Kerotest EV-11 Manuale utente

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

1 OF 25

KEROTEST FACTORY EV-11 GATE VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Table of Contents

1SCOPE .........................................................................................................................................................................................3

2PRODUCT DESCRIPTION AND FEATURES .....................................................................................................................................3

3CAUTIONS AND WARNINGS ........................................................................................................................................................4

4VALVE IDENTIFICATION...............................................................................................................................................................4

5VALVE COMPONENTS .................................................................................................................................................................5

6DIMENSION DATA.......................................................................................................................................................................6

7ACCESSORIES ..............................................................................................................................................................................7

7.1 LOCKING DEVICE .................................................................................................................................................................................7

7.2 POSITION INDICATOR ...........................................................................................................................................................................8

7.3 HANDWHEEL ......................................................................................................................................................................................9

7.4 VITON SEALING STIRRUP.......................................................................................................................................................................9

7.5 STEM DRIVE EXTENSIONS......................................................................................................................................................................9

7.6 COATING ...........................................................................................................................................................................................9

8FACTORY TESTING.....................................................................................................................................................................10

9STORAGE, HANDLING, AND INSTALLATION...............................................................................................................................11

9.1 STORAGE .........................................................................................................................................................................................11

9.2 HANDLING .......................................................................................................................................................................................11

9.3 INSTALLATION...................................................................................................................................................................................11

10 OPERATION...............................................................................................................................................................................13

10.1 GENERAL VALVE OPERATION ...............................................................................................................................................................13

10.2 OPERATING TORQUE..........................................................................................................................................................................13

10.3 CRITICAL TORQUE..............................................................................................................................................................................13

10.4 PRESSURE DROP................................................................................................................................................................................13

11 REPAIR SERVICE ........................................................................................................................................................................14

11.1 PRODUCT BOLT TORQUES ...................................................................................................................................................................14

11.2 SHUT-OFF OR SEAT LEAK ....................................................................................................................................................................14

11.3 EXTERNAL STEM PACKING LEAK AND REPLACEMENT PROCEDURE................................................................................................................14

11.4 STIRRUP SERVICING PROCEDURE ..........................................................................................................................................................17

11.5 EXTERNAL BONNET SEAL LEAK .............................................................................................................................................................19

11.6 USE OF SERVICE BOLT CLAMPS FOR BONNET LEAKS..................................................................................................................................19

11.7 BROKEN STEMS.................................................................................................................................................................................20

11.8 SERVICE PARTS ORDERING PROCEDURE .................................................................................................................................................21

APPENDIX A: BROKEN BOLT REMOVAL ..............................................................................................................................................22

INFORMATION AND BACKGROUND .................................................................................................................................................................22

EV-11 BOLT REMOVAL PROCEDURE...............................................................................................................................................................22

APPENDIX B: BONNET SCREW TIGHTENING PROCEDURE ...................................................................................................................23

INCREMENTAL TIGHTENING PROCEDURE:.........................................................................................................................................................23

CROSS-PATTERN TIGHTENING SEQUENCES:......................................................................................................................................................23

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

2 OF 25

Table of Tables

Table 1: Material Specifications ...........................................................................................................................................................5

Table 2: Valve Dimensions and Data ....................................................................................................................................................6

Table 3: Locking Device Options...........................................................................................................................................................7

Table 4: Handwheel Options ................................................................................................................................................................9

Table 5: Operating Square Extension ...................................................................................................................................................9

Table 6: Minimum Production Test Parameters .................................................................................................................................10

Table 7: Valve Torque Values .............................................................................................................................................................13

Table 8: Pressure Drop and Cv............................................................................................................................................................13

Table 9: Assembly Torque Values.......................................................................................................................................................14

Table 10: Packing Repair Kit Part Numbers ........................................................................................................................................16

Table 11: Disc Segment and Stirrup Service Kit Part Numbers............................................................................................................17

Table 12: Bolt Replacement Support Clamps......................................................................................................................................19

Table 13: Bonnet Bolt, Stem, and Seal Part Numbers.........................................................................................................................20

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 ..........................................................................................................................................12

Figure 6: Stem Packing Diagram .........................................................................................................................................................15

Figure 7: Stirrup Servicing ..................................................................................................................................................................18

Figure 8: Support Clamp Installations.................................................................................................................................................19

Figure 9: Bonnet Broken Bolt Diagram ...............................................................................................................................................22

Figure 10: Example Pattern for 12-Bolt Tightening Sequence.............................................................................................................24

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

3 OF 25

1 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:

•Low maintenance

•No gland tightening

•No lubrication required

•Full opening and compatible for hot tapping

•Bubble tight shut-off

•Low operating torque

•Field repairable

•Soft and resilient elastomer seat

•No conventional seats to damage –a one-piece rubber seal surrounds the top and sides of

the gate

•Valve body has a smooth bottom with no cavity to accumulate debris

•Bidirectional installation and operation

The intent of this manual is to acquaint our customers with installation, operation, and

maintenance/service repair techniques for EV-11 Gate Valves. EV-11 Gate Valves are cast steel

valves with a rubber sealing seat used in natural/fuel gas distribution pipelines and are available in

NPS 2 through NPS 12, in ASME/ANSI Pressure Classes 150 and 300 and intermediate pressure

rating of 500 CWP maximum operating pressure (psi). The valve end connections are welded,

flanged, and weld-by-flange. Temperature limits of the valves are -20°F to 300°F for Viton®

seals

and -20°F to 200°F for Buna seals with allowable pressures as shown in Figure 1.

Viton®is a registered trademark of The Chemours Company

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

4 OF 25

Figure 1: EV-11 Pressure-Temperature Chart

3 CAUTIONS AND WARNINGS

Within this document, you will see the following symbols.

•General Advisory Marking - for information or operational procedures, order of

operation, etc.

•Caution Marking –note designates an action or step that may result in personal injury

or death or equipment/property damage. Personnel performing activities should be

fully aware of the hazards and take necessary steps to prevent any injuries, damage,

or unsafe operating/repair conditions.

4 VALVE IDENTIFICATION

Each valve will have an identification nameplate attached with the following information:

•Manufacturing company

•ASME/ANSI pressure class, or intermediate pressure rating (such as 500 WOG or CWP

)

•Temperature and pressure ratings

•Body and stem materials

•Serial number

•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.

Serialization marking on tags began September 2014. As of February 2018, the serial number is also

stamped directly on the body of the valve

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

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

Steel, ASTM A216, Grade WCB or Ductile Iron

Disc Segments

Ductile Iron, ASTM A536

Seal Member (Stirrup)

Buna-N or Viton

Spreader

Ductile Iron, ASTM A536

Gland Bushing Retainer

Steel

Stem

Ni. PI. Steel or 416 Stainless Steel on later valves

Stem Nut

Manganese Bronze

Gland Bushing

Bronze

Weather Seal O-Ring

Buna-N or Viton

Bonnet O-Ring

Buna-N or Viton

Stem Seal O-Ring

Buna-N or Viton

Bushing Seal O-Ring

Buna-N or Viton

Operating Square Cap Screw or Nut

Alloy Steel

Bonnet Cap Screw

Alloy Steel, ASTM A193, Grade B7

Operating Square

Ductile Iron, ASTM A536

Thrust Washer

Bronze

Disc Segment Cap Screw

Alloy Steel

Washer

Brass (8" and smaller), Stainless Steel (NPS 10 and 12)

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

6 OF 25

6 DIMENSION DATA

All dimensions are in inches

Table 2: Valve Dimensions and Data

NPS

Size A

B +

FLG

B +

WE x FLG C

E +

Bore

Bolt

Hole Dia.

No. of

Bolts

Hand

Wheel OD

Wgt

FLG

Wgt

WE x FLG

TurnsTo

Class 150–285 MOP (Face-to-face per ANSI B16.5 and B16.10 CL 150)

9.75

7.00

8.50

7.75

6.00

3.63

0.75

4.75

0.75

12.13

8.00

11.13

9.56

7.50

5.00

0.96

6.00

0.75

14.5

13.75

9.00

12.00

10.50

9.00

6.19

0.94

7.50

0.75

18.5

18.50

10.50

15.88

13.19

11.00

8.50

1.00

9.50

0.88

166

140

160

20.3 ^

22.38

11.50

16.50

14.00

13.50

10.63

1.13

11.75

0.88

308

278

291

25.8 ^

27.25

13.00

18.00

15.50

16.00

12.75

1.19

14.25

1.00

644

500

572

32.5

30.75

14.00

19.75

16.88

19.00

15.00

1.25

17.00

1.00

760

687

724

38.5

500 CWP / Class 300–740 psi MOP (Face-to-face per ANSI B16.5 and B16.10 CL 300)

9.75

8.50

6.50

3.63

0.88

5.00

0.75

12.13

11.13

8.25

5.00

1.13

6.63

0.88

14.5

13.75

12.00

10.00

6.19

1.25

7.88

0.88

18.5

18.50

15.88

12.50

8.50

1.44

10.63

0.88

200

143

178

20.3 ^

22.38

16.50

15.00

10.63

1.63

13.00

1.00

375

278

335

25.8 ^

27.25

18.00

17.50

12.75

1.88

15.25

1.13

689

500

599

32.5

30.75

19.75

20.50

15.00

2.00

17.75

1.25

900

687

785

38.5

+B (FLG & WE x FLG) and E dimensions include .062 (1/16) inch raised face thickness.

^ Valves produced prior to 1986 will have single ACME stem threads and the number of turns will be double.

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

7 OF 25

7 ACCESSORIES

7.1 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.

Table 3: Locking Device Options

Valve

Size NPS

Valves built AFTER

9/1/1994

Valves built BEFORE

9/1/1994

54015672

54007513

3 –4

54015680

54008180

6 –8

54015698

54008446

10 –12

54015706

54014261

To install this device, perform the following (see Figure 3);

1. Remove nut which holds operating square in place and replace with swivel assembly

(1). Keep the lock washer (2) on the assembly.

2. Place cap (3) on swivel assembly (1).

3. Attach a padlock (not furnished) to swivel assembly to complete locking device.

Figure 3: Locking Device

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

8 OF 25

7.2 Position Indicator

Figure 4: 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.

3. Thread in gland bushing retainer studs (3)

until the bottom is in tapped bonnet hole.

Install heavy hex nuts (4) and tighten to

torque specified in Table 9.

4. Temporarily install the operating square (9)

and open valve fully. Remove operating

square.

5. Thread indicator collar (5) on indicator stem

(1) until the hole in the indicator collar aligns

with the "0" position on the indicator plate

(2A). Place indicator pin (6) through indicator

plate (2A) and drive into the hole in the

indicator collar (5) with a soft hammer.

6. Thread one jam nut (7) on each gland

bushing retainer stud (3). Place top plate (8)

over stem and gland bushing retainer studs.

Thread a second jam nut (7) on each gland

bushing retainer stud and then position the

top plate (8) over the upper stem turndown,

locking in the position with the four jam nuts

(7).

7. Place the operating square (9) on the stem

(1).

8. Thread swivel assembly (11) through washer

(10) into stem (1).

9. Place cap (12) over swivel assembly (11) and

insert locking pin (13) through hole in swivel

assembly.

10.To complete the locking device assembly,

attach a padlock (not furnished) to the locking

pin.

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

PAGE:

9 OF 25

7.3 Handwheel

If required, the 2” operating square may be removed and replaced with a handwheel.

Table 4: Handwheel Options

Valve

Size

NPS

Part Numbers for Given Handwheel Diameters (inches)

24**

30**

72530140

72530165

72530173

72530181

54003314

72530199

54003777

72530199

** for valves built prior to 9/1/1994

7.4 Viton Sealing Stirrup

Class 150 and 500 CWP rated EV-11 valves come standard with Buna-N stirrup seals. If

a customer requires the performance of a Viton®stirrup, these may be ordered at the

time of valve purchase or may be installed in the field by following Section 11.4. Contact

Kerotest for further details.

7.5 Stem Drive Extensions

EV-11 valves may require a permanently mounted stem extension for ease of operation.

Kerotest offers a valve connecting coupling along with a top operator that a customer

may join with 1-1/2 pipe, cut to the required length and welded to the fittings below.

Table 5: Operating Square Extension

Catalog No

Part Number

Description

9898-35

88392311

Top Operator

9898-34

72792856

Bottom Coupling

7.6 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.

The standard two component, high solids epoxy coating is generally applied 4 to 8 mils

dry film thickness (DFT) unless specified by the customer.

If a valve appears corroded prior to installation, particularly on the internal components,

contact Kerotest to determine if the valve can be installed.

EV-11 GATE VALVE

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

NO.:

K-1479

REV.:

DATE:

28OCT2021

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.

Table 6: Minimum Production Test Parameters

Table 6a: Hydrostatic Shell Test

Valve Size

NPS

Class 150 (285 psi MOP)

500 psi CWP

Class 300 (740 psi MOP)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

2 –4

450

875

1125

6 –10

450

875

1125

450

875

1125

Table 6b: Hydrostatic Seat Test *

Valve Size

NPS

Class 150 (285 psi MOP)

500 psi CWP

Class 300 (740 psi MOP)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

2 –4

315

550

815

6 –10

315

550

815

315

550

815

* Time Listed Per Each Side

Table 6c: Air Shell and Air Seat ** Test

Valve Size

NPS

Class 150 (285 psi MOP)

500 psi CWP

Class 300 (740 psi MOP)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

Time

(minutes)

Pressure

(psig)

2 –4

80 –100

6 –12

80 –100

** Time Listed Per Each Side

The above tests equal or exceed those valve tests required by API 6D.

Note: valves built before changes to US CFR in July 2006 were rated and tested as follows:

Class 150 –275 psi MOP

Class 300 –720 psi MOP

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