Metso GW Series Manuale operativo e di manutenzione

Control Valves

Globe 3-way, Diverting & Mixing type

Series GW

Installation, Maintenance and

Operating Instructions

4 GV 74 en • 11/2013

24 GV 74 en

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about safe handling and operation of the valve.

If you require additional assistance, please contact the manufacturer or manufacturer's representative.

Addresses and phone numbers are printed on the back cover.

See also www.metso.com/valves for the latest documentation.

SAVE THESE INSTRUCTIONS!

Subject to change without notice.

All trademarks are property of their respective owners.

Table of Contents

1 GENERAL...............................................................3

1.1 Scope of the manual ............................................3

1.2 Valve construction ................................................3

1.3 Valve markings .......................................................3

1.4 Technical specifications ......................................4

1.5 Valve seat leakage class ......................................4

1.6 Recycling and disposal ........................................4

1.7 Safety precautions ..............................................4

2 TRANSPORTATION, RECEPTION AND

STORAGE...............................................................4

3 VALVE INSTALLATION .........................................5

3.1 General ......................................................................5

3.2 Installation into the pipeline .............................5

3.3 Control valve assembly .......................................5

3.4 Valve insulation......................................................5

4 MAINTENANCE ....................................................5

4.1 General ......................................................................5

4.2 Gland packing adjustment.................................6

4.3 Replacing the gland packing ..........................6

4.4 Replacing the trim and body reassembly ....6

5 TESTING THE VALVE ............................................7

6 REMOVAL & MOUNTING THE ACTUATOR ..........8

7 TOOLS ...................................................................9

8 ORDERING SPARE PARTS ....................................9

9 EXPLODED VIEW AND PARTS LIST ...................10

10 DIMENSIONS AND WEIGHTS .............................11

10.1 Valve GW................................................................ 11

10.2 Actuators VD, VC................................................. 12

11 TYPE CODE .........................................................16

4 GV 74 en 3

1 GENERAL

1.1 Scope of the manual

This manual provides essential information on series GW,

Globe 3-way Diverting or Mixing type installed sliding stem

valves. Actuators and positioners are only discussed briefly.

Refer to the individual manuals for further information on

their installation, operation and maintenance.

1.2 Valve construction

Series GW valves are flanged (weld end available) 3-way

sliding stem control valves. Two seat rings and the plug

with stem is a module accessible through the bottom bon-

net opening (bottom entry) of the body.

GW valves are available both diverting and mixing flow for

a most primary application is in temperature control.

Our standard design combines the benefits of more strong

guiding with a top and bottom seat rings, and the solid cylin-

drical plug makes strong support to ensure valve alignment.

GW valves are available both cylindrical and V-port plug trim

depending from the application, standard is cylindrical plug.

This series are available to provide a series of reduced trim

and the standard seat tightness is class II, optional trims can

meet to class III and IV, ANSI/FCI 70.2.

The detailed structure is revealed by the type code shown

on the valve identification plate. The type code is explained

in Section 11.

1.3 Valve markings

The body markings are: manufacturer's trademark, nominal

size, pressure rating and material of the body. The valve has

an identification plate attached to it, see Fig. 2.

Markings on the identification plate:

1. Type designation (Valve code)

2. Size, Rating

3. Cv

4. Body material

5. Plug, Stem material

6. Seat material

7. Temp. min./max.

8. Maximum (shut-off) pressure

9. Valve manufacturing date

10. Tag No.

11. Serial No.

NOTE:

Selection and use of the valve in a specific application

requires close consideration of detailed aspects. Due to the

nature of the product, this manual cannot cover all the indi-

vidual situations that may occur when the valve is used.

If you are uncertain about use of the valve or its suitability

for your intended purpose, please contact Metso Automa-

tion for more information.

Fig. 1 Construction of the Neles GW series 3-way Valve

Mixing type Diverting type

Fig. 2 Identification(name) plate example

44 GV 74 en

1.4 Technical specifications

Face-to-face length: ANSI/ISA-75.08.01, 03, 05 &

ANSI/ISA-75.08.06 (Long)

Body rating: Class 150 to Class 600

PN 10 to PN 40

Max. pressure differential:

acc. to pressure class

Temperature range: -30° to +450 °C (depending on the

body materials and bonnet type)

Flow direction: indicated by an arrow on the body

Actuator mounting: threaded bonnet with yoke nut or

bolted yoke

Stem connection: clamp with bolts/nuts

Dimensions: see Section 10

Weights: see Section 10

Note that the max. shut-off pressure is based on the mechan-

ical maximum differential pressure at ambient temperature.

You must always observe the fluid temperature when decid-

ing on applicable pressure values. When selecting a valve

you must also check the noise level, cavitation intensity, flow

velocity, actuator load factor, etc. using Nelprof.

1.5 Valve seat leakage class

The valve follows the seat leakage classifications of ANSI/

FCI 70-2 requirement.

1.6 Recycling and disposal

Most valve parts can be recycled if sorted according to

material. Most parts have a material marking. A material list

is supplied with the valve. In addition, separate recycling

and disposal instructions are available from the manufac-

turer. A valve can also be returned to the manufacturer for

recycling and disposal for a fee.

1.7 Safety precautions

2 TRANSPORTATION, RECEPTION AND

STORAGE

Check the valve and the accompanying devices for any

damage that may have occurred during transport.

Store the valve carefully before installation, preferably

indoors in a dry place.

CAUTION:

Do not exceed the valve performance limitations!

Exceeding the limitations marked on the valve may cause

damage and lead to uncontrolled pressure release. Dam-

age or personal injury may result.

CAUTION:

Do not dismantle the valve or remove it from the pipe-

line while the valve is pressurised!

Dismantling or removing a pressurised valve will result in

uncontrolled pressure release. Always isolate the relevant

part of the pipeline, release the pressure from the valve

and remove the medium before dismantling the valve.

Be aware of the type of medium involved. Protect yourself

and the environment from any harmful or poisonous sub-

stances. Make sure that no medium can enter the pipeline

during valve maintenance.

Failure to do this may result in damage or personal injury.

CAUTION:

Beware of the plug movement!

Keep fingers, other parts of the body, tools and other

objects out of the open flow port. Leave no foreign

objects inside the pipeline. When the valve is actuated,

the plug functions as a cutting device. Close and detach

the actuator pressure supply pipeline for valve mainte-

nance. Failure to do this may result in damage or personal

injury.

CAUTION:

Protect yourself from noise!

The valve may produce noise in the pipeline. The noise

level depends on the application. It can be measured or

calculated using the Metso Nelprof software. Observe the

relevant working environment regulations in terms of

noise emission.

CAUTION:

Beware of a very cold or hot valve!

The valve body may be very cold or very hot during use.

Protect yourself against cold injuries or burns.

CAUTION:

When handling the valve or the control valve assem-

bly, take its weight into account!

Never lift the valve or control valve assembly by the posi-

tioner, the limit switch or their piping.

Place the lifting ropes securely around the valve body (see

Fig. 3). Damage or personal injury may result from falling

parts.

Fig. 3 Lifting the valve

4 GV 74 en 5

Do not remove the flow port protectors until immediately

before installation of the valve into the pipeline.

The valve is delivered in the closed position. A valve

equipped with a spring-return actuator is delivered in the

position determined by the spring.

3 VALVE INSTALLATION

3.1 General

Remove the flow port protectors and check that the valve is

clean inside.

3.2 Installation into the pipeline

Make sure no foreign particles, such as sand or pieces of

welding electrode, are in the pipeline, they may damage

the sealing surfaces.

The valve has an arrow indicating the flow direction. Install

the valve in the pipeline so that the flow direction of the

valve corresponds to the flow direction marked on the pipe.

The mounting orientation of the valve does not restrict the

operation of the valve, actuator or positioner. You should,

however, avoid installing the valve so that the shaft points

downwards as impurities in the fluid may enter and dam-

age the gland packing. Any leak from the packing may then

damage the actuator. See Fig. 6.

Choose flange gaskets according to the operating condi-

tions.

Do not attempt to correct a pipeline misalignment by

means of flange bolting.

Loads on the valve body from pipeline vibrations can be

reduced by supporting the pipeline properly. Reduced

vibration also increases the lifetime of the positioner.

Where necessary, you can support the valve by the body,

using regular pipe clamps and supports. Do not fasten sup-

ports to the valve or flange bolting or to the actuator, see

Fig. 4.

3.3 Control valve assembly

Check all joints, piping and cables.

Check that the actuator stop screws, positioner and limit

switches are calibrated. Refer to their installation, mainte-

nance and operating manuals.

3.4 Valve insulation

If necessary, the valve may be insulated. Insulation must not

continue above the upper level of the valve body, see Fig. 5.

4 MAINTENANCE

4.1 General

The Neles series GW 3-way valves require no regular main-

tenance. However, check the gland packing for leakage.

This section outlines the maintenance that can be carried

out by the user.

The numbers in parentheses refer to the parts lists and the

exploded views of the valve in Section 9.

CAUTION:

When handling the valve or the control valve assem-

bly, take its weight into account!

Fig. 4 Installing the control valve into pipeline using

supports

Fig. 5 Insulation of the valve

CAUTION:

Observe the safety precautions listed in Section 1.7

before starting work!

CAUTION:

When handling the valve or the control valve assem-

bly, take its weight into account!

NOTE:

If you send the valve to the manufacturer for repair, do not

dismantle it. Clean the valve carefully, including the inside.

For safety reasons, inform the manufacturer of the nature

of the medium when you send the valve.

NOTE:

Always use original spare parts to make sure the valve

functions as intended.

64 GV 74 en

4.2 Gland packing adjustment

In the event of a packing leakage tighten the hexagon nuts

(18) in ¼ turn steps each until the leakage is stopped. Do

not tighten more than necessary.

4.3 Replacing the gland packing

Make sure the valve is not pressurised.

Remove the actuator from the valve stem according

to the instructions given in the actuator manual.

Loosen and remove the hexagon nuts (18).

Remove the gland flange (9b), and gland (9a) up to

the valve stem.

Remove the old packing rings (69) using a pointed

tool, avoid damaging the seal surfaces and valve

stem.

Clean the packing ring counterbore.

Mount the new packing rings one by one into the

packing gland box using the gland as a tool and

mount the gland with hand-tightened nuts.

Fasten the gland with the hexagon nuts (18) and

tighten them.

Check leakage when the valve is pressurised.

Table 1 Required torques for bonnet nuts

4.4 Replacing the trim and body

reassembly

Make sure the valve is not pressurised.

Remove the actuator from the valve stem according

to the instructions given in the actuator manual and

next Section 6.

Turn the body (1) and remove the bottom hexagon

nuts (17).

Remove the bottom flange (26).

Remove the body gasket (65).

Remove the stem (5) and plug (3) sub-assembly.

Avoid from damaging the seating and guiding line

of the plug.

Remove the each two seat rings (7 & 7a) from body

(1) and bottom flange (26) using by fabricated

wrenches to be engaged the seat ring lugs and

adapted to shock wrench.

This is threaded type, if the seat ring is extremely

resistance to removal, the application of heat or pen-

etrating oil will be helpful.

Remove the hexagon nuts (18), gland flange (9b)

and packing gland (9a) from the bonnet (8).

Remove the old packing rings (69).

CAUTION:

Do not dismantle the valve or remove it from the pipe-

line while the valve is pressurised.

Fig. 6 Gland packing

Valve Size Rating

(ANSI)

Bonnet Stud Bolts Required Torques

(± 5 % allowable)

mm in Size Q`ty

Carbon Steel

Bolts St. Steel Bolts

Nm lbf ft Nm lbf ft

25 1 150-300 1/2"-13UNC 4 44 32 35 26

600 1/2"-13UNC 4

40 1.5 150-300 1/2"-13UNC 4 61 45 49 36

600 1/2"-13UNC 4

50 2 150-300 1/2"-13UNC 8 101 74 80 59

600 1/2"-13UNC 8 158 116 123 90

80 3 150-300 3/4"-10UNC 8 176 129 136 100

600 3/4"-10UNC 8 211 155

100 4 150-300 7/8"-9UNC 8 222 163 160 118

600 7/8"-9UNC 8 327 240

150 6 150-300 1"-8UNC 8 316 232 291 214

600 1"-8UNC 12 327 240

200 8 150-300 1-1/4"-8UNC 8 478 351 478 351

600 1-1/4"-8UNC 12 653 479 653 479

250 10 150-300 1-1/4"-8UNC 12 486 356 486 356

600 1-1/4"-8UNC 16 909 667 716 525

Fig. 7 Tightening sequence of the bonnet nuts

NOTE:

The trim set consists of the seat rings, valve plug and stem,

gaskets (for body).

CAUTION:

If using heating devices, insure that proper safety

practices are observed. Such items as the flammability

and toxicity of the controlled substance must be consi-

dered and proper precautions and permissions taken.

4 GV 74 en 7

Clean the body gasket surface.

Insert and tighten the each new top and bottom seat

rings (7 & 7a) into the body (1) and bottom flange

(26).

Insert the stem (5) & plug (3) sub-assembly from top

side into the body very carefully.

Insert the body gasket (65) into bottom side of the

body.

Mount the bottom flange (26) on the body carefully

maintaining alignment with the plug and stem in

the closed

position, so that the arrow on the body and on the

bonnet point in the same direction.

Insert the hexagon nuts (17) into stud (13) and

slightly fasten the nuts.

Insert the packing rings (69) according to above 4.3

Tighten hexagon nuts (17) until plug and seat con-

tact is obtained with proper bolt torque.

5 TESTING THE VALVE We recommend that the valve body is pressure-tested after

the valve has been assembled.

The pressure test should be carried out in accordance with

an applicable standard for the pressure rating. The valve

must be in the open position during the test.

CAUTION:

Do not strongly tighten hexagon nuts (17) at this time.

CAUTION:

Do not reuse the spiral wound gaskets (65), this is

need to be replace each time the valve is disassemb-

led.

CAUTION:

The all related parts (seat ring, plug & stem, bonnet)

must be properly aligned in the body.

NOTE:

If the valve have excess leakage, the plug and seating sur-

face need lapping and cleaning.

Fig. 8 Conventional Cylindrical Plug Trim

Fig. 9 Different trim designs

Cylindrical plug trim V-port plug trim

CAUTION:

Pressure testing should be carried out using equip-

ment conforming to the correct pressure class!

84 GV 74 en

6 REMOVAL & MOUNTING THE

ACTUATOR

The actuator is attached to the valve according to the manual

for actuator with body assembly and plug stem adjustment .

Several types of Metso actuators can be used with suitable

clamps. Refer to the model VD spring-diaphragm and VC

double acting cylinder actuator manuals for further informa-

tion on their installation, maintenance and operation.

A. Actuator removal for Reverse <air to top seat close,

stem retract> actuator (Fig. 10)

Lift up to the valve plug 100% from the seat ring,

using by specified air pressure.

Loosen the stem locknut and socket head screws

(27) and hexagon nuts(28).

Remove the clamp (26).

Shut off and disconnect air supply line.

Support actuator with the suitable lifting device.

Remove the yoke nut.

Remove the actuator from the valve body assembly.

B. Actuator replacement (mounting) for Reverse <air to

top seat close, stem retract> actuator (Fig. 10)

Mount the new or repaired actuator on top of the

bonnet, using a suitable lifting device.

Insert the yoke nut and tightly fasten the yoke by

turning the yoke nut clockwise using tightening

tools.

Connect air line and accessories.

Lift the top stem (18), using by specified air pressure.

Adjustment stem length after clamping the clamp

(26) according to rated travel(stroke) as ‘open’ and

‘close’ position as per pressurizing and depressuriz-

ing the lower diaphragm chamber.

Tighten stem socket head screws (27) and hexagon

nuts (28) with stem locknut.

C. Actuator removal for Direct <air to bottom seat

close, stem extend> actuator (Fig. 10)

Shut off and disconnect the air supply lines and

accessories.

Loosen stem locknut and socket head screws (27)

and hexagon nuts (28).

Remove the clamp (26).

Support actuator with the suitable lifting device.

Remove the yoke nut.

Remove the actuator from the valve body assembly.

D. Actuator replacement (mounting) for Direct <air to

bottom seat close, stem extend> actuator (Fig. 10)

Mount the new or repaired actuator on top of the

bonnet, using a suitable lifting device to setting.

Insert the yoke nut and tightly fasten the yoke by

turning the yoke nut clockwise using tightening

tools.

Connect air line and accessories.

Down the top stem (18), using by specified air pres-

sure.

Adjust stem length after clamping the clamp accord-

ing to rated travel (stroke) as ‘open’ and ‘close’ posi-

tion as per pressurizing and depressurizing the

upper diaphragm chamber.

Tighten socket head screws (27) and hexagon nuts

(28) with stem locknut.

E. Type ‘VC’ Springless Cylinder, Double Acting Actuator

This actuator is springless cylinder, double acting actuator,

can use the 3/8”, 1/2” NPT port according to specified on the

data sheet for all air lines.

Refer to the model VC double acting cylinder actuator man-

uals for further information on their installation, mainte-

nance and operation.

CAUTION:

Beware of the plug movement!

Do not use air pressure higher than what specified on the

identification plate.

CAUTION:

Avoid to turn the valve plug and stem when plug is on

seat ring to prevent the seating line from being dama-

ged.

Fig. 10 VD Actuator

͵ΚΣΖΔΥͲΔΥΚΠΟΒΔΥΦΒΥΠΣ

ͲΚΣΥΠʹΝΠΤΖΤΥΖΞΖΩΥΖΟΕ

΃ΖΧΖΣΤΖͲΔΥΚΠΟΒΔΥΦΒΥΠΣ

ͲΚΣΥΠ΀ΡΖΟΤΥΖΞΣΖΥΣΒΔΥ

4 GV 74 en 9

7TOOLS

Removal of the actuator

L- wrench set (mm)

Hex. socket wrench set

Chisel and hammer (10 pound)

+,- drivers

8 ORDERING SPARE PARTS

When ordering spare parts, always include the following

information:

type code, sales order number, serial number

number of the parts list, part number, name of the

part and quantity required

This information can be found from the identification plate

or documents.

NOTE:

Always use original spare parts to make sure that the valve

functions as intended.

10 4 GV 74 en

9 EXPLODED VIEW AND PARTS LIST

Item Description Recommended spare part

1BODY

3* PLUG

5* STEM

6* PLUG PIN

7SEATRING

7a SEAT RING

8BONNET

9a GLAND

9b GLAND FLANGE

11 YOKE NUT

13 STUD

14 STUD

17 HEXAGON NUT

18 HEXAGON NUT

21 LANTERN RING

22** PACKING SPRING

26 BOTTOM FLANGE

30 HEXAGON SCREW

30a WASHER

30b SPRING WASHER

65 BODY GASKET X

67 PACKING SPACER

69** V-RING SET X

69 PACKING RING X

86 FLOW DIRECTION ARROW

*) Delivered as a set

**) Packing type of V-Ring set

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