Fasani Bolted Bonnet Globe Valves

VALVE STORAGE

Preparation and preservation for shipment

All valves are properly packed to protect parts subject to deterioration during transportation and storage on site. The following precautions should be taken:

1. The valves must be packed with the disc in the closed position.
2. Flanged sealing valves: Flange sealing surfaces (raised faces) must be protected with suitable protective grease. End faces must be protected with plastic or wooden discs fixed with straps.
3. Buttweld end valves: Weld ends must be protected with suitable protective material like Deoxaluminite and closed with plywood or plastic discs fixed by straps.

2. All actuated valves must be carefully and securely palletized or crated to ensure that actuator parts (especially pneumatic piping or accessories) do not extend beyond the skid/crate.

3. The type of packing must be defined in the Customer's Order and must be appropriate for safe transportation to the final destination and eventual conservation before installation.

Handling requirements

A - Packed valves

Crates: Lifting and handling of packed valves in crates should be done using a fork lift truck with appropriate fork hitches.

Cases: Lifting of packed valves in cases should be done using the marked lifting points and at the center of gravity position. Transportation of all packed material must be carried out safely and following local safety regulations.

B - Unpacked valves

1. Lifting and handling of these valves must be done using appropriate means and respecting carrying limits. Handling must be done on pallets, protecting machined surfaces to avoid damage.

2. For valves of large dimensions, sling and load hooking must be carried out using appropriate tools (brackets, hooks, fasteners, ropes) and load balancing tools to prevent falling or movement during lifting and handling.

INSTALLATION

Preparation before installation

1. Carefully remove the valve from the shipping package (box or pallet) avoiding any damage to the valve or its actuator, instrumentation, or pneumatic/hydraulic systems.

2. Valves are shipped with ends protected by caps and a thin layer of protective grease. Before installation, remove caps, clean carefully, and degrease both surfaces with a solvent. Clean the inside of the valve using an air line. Ensure no solid objects (wood, plastic, packing materials) are 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 intended service and as specified.

4. Define the preferred mounting orientation with respect to system pressure. Identify the upstream side (high pressure) and downstream side (low pressure) using the arrow on the body.

WARNING: Verify that the direction of flow in the line corresponds to the arrow indicated on the valve body.

Refer to the actuator user manual for actuator preparation.

Storage and preservation before installation

If valves are to be stored before installation, storage must be carried out in a controlled way according to the following criteria:

1. Valves must be stored in a closed, clean, and dry storage room.
2. The disc must be in the closed position, and end faces must be protected with plastic or wooden discs fixed with straps. Keep original protection if possible.
3. Periodical checks must be carried out in the storage area to ensure the above conditions are maintained.

For actuated valves, refer to the actuator manual for additional warnings.

NOTE: Storage in an open area for a limited period is acceptable only if valves have appropriate packing (cases lined with tarred paper, contents protected with barrier sacks). Do not place consignment packages directly on the ground. Do not expose consignment packages to weather or direct sunlight. Check packaging every two months.

CAUTION: For valve handling and lifting, lifting equipment (fasteners, hooks, etc.) must be sized and selected considering the valve weight indicated in the packing list/delivery note. Lifting and handling must be performed only by qualified personnel. Do not use lifting points on the actuator, if any, to lift the valve; these are for the actuator only. Caution must be taken during handling to avoid passing over workers or areas where a fall could cause damage. Local safety regulations must be respected.

Installation instructions

Globe valves are normally installed in horizontal pipes with vertical stems. They can also be installed in vertical or horizontal pipes with stems other than vertical, which may require special construction depending on valve size, service condition, material, and operator type.

For correct operation, Fasani recommends installing and orienting the valve according to Figure 2. Deviations from these positions may cause incorrect valve operation and/or rapid deterioration.

Unless otherwise recommended by Fasani, the valve should be installed with the disc in the closed position to prevent damage to the seat ring during installation. Special care should be taken with 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 valves during installation MUST follow the same criteria and instructions as described in "Handling requirements" and "Storage and preservation before installation".

Buttweld valves

Position the valve and check alignment with the pipe, then proceed with welding according to the applicable welding procedure.

Flanged valves

Place the valve between the two flanges of the pipe and position the seal gasket between the valve flange and the pipe flange. Assemble the valve to the pipe using bolts, tightening them progressively in a crossing pattern to the requested torque value indicated by the plant's Engineering Company.

IMPORTANT: After valve installation and before line testing, perform accurate cleaning of the lines to eliminate dirt and foreign objects that could compromise seat/disc tightness and valve operation.

After valve installation and before line pressurization, perform the following activities:

• Verify tightening of all threaded plugs.
• Tighten the packing bolts.
• Verify the torque of the body-bonnet bolts.
• Fully stroke the valve.
• Remove the paper protecting the stem; grease the stem and bearings.

Refer to Table 1 (Bolt torque figures for body-bonnet flanged connections) and Table 2 (Bolt torque figures for packing bolts).

Refer to the actuator instruction manual for commissioning and start-up procedures.

Valve verification before start up

1. Tighten the packing just enough to prevent stem leakage. Over-tightening reduces packing life and increases operating torque. Packing bolt torque figures can be calculated as indicated in Table 1.
2. Check valve operation by stroking it to "full open" and "full close".

IMPORTANT: If the piping system is pressurized with water for testing, and the system has been shut down after testing for a long time, adopt the following recommendations:

• Use a corrosion inhibitor with water to pressurize the piping system.
• After testing, depressurize the piping system and completely drain the test water.

MAINTENANCE

Fasani bolted bonnet globe valves are designed for minimum maintenance. This manual describes on-site repairs such as:

• Packing maintenance
• Body/bonnet flange gasket maintenance

All other repairs should be performed by Emerson.

Packing maintenance

If leakage is observed through the packing, tighten the gland nuts slowly and evenly until leakage stops.

CAUTION: Do not over-tighten packing gland nuts, as this will increase the torque required to operate the valve. When tightening the gland nut, use half-turn increments until leakage stops.

Refer to Figure 4.

To replace the packing, proceed as follows:

1. Open the valve completely 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 worn-out packing using a hooking wire.
5. For better tightness, accurately clean the stem and stuffing box, ensuring no scratches or seizing signs.
6. Repack by placing one ring at a time around the stem inside the stuffing box, ensuring correct orientation. Press into the bottom (refer to Figure 3).
7. When the stuffing box is filled, replace the gland (9) and gland flange (10) in their original positions.
8. Tighten gland nuts according to Table 2 (Bolt torque figures for packing bolts).
9. Cycle the valve.
10. Pressurize the line.
11. If leakage is detected, tighten the gland nuts slowly and evenly until leakage stops.

Body-bonnet flange gasket maintenance

WARNING: Before starting any maintenance, depressurize, drain, and vent the line. Check that valves are not hot; disconnect any electrical power supply. Failure to do so may cause serious personal injury and/or equipment damage.

1. Before replacing the gasket, carefully clean the flange surfaces.
2. Place the gasket in its seat and carefully position the bonnet flange, ensuring it is perfectly parallel to the gasket face. Do not use bolts to achieve this alignment.
3. For vertical coupling (valve with horizontal stem), position the bonnet flange using a hoist. Secure it with four bolts placed at 90° intervals and tighten them until the flanges are perfectly coupled in their seat. Insert all other bolts.
4. During tightening, ensure flange faces remain perfectly parallel.
5. Tighten bolts in the sequence indicated in Figure 5. For the first turn, use approximately 1½ of the maximum torque listed in Table 1. For better joint performance, tighten all bolts again after the equipment has been pressurized.

TROUBLESHOOTING GUIDE

OPERATIONS INSTRUCTIONS

The following instructions will help provide a satisfactory and long-life service of the bolted bonnet globe valves:

1. Make sure to perform periodic valve verification as described in the next paragraph.
2. In case of actuated valves, always follow the specific instructions given by the actuator's manufacturer.
3. Never change the setting of torque and/or limit switches which have been carefully set during the final test at the workshop.

Periodic valve verification during service

A - Normal check

1. Verify monthly that there is no leakage from the packing or in the body/bonnet area. If leakage is detected from the packing, tighten nuts according to the procedure described in the Maintenance Section. If leakage does not stop, follow the procedure for packing maintenance. If leakage is detected from the body/bonnet, tighten nuts as indicated in Table 1. If leakage does not stop, follow the maintenance procedure for body/bonnet gasket replacement.
2. Every 2/3 months, depending on operating frequency, verify the greasing of bearings and stem thread.
3. For actuated valves, in addition to the above, refer to the warnings in the actuator manual.

B - Preventive actions

1. Every 3 months, verify the tightness of gland bolts.
2. Every 6 months for motorized valves and every 8 months for hand-operated valves, grease stem and bearings.
3. Every 12 months, check the travel of the gland follower, setting a new packing when the end of the travel is approaching.
4. Every 4 years, disassemble critical service valves and/or actuated valves, verifying sealing surfaces and lapping them again if necessary. Substitute the bonnet gasket and packing, and grease the stem.
5. For the actuator, proceed as indicated in its maintenance manual.

TABLES

TABLE 1 - BOLT TORQUE FIGURES FOR BODY-BONNET FLANGED CONNECTIONS

(Corresponding to approx. 40% of yield strength on dry steel surface)

TABLE 2 - Torque (Nm) for packing bolts

GREASES AND SPECIAL TOOLS

Greases

To lubricate bearings on manual and gearbox operated valves, Emerson suggests using the grease AGIP GRMUEP2 or an equivalent product, as shown in the following table:

TABLE 3 - GREASE AND LUBRICANT LIST

For stem thread lubrication, use grease SIGNAL CEP 30 produced by Viscol. Alternatives include CEPLATTYN 300 (REINER-FUCHS) or GRAFLOSCON (KLUBER). Grease with more than 25% pure graphite content (carbon 98%), granulometry 5 microns, without abrasive agents can also be used.

For actuator lubrication, refer to the relevant manual.

Special tools

No special tools are required for the maintenance operations described in this manual.

VALVE REMOVAL

If the valve needs to be removed from the line for extraordinary reasons, the user should ensure the following:

1. The valve is depressurized, drained, and vented.
2. The pipe shall be cut as far away from the valve as possible (only for welded valves).

FIGURES

FIGURE 1: Valve slinging

Diagram showing recommended valve slinging positions.

FIGURE 2: Installation positions recommended

Diagram illustrating recommended installation positions for globe valves, indicating flow direction and maximum angle deviations.

FIGURE 3: Packing rings

Diagram showing packing ring types: 1 = Braided graphite rings, 2 = Die formed graphite (4 rings).

FIGURE 4: Gland and gland flange components

Diagram showing components related to gland tightening and packing replacement, with numbered parts.

FIGURE 5: Bolt tightening sequence

Diagram illustrating the recommended sequence for tightening body-bonnet flange bolts.

General Disclaimer

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.

Fasani 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. While every effort has been made to ensure 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 Emerson's terms and conditions, which are available upon request. Emerson reserves the right to modify or improve product designs or specifications at any time without notice.

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