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Kerotest EV-11 Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Table of Contents

1
SCOPE ......................................................................................................................................................................................... 3
2
PRODUCT DESCRIPTION AND FEATURES ..................................................................................................................................... 3
3
CAUTIONS AND WARNINGS ........................................................................................................................................................ 4
4
VALVE IDENTIFICATION ............................................................................................................................................................... 4
5
VALVE COMPONENTS ................................................................................................................................................................. 5
6
DIMENSION DATA ....................................................................................................................................................................... 6
7
ACCESSORIES .............................................................................................................................................................................. 7
7.1
................................................................................................................................................................................. 7
7.2
7.3
...................................................................................................................................................................................... 9
7.4
V
7.5
7.6
........................................................................................................................................................................................... 9
8
FACTORY TESTING ..................................................................................................................................................................... 10
9
STORAGE, HANDLING, AND INSTALLATION ............................................................................................................................... 11
9.1
......................................................................................................................................................................................... 11
9.2
....................................................................................................................................................................................... 11
9.3
................................................................................................................................................................................... 11
10
OPERATION ............................................................................................................................................................................... 13
V
.......................................................................................................................................................................... 13
.............................................................................................................................................................................. 13
................................................................................................................................................................................ 13
11
REPAIR SERVICE ........................................................................................................................................................................ 14
................................................................................................................................................................................. 20
APPENDIX A: BROKEN BOLT REMOVAL .............................................................................................................................................. 22
APPENDIX B: BONNET SCREW TIGHTENING PROCEDURE ................................................................................................................... 23
EV-11 GATE VALVE
INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL
KEROTEST FACTORY EV-11 GATE VALVE
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NO.: K-1479
REV.: 4
DATE: 28OCT2021
PAGE: 1 OF 25

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Summary of Contents for Kerotest EV-11

  • Page 1: Table Of Contents

    REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 1 OF 25 KEROTEST FACTORY EV-11 GATE VALVE INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Table of Contents SCOPE ......................................3 PRODUCT DESCRIPTION AND FEATURES ............................. 3 CAUTIONS AND WARNINGS ................................ 4 VALVE IDENTIFICATION ................................
  • Page 2 Table 14: Bonnet Bolt Removal Chart ..............................22 Table 15: Cross-Pattern Tightening Sequences ........................... 23 Table of Figures Figure 1: EV-11 Pressure-Temperature Chart ............................4 Figure 2: Valve Components ................................. 5 Figure 3: Locking Device ..................................7 Figure 4: Position Indicator .................................. 8 Figure 5: Bolt Torquing Pattern Examples ............................

  • Page 3: Scope

    This installation, operation, and maintenance manual defines the procedures for proper use and common repairs on the EV-11 line of soft seat gate valves made by Kerotest Manufacturing Corp. This manual is only to be used by personnel familiar with this guide and operation of the EV-11. 2 PRODUCT DESCRIPTION AND FEATURES Below are some of the features of the Kerotest EV-11 gate valves: •...

  • Page 4: Cautions And Warnings

    • Date of manufacture • EV-11 (name of the product line) Kerotest refers to valves marked 500 WOG (Water, Oil, Gas) and 500 CWP (Cold Working Pressure) as equivalent terms. This rating indicates the maximum operating pressure in psi at temperatures up to 100°F.

  • Page 5: Valve Components

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 5 OF 25 5 VALVE COMPONENTS Figure 2: Valve Components Table 1: Material Specifications Item Part Name Material Body Steel, ASTM A216, Grade WCB Bonnet...

  • Page 6: Dimension Data

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 6 OF 25 6 DIMENSION DATA All dimensions are in inches Table 2: Valve Dimensions and Data Bolt No. of Hand Turns To WE x FLG C...

  • Page 7: Accessories

    7 ACCESSORIES Locking Device EV-11 valves can be ordered with a locking device installed or it may be installed by customers. This locking device prevents unauthorized users from changing the valve state (opened or closed) with a customer supplied lock. When installed, the lock and/or the cap may turn, but no torque is applied to the stem.

  • Page 8: Position Indicator

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 8 OF 25 Position Indicator 1. Install indicator stem (1) as described in the applicable steps in Sections 11.3 and 11.4. 2. Install gland bushing retainer (2) with indicator plate (2A) attached.

  • Page 9: Handwheel

    Bottom Coupling Coating The EV-11 valve is ordered with either a zinc chromate gray primer coating or a two- component, high solids green epoxy coating. The gray primer will provide a limited indoor non-exposed protection against corrosion. It is the responsibility of the customer to provide long duration corrosion protection coverings or systems once installed per CFR 192 Subpart I.

  • Page 10: Factory Testing

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 10 OF 25 8 FACTORY TESTING To be certain that all valves shipped from the factory are bubble tight, they are subjected to the following tests.

  • Page 11: Storage, Handling, And Installation

    For heavy large valves, use rated lifting slings or straps. The valve or valve assembly must not be lifted by the operating square or handwheel. Most EV-11 valves with the operating square facing up are top-heavy and can shift or rotate in the sling.

  • Page 12: Figure 5: Bolt Torquing Pattern Examples

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 12 OF 25 • Bolting and gasketing practice conforming to ASME B16.5 is suggested. The bolts and gaskets used on installation must be selected to match operating conditions, temperature, pressure and medium.

  • Page 13: Operation

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 13 OF 25 10 OPERATION 10.1 General Valve Operation • Standard valves are equipped with a 2” operating square and can be operated with an adaptor tool or wrench.

  • Page 14: Repair Service

    Sales Representative. 11.1 Product Bolt Torques The table below shows the nominal torque values for the screws used in an EV-11 valve and are referenced in various service conditions discussed. Table 9: Assembly Torque Values...

  • Page 15: Figure 6: Stem Packing Diagram

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 15 OF 25 11.3.1 Condition 1: Valve Under Pressure Using Figure 6, open valve fully. Apply an additional opening torque equal to the operating torque to stop gas flow between the thrust washer (10) and the stem shoulder.

  • Page 16: Table 10: Packing Repair Kit Part Numbers

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 16 OF 25 Lubricate new O-rings and gland bushing with a suitable valve lubricant. Install new gland bushing O-rings (7) on the gland bushing (6).

  • Page 17: Stirrup Servicing Procedure

    Table 9. Note: Kerotest's current policy is to supply these items (stirrup, spreader, disc segments, disc seal washers, and hex socket head cap screws) as an assembly only, due to past cases of improper assembly and updated designs.

  • Page 18: Figure 7: Stirrup Servicing

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 18 OF 25 8. Insert the stem nut (4) into the pocket of the spreader (3) and thread the disc assembly onto the valve stem. Position the disc assembly approximately halfway up the stem.

  • Page 19: External Bonnet Seal Leak

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 19 OF 25 11.5 External Bonnet Seal Leak Another possible cause for an external leak could be a failure at the seal between the valve bonnet and body.

  • Page 20: Broken Stems

    Note: Kerotest part numbers for bonnet bolts are listed in Table 13. After replacing all of the existing bonnet bolts, if the leakage has stopped, the repair is complete, and the valve is ready for service.

  • Page 21: Service Parts Ordering Procedure

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 21 OF 25 11.8 Service Parts Ordering Procedure Proper identification of replacement parts or valves will improve deliveries and eliminate order-processing errors. When ordering replacement parts and the service part numbers are not identified in the reference tables, first identify the part from the illustration in the introduction.

  • Page 22: Appendix A: Broken Bolt Removal

    A good quality center punch will be needed. Bolts should be punched and drilled as close to the center of the bolt as possible. Kerotest offers a Bolt Repair Tool Kit, Part Number 72631146. This kit includes all necessary punches, drill bits and easy-outs for removing bonnet bolts on valve sizes NPS 2 through 8.

  • Page 23: Appendix B: Bonnet Screw Tightening Procedure

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 23 OF 25 APPENDIX B: BONNET SCREW TIGHTENING PROCEDURE When tightening the bonnet screws or all-thread and nuts, use an incremental torque tightening procedure in the cross-pattern outlined below (taken from ASME PCC-1 – 2010, Table 2 and...

  • Page 24: Figure 10: Example Pattern For 12-Bolt Tightening Sequence

    NO.: K-1479 EV-11 GATE VALVE REV.: 4 INSTALLATION, OPERATION, AND DATE: 28OCT2021 MAINTENANCE MANUAL PAGE: 24 OF 25 Figure 10: Example Pattern for 12-Bolt Tightening Sequence...
  • Page 25 Kerotest Manufacturing Corp. 5500 Second Avenue Pittsburgh, PA 15207 Telephone: (412) 521-4200 www.kerotest.com sales@kerotest.com Prior Document Releases This procedure was previously distributed as “Kerotest EV-11 Gate Valve Operations Manual” Date Description 17NOV1993 06MAY1996 15MAR1999 Retyped. Various editorial corrections throughout manual...

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