must have had nondestructive examination carried out in accordance with Appendix 7 of the code. Refer to APV. s) End Flanges: The end flange design of this product has been verified by either: ASME Boiler and Pressure Vessel Code Section VIII Division 1 calculation method;...
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Page 10: Temporary Storage
2 . 0 O P E R A T I O N The design of APV Standard Type plug valves is provide bubble tight shut off. Plug valves have a quarter turn operation (i.e. They have a 90 degree rotation of the plug in operating... -
Page 11: Manual Operation
LUBRICATED PLUG VALVES - SAPM/SAPL Plug valves can be used for throttling for limited periods as normally used for vent applications, by-pass, blow down, kicker, equalisation, etc. If a plug valve is used for throttling for limited periods, then its... -
Page 12: Gearbox Operation
During operation of the valve the use of excessive side loading on the wrench should be avoided. APV provide wrenches that are sized so that the force to operate the valve should be 15 NM maximum at the end of the wrench. -
Page 13: Installation Instructions
3 . 0 I N S T A L L A T I O N 3.1 INSTALLATION INSTRUCTIONS a) APV Standard Type plug valves are bidirectional, and can be installed vertical (stem operating end at the top), horizontal or any angle in between. Operating torque will increase considerably if the valve is installed in any other position, possibly resulting in seizure. -
Page 14: Installation Positions
LUBRICATED PLUG VALVES - SAPM/SAPL 3.2 INSTALLATION POSITIONS Plug valves are usually bidirectional, and therefore may be installed in either direction. In some cases, plug valves may be unidirectional, in which case the direction of flow will be indicated on the valve body. - Page 15 LUBRICATED PLUG VALVES - SAPM/SAPL Install the correct studs and nuts for the application and place the gasket between the flange facings. Stud nuts should be tightened in an opposing crisscross pattern in equal increments to ensure even gasket compression.
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Page 16: Maintenance
All valves are factory tested in accordance with valve industry standards API 6D, API 598, BS EN 12266-1 or BS.5158, unless otherwise specified. It is recommended that you contact APV if there is an operational need to test the valve at a higher pressure, temperature or duration. - Page 17 Sealant can be injected whist the valve is in-line and under full working pressure. The following is only an indicative summary of procedures. APV lubricated plug valves are designed to be lubricated using two different methods - Via built-in lubricant screw using grease sticks.
- Page 18 LUBRICATED PLUG VALVES - SAPM/SAPL 4. If necessary repeat procedure until lubricant is visible inside valve cavity. Method 2 with hydraulic lever gun 1. Charge the lever gun following manufacturers instructions. 2. Connect coupler of the lever gun to the universal button head of the lubricant screw.
- Page 19 LUBRICATED PLUG VALVES - SAPM/SAPL smaller size and lower pressure plug valves, ‘packing sticks’ are used and can be screwed in through the top of the stem with a bolt in lieu of using a grease fitting. If there is no body grease fitting, then the sealant channel on top of the stem supplies sealant to the plug and the seat.
- Page 20 LUBRICATED PLUG VALVES - SAPM/SAPL TABLE 3 Frequency of lubrication using operation frequency as a guide FREQUENCY OF SEALANT INJECTION FOR A VALVE IN FREQUENCY OF VALVE STANDARD SERVICE NO MORE THAN NO LESS THAN 10-100 times a day Daily...
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Page 21: Inspection And Repair
The below procedure is a general guide, parts vary according to size & class. Disassembly should be performed by an APV approved service centre. Refer Appendix A, B & C as a guide but consult the as-built drawing as designs vary according to size, class & style. -
Page 22: Troubleshooting Guide
Improper setting of gear operator stops Reset stops for proper installation 1. Inject sealant 1. Sealant level low 2. Flush the valve with valve flush. Follow APV’s instructions 2. Dried out sealant Difficult to operate 3. Inject low temperature sealant and/or insulate. Consult APV 3. - Page 23 LUBRICATED PLUG VALVES - SAPM/SAPL A P P E N D I X A Range & Types Wrench Lubricant fitting (Combination plunger) Check valve Gland stud Gland Gland packing Shim packing ring Bonnet Gasket Stud Body Sealant channels Plug inches...
- Page 24 LUBRICATED PLUG VALVES - SAPM/SAPL A P P E N D I X B Sample Drawing Australian Pipeline Valve - Installation, Operation and Maintenance Manual...
- Page 25 Check Valve Cover * Combination button head fitting & plunger for packing sticks. 9/10 ** Integral plug & stem inherently anti-static. * Indicative sample SAPM B.O.M. only, refer to as-built drawing. Australian Pipeline Valve - Installation, Operation and Maintenance Manual...
- Page 26 LUBRICATED PLUG VALVES - SAPM/SAPL A P P E N D I X D Typical Main Material Types Category Body/ Bonnet Plug Stem Bolt/ Nut A216 WCB/WCC A216 Gr. B A29 Gr. 4140 A193-B7M Cast iron A216 Gr. B GGG40.3. GG25 UNS 4100 Gr.
- Page 27 LUBRICATED PLUG VALVES - SAPM/SAPL A P P E N D I X E Dimensions regular pattern plug valves standard type ØE ØE ANSI 150 SCREWED OR SOCKET ENDS WRENCH OPERATED Size Inch 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” Plug port area Weight (approx) REGULAR PATTERN ANSI 150* &...
- Page 28 LUBRICATED PLUG VALVES - SAPM/SAPL A P P E N D I X F Indicative Body/bonnet bolting torque ft·lb (N·m) Bolting Material Stud Size B7M/L7M B7/B16/L7 B8/B8M CL.1 B8/B8M CL.2 3/8 - 16 UNC (20) (27) (20) (27) 7/16 - 14 UNC...
- Page 29 LUBRICATED PLUG VALVES - SAPM/SAPL A P P E N D I X G Bolt Tightening Sequence Torque chart 125Lb 150Lb 300Lb 2” 3” 4” 6” 1080 8” 2030 3205 10” 2165 3259 12” 3120 5200 14” 4845 8485 16”...
- Page 30 NOTES Australian Pipeline Valve - Installation, Operation and Maintenance Manual...
- Page 31 NOTES Australian Pipeline Valve - Installation, Operation and Maintenance Manual...
- Page 32 If you have any requirements in the field of valves, please contact us for a prompt response. Continuous development of Australian Pipeline Valve products may necessitate changes in the design or manufacture process. Australian Pipeline Valve reserves the right to effect any such changes without prior notice. IOM APV Plug Lubricated ©...
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