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Related Manuals for Flowserve Durco Sleeveline G4XZ
Summary of Contents for Flowserve Durco Sleeveline G4XZ
- Page 1 G4XZ Valves Installation Operation Sleeveline® Plug Valves Maintenance VAIOM000321-00(EN) Original Instructions These instructions must be read prior to installing, operating, and maintaining this equipment.
- Page 2 G4XZ Sleeveline® Plug Valve User Instructions Copyright All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior permission of Flowserve Corporation. Document Version...
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Page 3: Table Of Contents
G4XZ Sleeveline® Plug Valve User Instructions CONTENTS General Information ........................5 Scope of manual ............................5 Disclaimer ..............................5 Certification instruction ..........................5 Units ................................6 Safety Information ........................... 6 Intended use ..............................6 Safety symbols and description ........................6 General hazard sources ..........................7 Qualified personnel and targeted group ....................8 Industrial health and safety measures .......................8 Potential explosive areas ..........................8 Protective equipment ..........................9... - Page 4 G4XZ Sleeveline® Plug Valve User Instructions Reassembly : Plug Assembly ........................199 Reassembly: Sleeve Installation ..............Error! Bookmark not defined.9 Reassembly: Remaining Components………………………………………………………………………………….………………….21 8.10 Post Maintenance Inspection ........................22 Troubleshooting Guide ......................... 22 10 Returns and Disposal ........................24 10.1 Returns ................................
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Page 5: General Information
Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Flowserve’s warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in use. -
Page 6: Units
The product/system must not be operated beyond the parameters specified for the application. If there is any doubt as to the suitability of the product/system for the application intended, contact Flowserve for advice, quoting the serial number. • Installing, operating, or maintaining the product/system in any way that is not covered in this User Instruction could cause death, serious personal injury, or damage to the equipment. -
Page 7: General Hazard Sources
2.3 General hazard sources 2.3.1 Mechanical Hazards a) Lifting limits and guidelines Note: The load values mentioned in this section are Flowserve recommendations only. All lifting must be done in compliance with site safety protocol, local regulations, and related industry standards. -
Page 8: Qualified Personnel And Targeted Group
G4XZ Sleeveline® Plug Valve User Instructions • Loads in excess of 23kg (50 lb.) should only be lifted by appropriate mechanical means and in accordance with current local legislation or with the assistance of additional personnel. • Lifting items less than 23kg (50 lb.) may be prohibited without assistance if the lift is repetitive and/or awkward (i.e., away from the body, above the shoulders or below the knees) thus placing excessive stress on the personnel. -
Page 9: Protective Equipment
G4XZ Sleeveline® Plug Valve User Instructions 2.7 Protective equipment Wear the necessary protective equipment during the unpacking, installation, operation, and maintenance of valves. Product Description 3.1 General product description The Durco G4X product is a non-lubricated sleevelined quarter turn plug valve rated to ASME Class 150 and Class 300 designs at pressures to 51 bar (740PSI) and temperatures to 232 degrees C (450 F). -
Page 10: Connections
Any shortage and/or damage must be reported immediately to Flowserve and must be received in writing within one month of receipt of the equipment. Later claims cannot be accepted. - Page 11 4.2.1.2 During on-site storage, all valves with special cleaning and/or preparation, should be kept in original special packaging as shipped from Flowserve for protection from contamination. 4.2.1.3 Valves should be stored indoors, above ground and protected from harsh environments.
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Page 12: Installation
Flowserve normally supplies B7 (carbon steel) for ductile cast iron and carbon steel valves. For stainless steel and high alloy valves, B8 (stainless steel) fasteners are supplied as standard. - Page 13 Compliance is made with NSI B18.2.2 (1987), Square and Hex Nuts, when studs and heavy hex nuts are required. Additional information on these items may be obtained from the Flowserve Corporation, Cookeville Valve Operation, Cookeville, Tennessee.
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Page 14: Commissioning
G4XZ Sleeveline® Plug Valve User Instructions 5.2.3 Flow Direction The G4X is vented to ensure integrity of valve cavity. The Plug is vented and is marked with a V on the top of the stem as well as the side of the stem. Flow direction on the valve is indicated with an arrow on the end flange (if applicable). -
Page 15: Normal Operation
G4XZ Sleeveline® Plug Valve User Instructions 7.3 Normal operation (List the product/system normal operating range, limits, and if applicable, any specific activities to properly operate the equipment.) Maintenance 8.1 Schedule Do not attempt any maintenance of these valves while in operation or under pressure. Actuated valve air and/or electrical power supplies must be locked off and isolated prior to any maintenance work. -
Page 16: Special Tools
G4XZ Sleeveline® Plug Valve User Instructions 8.3 Special tools Diaphragm guide Calibrated press Sleeve insertion tooling 8.4 Required replacement parts for maintenance Packing Diaphragms (metal and plastic) Thrust collar assembly Bolting O-rings 8.5 Disassembly Do not attempt any maintenance of these valves while in operation or under pressure. Actuated valve air and/or electrical power supplies must be locked off and isolated prior to any maintenance work. - Page 17 G4XZ Sleeveline® Plug Valve User Instructions 8.5.1.5 Once the plug has lifted, the packing and plug adjuster fasteners can be completely removed. 8.5.1.6 Gradually loosen but do not remove the top cap fasteners. Rotate plug to completely free it from sleeve compression. 8.5.1.7 Remove top cap fasteners and top cap from the plug stem.
- Page 18 The product smart code is provided on nameplate. To ensure continued satisfactory operation, replacement parts to the original design specification should be obtained from Flowserve. Any change to the original design specification (modification or use of non-standard part) will invalidate the product safety certification.
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Page 19: Reassembly: Sleeve Installation
G4XZ Sleeveline® Plug Valve User Instructions 8.7 Reassembly: Plug Assembly Diaphragm Installation 1. Install PFA diaphragm with assistance of G4X diaphragm guide; install with reverse lip pointing down as shown in Figure 8.7. 2. For fire sealed valves, install an additional metal diaphragm. ID radius should follow PFA diaphragm downward. - Page 20 G4XZ Sleeveline® Plug Valve User Instructions Figure 8.8.1 For 3” and larger valves, install sleeve “shoehorns” into the bowl/waterway in order to guide the sleeve past the lower part of the waterway opening without being damaged. b. Push the sleeve using the plunger(s) until the sleeve drops below the top counterbore lip of the valve body.
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Page 21: Reassembly: Remaining Components
G4XZ Sleeveline® Plug Valve User Instructions Figure 8.8.3 e. Apply a thin film of silicone or other approved lubricant to the sizing plug. Push the sizing plug into the sleeve until it bottoms against the counterbore of the valve body. Allow the sizing plug to remain in position for one minute. -
Page 22: Post Maintenance Inspection
G4XZ Sleeveline® Plug Valve User Instructions 14. Install nuts onto studs and torque to values listed in Table 8.5, while ensuring the adjuster is kept level with Thrust collar. 15. Place packing adjuster over stem and packing gland. Insert adjuster screws and tighten to finger tight. - Page 23 G4XZ Sleeveline® Plug Valve User Instructions Problems Problem Descriptions Possible Causes Recommended actions Check for alignment of components, including side loading and extensions Check for damage on stem, inside thrust collar, and inside Packing Gland Remove stem packing from Thrust Collar and replace new stem packings.
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Page 24: Returns And Disposal
G4XZ Sleeveline® Plug Valve User Instructions Problems Problem Descriptions Possible Causes Recommended actions A small Reduction of force on plug adjuster may be made to Plug Adjustment may be see if operation force is reduced; overtightened however, this may cause internal through leakage. - Page 25 G4XZ Sleeveline® Plug Valve User Instructions accordance with local/regional regulations. This includes any liquid and/or gas in the “seal system” or utility. Refer to Safety Data Sheets and make sure that hazardous substances or toxic fluids are disposed of safely and that the correct personal protective equipment is used. All activities involving hazardous substances or toxic fluids must be in compliance with published safety standards.
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Page 26: Annex A: Declaration Of Conformity
G4XZ Sleeveline® Plug Valve User Instructions Annex A: Declaration of Conformity If the product/system is being sold into a country which requires a Declaration of Conformity (DoC), an example of each DoC for the subject product/system must be included in this Annex. (For additional information on regulatory compliance refer to CORP-ENG-0004.) Below is an example of Declaration of Conformity for the product/system. - Page 27 Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve product might be used in numerous application under a wide variety of industrial service conditions.
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