Pressure Seal Manual
Pressure Seal Manual
Pressure Seal Manual
PRESSURE SEAL
VALVES
INSTRUCTION
MANUAL
MANUAL
NUMBER
69-1
-1-
Powell Pressure Seal Valves are built to high standards of precision and accuracy and must pass rigid
inspection before leaving the factory. It is imperative that the valves be properly installed, maintained and
operated to assure satisfactory performance.
The purpose of this service manual is to instruct installation crews, maintenance foremen and operating
personnel in these fundamentals. This manual should be kept available to these presonnel at all times so that
they may become familiar with the details of these valves.
Powell Pressure Seal Valves are intended for high pressure, high temperature services of all fluids where
severe coking is not a factor. They are guaranteed to be in good condition; however, we assume no
responsibility for damage to valves due to faulty installation, improper operation or other conditions beyond
our control.
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INDEX
Page Page
ADAPTO GEAR OPERATED
VALVES GLOBE VALVES
Upper Assembly 45 “Y” Take-Up Screw Design 59
Bonnet Stud Design 61
ANGLE VALVES Bonnet Stud Design
Bonnet Take-Up Screw Design (Hammer-Blow Handwheel) 62
(Bolted Yokearm Style) 60 “Y” Non-Return (Stop Check) 65
Instruction for Repair of Valve Instructions for Repair of Seats 52, 53
Seats 52, 53, 54, 54, 55, 56
55, 56
INSTALLATION
CHECK VALVES Cleaning the Pipe Lines 4
“Y” Check 63 Cleaning the Valve 4
“Y” Check (Threaded Retainer Insulation 4
Style) 63 Lifting Lugs 4
Horizontal Check 64 Packing Lists 4
Supporting the Valve 4
COMPONENT PARTS OF Unloading 4
PRESSURE SEAL JOINT 57 Welding 4
-3-
INSTALLATION
When your valves arrive you will find an envelope containing a PACKING LIST – an itemized
statement of all valves and parts included in the shipment. The Receiving Clerk should check and
account for each item on the list. Keep this PACKING LIST as a part of the permanent records of these
valves.
UNLOADING of valves should be done with care. Remember that although a valve is a rugged
piece of equipment it may still be damaged by abusive handling. Skidded valves should not be removed
from skids until immediately before installation. LIFTING LUGS incorporated on the yokearm of many
Pressure Seal Valves greatly facilitate handling.
3) WELDING and stress relieving should conform to the A.S.M.E. Boiler Code.
Valve stems should be opened slightly during preheat, welding and post
heating operations.
4) CLEANING OF THE PIPE LINES in which valves are installed and all
connecting lines is essential before the unit is put in operation. Welding
beads, scale and foreign matter in the lines cause damage to the valve seats
resulting in leakage.
5) INSULATION should not be applied to the valve above the knockout holes.
2) Powell Pressure Seal Valves have a BACK SEAT on the stem, which seats
against a stellited guide in the bonnet when the valve is fully opened. This
seat will hold pressure if both surfaces are clean; however, this is difficult to
determine, and consequently, packing a valve under pressure is hazardous
and not recommended.
-4-
4) SPECIAL TOOLS are available for the general maintenance of Powell
Pressure Seal Valves.
a) Torque Wrench
b) Laps for pressure seal joint
c) Grinder for pressure seal body seat
d) Tools for repairing valve sealing surfaces
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POWELL Cast Steel
-6-
Pressure Seal Valves
-7-
DISASSEMBLY AND REASSEMBLY OF
THE PRESSURE SEAL JOINT
Disassembly and reassembly of the Pressure Seal Joint is simple if directions are followed.
Powell Pressure Seal Valves utilize four types of design (1) Bonnet Locknut Design, (2) Bonnet
Take-Up Screw Design (Bolted Yokearm Style), (3) Bonnet Take-up Screw Design (Threaded
Yokearm Style), and (4) Bonnet Stud Design.
Although Gate Valves are illustrated with the disassembly and reassembly instructions for the
various types of Powell Pressure Seal Joint Designs on the following pages, these instructions
also apply, with minor modifications, to Globe, Angle, Non-Return (Stop-Check) and Check
Valves.
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O.S. & Y. GATE VALVE
BONNET LOCKNUT DESIGN
- 10 -
DISASSEMBLY
- 11 -
3. a) Close the valve.
- 12 -
5. a) Continue to turn the handwheel in a counter-
clockwise direction. As the back seat of the
stem seats against the bonnet, the bonnet,
gasket, and protective ring will be raised
from the body.
- 13 -
7. a) Lift the bonnet along with the gland,
protective ring and gasket out of the body,
care being taken not to scar the gasket
seating surface of the body.
- 14 -
REASSEMBLY
- 15 -
3. a) Put a new gasket in place, making sure all
surfaces are clean. (It is essential to install a
new gasket whenever the pressure seal joint
is broken.) (See page 47 for special
instructions.)
- 16 -
5. a) Install eyebolt clamp and eyebolts.
c) Close valve.
- 17 -
O.S.Y. GATE VALVE
- 18 -
DISASSEMBLY
- 19 -
3. a) Close the valve.
- 20 -
5. a) Continue to turn the handwheel in a
counterclockwise direction. As the back
seat of the stem seats against the bonnet, the
bonnet, gasket, and protective ring will be
raised from the body.
- 21 -
7. Lift the bonnet along with the gland, protective
ring and gasket out of the body, care being taken
not to scar the gasket seating surface of the body.
- 22 -
REASSEMBLY
- 23 -
3. a) Put a new gasket in place, making sure all
surfaces are clean. (It is essential to install a
new gasket whenever the pressure seal joint
is broken.) (See page 47 for special
instructions.)
- 24 -
5. a) Install and tighten nuts on the yokearm
studs.
b) Close valve.
TABLE I
- 25 -
O.S.Y. GATE VALVE
- 26 -
DISASSEMBLY
- 27 -
3. a) Close the valve.
- 28 -
5. a) Continue to turn the handwheel in a
counterclockwise direction. As the back
seat shoulder of the stem seats against the
bonnet, the bonnet, gasket, and protective
ring will be raised from the body.
- 29 -
7. Lift the bonnet along with the gland, protective
ring and gasket out of the body, care being taken
not to scar the gasket seating surface of the body.
- 30 -
REASSEMBLY
- 31 -
3. a) Put a new gasket in place, making sure all
surfaces are clean. (It is essential to install a
new gasket whenever the pressure seal joint
is broken) (See page 47 for special
instructions.)
- 32 -
5. a) Close valve.
TABLE I
- 33 -
O.S. & Y. GATE VALVE
- 34 -
DISASSEMBLY
- 35 -
3. a) Close the valve.
- 36 -
5. a) Continue to turn the handwheel in a counter-
clockwise direction. As the back seat
shoulder of the stem seats against the
bonnet, the bonnet, gasket and protective
ring will be raised from the body.
- 37 -
7. Lift the bonnet along with the gland, protective
ring and gasket out of the body, care being taken
not to scar the gasket seating surface of the body.
- 38 -
REASSEMBLY
- 39 -
3. a) Put a new gasket in place, making sure all
surfaces are clean. (It is essential to install a
new gasket whenever the pressure seal joint
is broken.) (See page 47 for special
instructions.)
- 40 -
5. a) Install eyebolt clamp and eyebolts.
c) Close valve.
TABLE I
- 41 -
Types of Segmental Thrust Rings showing the location
of the segments in relation to the Knockout Holes.
- 42 -
Upper Assembly of Bevel Gear Operated Valves
- 43 -
Upper Assembly of Motor Operated Valves
- 44 -
UPPER ASSEMBLY OF ADAPTO GEAR OPERATED VALVES
- 45 -
UPPER ASSEMBLY OF GEARED HAMMER BLOW HANDWHEEL
- 46 -
SPECIAL INSTRUCTIONS FOR EXTREME LAPPING
OR GRINDING OR THE PRESSURE SEAL GASKET SEAT
THE BODY
FOR VALVES WITH TAPERED BODY NECK DESIGN
If the pressure seal gasket seat in the body has steam cuts, extensive lapping may be
necessary. This results in a dropping of the pressure seal seat in the body. The maximum
allowable clearance between the segmental thrust rings and the protective ring is .010 inches (see
drawing page 58). If extensive lapping causes a greater clearance, an oversize protective ring
must be installed. These are normally supplied 1/16” oversize in thickness and must be faced off
to fit.
After prolonged lapping the lap may have worn off angle. A machine cut should be taken
off the lap to correct this angle prior to final lapping.
Special grinding tools are available that greatly accelerate repair of a valve that requires
considerable metal removal from the seat. Final lapping should always be performed after
grinding.
THE BONNET
If the pressure seal seat in the bonnet has steam cuts it is recommended that the seating
surface be faced off on a lathe and then lapped.
- 47 -
INSTRUCTIONS FOR LAPPING PRESSURE SEAL JOINT
AFTER THE VALVE HAS BEEN DISASSEMBLED, THE INSIDE OF THE BODY AND OUTSIDE OF THE
BONNET SHOULD BE CLEANED, AND THE BODY SEATING SURFACE AND THE BONNET SEATING
SURFACE EXAMINED (SEE JOINT DETAIL, PAGE 58). IF EITHER OF THESE SEATS ARE MARRED OR
SCORED THEY SHOULD BE LAPPED.
A LAP WITH A MATCHING INSIDE BEVEL SHOULD BE PLACE THE LAP OVER THE BONNET AND ROTATE THE
USED FOR THE BONNET. SPREAD A FINE LAPPING LAP CLOCKWISE AND COUNTERCLOCKWISE
COMPOUND EVENLY ON THE BEVELED SURFACE, APPROXIMATELY A QUARTER TURN. RAISE THE LAP
KEEPING THE OTHER SURFACES CLEAN. OFF THE SEAT SLIGHTLY AT FREQUENT INTERVALS
AND TURN APPROXIMATELY A HALF TURN AND
CONTINUE LAPPING
CLEAN THE LAPPED SURFACES AND RUB A SMALL AMOUNT OF BLUING ON THE LAP. ROTATE THE LAP APPROX. 15
DEGREES OVER THE BONNET SEATING SURFACES AND THEN CHECK THE SURFACE FOR IMPERFECTIONS. IF THE
SURFACE IS NOT PERFECT MORE LAPPING IS REQUIRED.
- 48 -
A LAP WITH A BEVEL TO AGREE WITH THE ANGLE IN
THE BODY SHOULD BE USED. SPREAD A VERY FINE
COMPOUD ON THE BEVELED SURFACE OF THE LAP, INSERT THE LAP INTO THE BODY
KEEPING THE OTHER SURFACES CLEAN.
LAP THE SEAT BY ROTATING THE LAP CLOCKWISE AND COUNTERCLOCKWISE APPROXIMATELY A QUARTER TURN.
RAISE THE LAP OFF THE SEAT SLIGHTLY AT FREQUENT INTERVALS AND TURN APPROXIMATELY A HALF TURN AND
CONTINUE LAPPING. CHECK THE SEAT PERIODICALLY WITH BLUING AS PREVIOUSLY DESCRIBED IF THE SEAT IS NOT
PERFECT MORE LAPPING IS REQUIRED.
- 49 -
INSTRUCTIONS FOR REPAIR OF GATE VALVE SEATS
- 50 -
After completion of the circling and polishing operations the seating surfaces of the wedge and
seat rings should be thoroughly cleaned. A small amount of bluing should then be rubbed on
both faces of the wedge, the wedge installed in the body in the seated position and tapped with a
brass bar. The wedge should then be removed from the body by tapping on the outside of the
valve body to jar the wedge loose. Both faces should be examined to insure that there is a
complete round bearing.
Prior to reassembly of the valve the inside of the body and the entire wedge should be examined
and any grit from the circling operation removed. The faces of the wedge and seat rings should
be thoroughly cleaned.
- 51 -
INSTRUCTIONS
FOR REPAIR OF
Seat and disc seating surfaces should be examined visually for damage such as grooves resulting
from erosion, pits or mars resulting from entrapment of foreign material between the seating
surfaces, or out-of-round condition of the body or seat ring seating surface.
In most instances, it will be necessary to run a bearing check by rubbing a small amount of
bluing on the disc seating surface, inserting the stem and disc assembly into the body and using
the bonnet as a guide, rotate the stem and disc assembly approximately 15 degrees. After
removing the bonnet and stem and disc assembly from the body, examine the body or seat ring
seating surface. If the bluing transferred to the body or seat ring seating surface does not result
in a complete round bearing, the seat can be assumed to be out-of-round and this condition must
be eliminated as the first step on repairing the seats.
Where indentations, grooves, pit marks, mars or other imperfections on the body seat or seat ring
are greater than approximately 0.010” deep, or where an out-of-round condition is indicated, the
initial step in repairing the seat should be a circling operation using a lap with strips of 40 grit
emery paper inserted between the lap plate and the lower guide plate as illustrated in Figure 1.
Follow with another circling operation using 80 grit emery paper and a final polishing operation
using 150 grit emery paper.
- 52 -
An upper lap guide assembly should be used during all circling and polishing operations. The
upper guide assembly is to be bolted to the top of the body on all globe, angle and non-return
(stop check) type valves, and screwed into the neck of the threaded retainer style check valves.
Most guide assemblies for other style check valves are provided with brackets which extend
down over the O.D. of the body and lock screws facilitate holding the guide in place. If this
feature is not provided, it will be satisfactory in most cases to proceed without bolting the guide
assembly to the body.
Rotation of the lap should be by means of an air wrench attached to the top of the lap shank.
Figure 2 illustrates typical tool set-up used in the circling and polishing operations.
- 53 -
- 54 -
The circling and polishing operations on the body seat or seat ring should be followed by a lapping
operation using the lap without the strips of emery paper. Spread a fine lapping compound evenly on the
beveled surface of the lap. The upper guide assembly is to be used during the seat lapping operation. The
lap handle should be inserted into the hole near the top of the lap shank. It is important that only light
pressure be applied to the lap handle during lapping operations. Lap the seat by rotating the lap clockwise
and counterclockwise approximately a quarter of a turn. Strokes should be light and the lap raised off the
seat slightly and the lap rotated to a new position at frequent intervals. Apply fresh lapping compound
frequently and continue lapping until imperfections are removed. The seat should be checked
periodically with bluing following the method previously outlined. If the results of the bluing check do
not indicate a full round bearing, additional lapping will be required.
On larger size valves, it will be necessary to partially support the lap by means of a spring as illustrated in
Figure 3 to insure that the pressure of the lap against the seat is light. This method of support is
recommended for large size valves which are installed in the line with the body neck up.
When globe or angle valves are installed in the neck down position, or in any position where the neck is
below the horizontal, it will be necessary to hold the lap in place on the seat with light pressure applied to
the lap by means of a spring between the lap guide assembly and the lap as illustrated in Figure 4.
The seat lapping operations using a lap should be followed by lapping the valve disc to the seat using the
same procedures. The ball seat on the disc should be examined and any damage repaired before
proceeding with the lapping of the disc to the seat.
On swivel disc design globe and angle valves, it will be necessary to remove the disc locknut washer to
eliminate the end play in the stem and disc assembly; also, insert pin in regrinding pin hole on the side of
the hexagon of the disc nut, making sure that the pin goes through the regrinding pin hole in the stem to
insure rotation of the disc with the stem by means of the valve handwheel during the lapping operation.
On globe and angle valves which have a one-piece stem and disc, it will be necessary to install the special
handle provided to facilitate rotation. The key in the handle collar fits the keyway in the stem and the
handle is maintained in position on the stem by means of lockscrews.
On non-return (stop check) and check type valves, a disc driver is bolted to the disc at the tapped holes in
the top of the disc as illustrated in Figure 5 to facilitate rotation of the disc. The upper lap guide and
spring arrangement are again used as previously described for lapping operations with the lap.
Lapping operation should be accomplished following the procedures as previously described. After
completion of lapping, check for bearing as previously outlined. A full-round narrow bearing should be
obtained to insure a tight seat.
Prior to assembly, all parts should be thoroughly cleaned. All residue from the lapping and bearing check
operations must be removed from all parts including the body.
- 55 -
FIGURE 5
- 56 -
COMPONENT PARTS OF THE PRESURE SEAL JOINT
- 57 -
DETAIL OF THE POWELL
PRESSURE SEAL JOINT
- 58 -
“Y” GLOBE VALVE
- 59 -
ANGLE VALVE
- 60 -
GLOBE VALVE
- 61 -
GLOBE VALVE
- 62 -
“Y” CHECK VALVE
- 63 -
HORIZONTAL CHECK VALVE
- 64 -
“Y” GLOBE NON-RETURN (STOP CHECK) VALVE
- 65 -
NOTES
- 66 -
NOTES
- 67 -
PEOPLE WHO KNOW VALVES KNOW POWELL
- 68 -