Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual

OPERATION AND
MAINTENANCE MANUAL

DN80-600 PN16 Flange / Flange,

Metal Seated Gate Valves

Operation & Maintenance Manual – DN80-600 PN16 FL-FL MSV 20120528 Page 1 of 5

Q-Pulse Id: VM479 Active: 10/07/2015 Page 1 of 8

 Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual

CONTENTS

1.00.00 INSTRUCTIONS ............................................................................ 3

1.01.00 OPERATING INSTRUCTIONS .................................................. 3
1.02.00 MAINTENANCE INSTRUCTIONS.............................................. 4
1.03.00 HANDLING INSTRUCTIONS ..................................................... 4
2.00.00 SPARE PARTS LIST ..................................................................... 4
3.00.00 ADDRESS FOR QUERIES ............................................................ 5
4.00.00 APPENDICES ................................................................................ 5
4.01.00 Drawing – 00-16-02-1061 – DN80-600 PN16 MS Valve ............ 5
4.02.00 Installation Guidelines – DI Flanged Joints................................. 5

Operation & Maintenance Manual – DN80-600 PN16 FL-FL MSV 20120528 Page 2 of 5

Q-Pulse Id: VM479 Active: 10/07/2015 Page 2 of 8

 Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual

1.00.00 INSTRUCTIONS

1.00.01 This manual covers Tyco Waters’ DN80-600, PN16, Flange /

Flange, Metal Seated Gate Valves. All flanges are drilled in
accordance with AS4087 Figure B5.

1.01.00 OPERATING INSTRUCTIONS

1.01.01 The valves are available in clockwise and anti-clockwise closing

configurations. The direction of closing for your valve will be
indicated by the colour of the spindle cap or marked by an arrow
on top of the hand wheel.

Clockwise closing valves are identified by a red spindle cap or

a red arrow on top of the hand wheel.

Anti-Clockwise closing valves are identified by a black spindle

cap or a black arrow on top of the hand wheel.

1.01.02 The approximate number of turns from open to close is shown in

the table below:

Valve Size Turns to close

80 20
100 23
150 26
200 34
225 38
250 42
300 50
375 62
450 76
500 82
600 98

1.01.03 Valves of this type are not designed for throttling purposes.

1.01.04 The allowable pressures for Class 16 Metal Seated Valves are:
• Allowable Operating Pressure (AOP) - 1600kPa.
• Maximum Allowable Operating Pressure (MAOP) - 1920kPa
• Allowable Site Test Pressure (ASTP) - 2400kPa

Seat leakage may occur at the MAOP, however structural

damage will not occur. ASTP should be applied only with the
gate in the fully open position.

Operation & Maintenance Manual – DN80-600 PN16 FL-FL MSV 20120528 Page 3 of 5

Q-Pulse Id: VM479 Active: 10/07/2015 Page 3 of 8

 Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual

1.01.05 Care should be taken to remove any foreign material from the
pipeline and particularly from the bottom of the valve body.
Closing the wedge onto solid debris may damage the gunmetal
sealing rings.

1.01.06 The approximate Sealing Torque is shown in the table below:

Valve Size Sealing Torque Nm

80 30
100 40
150 50
200 70
225 90
250 120
300 170
375 280
450 400
500 520
600 780

1.02.00 MAINTENANCE INSTRUCTIONS

1.02.01 This type of valve does NOT require any lubrication.

1.02.02 In the unlikely event of any of the long life Spindle Sealing Rings
(items 14 &15) requiring replacement, ensure valve is fully
DEPRESSURISED and remove spindle cap & stem seal
housing (items 6 & 3) by removing Socket Head Screws (item
12). This will permit the stem seal housing (item 3) to be
removed from the Spindle (item 5) for replacement of the
appropriate rings.

1.02.03 Re-assemble in the reverse sequence using any commercially

available water pump grease applied to the upper end of the
Spindle to aid assembly. Reseal Screws with silicon sealant.

1.03.00 HANDLING INSTRUCTIONS

1.03.01 The valve should lay flat on its flanges in a horizontal position
when being transported via a truck or forklift.

2.00.00 SPARE PARTS LIST

2.00.01 Spare parts are NOT normally required for this type of valve.

Operation & Maintenance Manual – DN80-600 PN16 FL-FL MSV 20120528 Page 4 of 5

Q-Pulse Id: VM479 Active: 10/07/2015 Page 4 of 8

 Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual

2.00.02 In the unlikely event of a sealing ring failure the appropriate ring
may be selected from items 14 & 15 in the attached general
assembly drawing.

3.00.00 ADDRESS FOR QUERIES

3.00.01 Additional information can be found at www.tycowater.com. If

you require further assistance, please contact your nearest Tyco
Water Customer Centre.

4.00.00 APPENDICES

4.01.00 Drawing – 00-16-02-1061 – DN80-600 PN16 MS Valve

4.02.00 Installation Guidelines – DI Flanged Joints.

Operation & Maintenance Manual – DN80-600 PN16 FL-FL MSV 20120528 Page 5 of 5

Q-Pulse Id: VM479 Active: 10/07/2015 Page 5 of 8

 Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual
1 2 3 4 5 6 7 8
ITEM DESCRIPTION QTY MATERIAL
1 BODY 1 SGI 400-15 (MIN)
2 BONNET 1 SGI 400-15 (MIN)
A 1
3 STEM HOUSING LGM C83600 A

4 WEDGE 1 LGM C83600

5 STEM 1 SS 431
6 STEM CAP 1 SGI 400-15 (MIN)
13 15 7 THRUST WASHER 1 GLASS FILLED ACETAL
6 1
This drawing remains the property of TYCO WATER and must not be copied, lent of used in any way detrimental to the interests of this company.

8 BODY GASKET EPDM

9 STEM HOUSING GASKET 1 EPDM
All drawings must be returned immediately to the owner on completion of the undertaking for which they were issued, or upon prior request.

10 WEDGE NUT 1 LGM C83600

14 12
3 11 COUNTER SUNK SCREW 1 SET SS 316
1 SET B
B 12 SOCKET HEAD CAP SCREW SS 316
9
13 HEX HEAD SCREW 1 SET SS 316
2 7 14 O' RING 1 SET NITRILE
5 C 15 WIPER RING 1 NITRILE
16 BODY RING 1 LGM C83600
17 BACKSEAL GROMMIT 1 NITRILE
11
H

1 17
C Size AS/ NZS 4087 Fig.B5 C
Weight Turns t o
DN(mm) F D P CD d n A C H L Kg Close
80 122 185 146 18 4 80 209 367 203 18 20
10 100 154 215 178 18 4 100 231 402 229 24 23
150 211 280 235 18 8 150 321 502 267 43 26
200 268 335 292 18 8 200 393 610 292 75 34
225 300 370 324 18 8 225 429 649 305 85 38
250 328 405 356 22 8 250 461 723 330 110 42
300 378 455 406 22 12 300 560 810 356 160 50
375 463 550 495 26 12 375 685 960 381 340 62

4 400(375) 489 580 521 26 12 375 685 960 381 380 69

D 450 552 640 584 26 12 450 811 1145 432 560 76 D

500 609 705 641 26 16 500 915 1290 457 710 82

D
A
F

600 720 825 756 30 16 600 1081 1467 508 940 98

NOTES: 1.FLANGE DRILLING SHOWN IS A

PRACTICAL REPRESENTATION ONLY.
2. ITEM 11 & 12 FILLED WITH SILICONE.
3. DIMENSION "C" REPRESENTS THE APPROXIMATE E
16 OVERALL WIDEST VALUE OF THE ASSEMBLY
d IN THE SHOWN VIEW ORIENTATION.
E
PCD
L n
Monday, 6 February 2012 2:22:20 PM

DRAWN: DATE:
CK 20/01/2012 63 Currumbin Creek Rd
PO Box 150
CHECKED: DATE: CURRUMBIN 4223
Tel: +61 7 5589 4427
JH 20/01/2012 Fax: +61 7 5589 4466
SCALE: SHEET: ALL DIMENSIONS TOLERANCES : Dims : 0.25 REVISION
THIS DRAWING IS THE PROPERTY OF TYCO WATER PTY LTD ARE IN MM UNLESS Cast Dims: 1.00
CURRUMBIN, ABN 75 087 415 745 AND IS PROTECTED BY COPYRIGHT. © NTS 1 OF 1 OTHERWISE SPECIFIED. Angular: 0.025
THE USER AGREES THAT, IN CONSIDERATION OF TYCO LENDING
THE DRAWING TO THE USER, THIS DRAWING WILL BE USED ONLY FOR
THE PURPOSES AUTHORISED BY TYCO.
MATERIAL: TITLE:
AS1100 Cast Angular: 1.00
1
THE USER WILL RETURN THIS DRAWING WITH
ALL COPIES AND REPRODUCTIONS TO TYCO ON REQUEST.
Dn80 - DN600 FIGURE 400
METAL SEATED - PN16 SIZE
SURFACE TREATMENT: DWG NO:

A3
ASSEMBLY
1 LISTED AND RELEASED 20/01/2012 CK JH SUB 00-16-02-1061
ASSEMBLY
PART SURFACE FINISH: BPCS NO:
REV REVISION DESCRIPTION DATE BY CHKD THIRD ANGLE PROJECTION DETAIL

Q-Pulse Id: VM479 Active: 10/07/2015 Page 6 of 8

 Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual

DI Flanged Joints
Installation guidelines for
Installation Guidelines
ductile iron flanged joints

Notes
 Grade 4.6 galvanised mild steel or Grade
316 property class 50 stainless steel bolts
are proposed for joining Class 16 flanges
except for DN900.
 Grade 8.8 galvanised steel or Grade 316
property class 70 stainless steel stud bolts
are proposed for joining Class 35 flanges
& DN900 Class 16 flanges.
 Bolt tensions have been calculated
1 5
Thoroughly clean the flange faces to Insert four bolts in locations 1 to 4 as
be jointed, ensuring there is no dirt, indicated on the diagram below and
particles of foreign matter, protrusions position the insertion gasket on the
or coating build-up on the mating bolts, taking care not to damage the
surfaces. Use a scraper or wire brush gasket surface.
to remove any irregularities.
6

to counter the force due to expected

internal pressure and to provide adequate
sealing stress on the nominated gasket
material, without exceeding the maximum
allowable gasket stress at the time of
installation. The necessary torques to
induce these tensions are estimated
for raised face ductile iron flanges with
common surface finishes used in the
Water Industry.
 The application of excessive torque at
the time of installation may overstress
the gasket causing crushing or extrusion,
which can lead to leakage at operating
pressures.
 The surface conditions of the threads
as a result of rust, plating, coating and
lubrication are the predominant factors
influencing the torque/tension relationship.
However there are many others including
thread fit, surface texture and the speed
and continuity of tightening.
 The flange faces are assumed to have a
surface roughness of Ra = 10 - 12 µm.
 A torque wrench is most commonly
utilised to achieve the required bolt
tension, however in critical applications a
hydraulic tensioner should be used.
 Special care should be taken when jointing
screw-on flanges as excessive torques can
cause damage to the epoxy seal.
2 Offer the adjoining flange to the bolts,
Ensure that the mating threads of all
nuts and bolts are clean and in good
condition.
3 Tighten nuts to finger tight and check
Evenly apply a suitable lubricant
(e.g. molybdenum disulphide) to all
mating threads, including the nut load
bearing face.
4
Align the flanges to be joined and
ensure that the components are
satisfactorily supported to avoid
bending stress on the flanged joint
during and after
assembly.
Star pattern
tightening sequence
1
16
12 5 Tighten to 60% of estimated torque
8 9
taking care to maintain alignment and
support of the components.
7
alignment of flange faces and gasket.
8
Insert the remaining bolts and tighten
nuts to finger tight.
9
Determine the required bolt tension
and the estimated torque from the
Estimated Tightening Torque Values
Tables.
10
Tighten nuts to 30% of estimated
torque using the star pattern detailed
on the diagram below.
11
using the same tightening sequence.

4 13 12
Tighten to 100% of estimated torque
14 3
using the same tightening sequence.
10 7
13
6 11
2 15 Finish with one final pass, torquing in
a clockwise direction.

© Copyright by Tyco International Ltd

Q-Pulse Id: VM479 Active: 10/07/2015 Page 7 of 8
 Tyco Water - DN80-600 PN16 Flange Metal Seated Gate Valves - Operation and Maintenance - Vendor Manual

Estimated tightening torque values

Standard pressure flanges
AS 4087 Figure B5 Class 16
Grade 4.6 Galvanised Steel Bolts & Nuts or Grade 316 Class 50 Stainless Steel
Bolts & Nuts. Full Face Gasket – 3 mm EPDM Seal-16.
 ‘Lightly Oiled’ refers to the application of a
Nom Bolt Number Bolt Bolt Estimated Torques Nm good quality lubricating oil and is the usual
Size Size of Bolts Length Tension Galvanised Stainless as received condition of fasteners.
 ‘Well lubricated’ refers to the application

Lightly Well Well of molybdenum disulphide grease, or

Oiled Lubricated Lubricated equivalent antiseize compound.
DN mm kN µ = 0.22 µ = 0.15 µ = 0.20  The estimated torques provided in the

tables at left are based on the coefficients

80 M16 4 65 20 70 50 65 of friction (µ) indicated. Where other
coefficients apply, alternative torques
100 M16 4 75 20 70 50 65 should be calculated.
150 M16 8 75 20 70 50 65  Required bolt tensions and estimated

torques have been assessed using

200 M16 8 75 20 70 50 65 established engineering principles,
225 M16 8 75 25 90 60 80 however, variation in installation
procedures may result in different
250 M20 8 90 35 160 110 140 requirements.
300 M20 12 100 35 160 110 140
375 M24 12 120 50 270 180 240
450 M24 12 120 55 290 200 270
500 M24 16 120 55 290 200 270
600 M27 16 130 70 420 290 380
750 M30 20 140 80 530 360 480
*900 M33 24 195 200 1460 990 1320
*Grade 8.8 galvanised steel studs and nuts or Grade 316 Class 70 stainless steel studs and nuts.
Full face gasket – 1.5 mm TEADIT NA1000 compressed fibre used for DN 900 Class 16 flanges.

Estimated tightening torque values

High pressure flanges
AS 4087 Figure B6 Class 35
Grade 8.8 galvanised steel studs and nuts or Grade 316 Class 70 stainless steel
studs and nuts. Full face gasket – 1.5 mm TEADIT NA1000 compressed fibre.

Nom Bolt Number Bolt Bolt Estimated Torques Nm

Size Size of Bolts Length Tension Galvanised Stainless
Lightly Well Well
Oiled Lubricated Lubricated
DN mm kN µ = 0.22 µ = 0.15 µ = 0.20
80 M16 8 110 50 180 120 160
100 M16 8 110 50 180 120 160
150 M20 12 130 80 350 240 320
200 M20 12 130 80 350 240 320
225 M24 12 150 115 610 420 550
250 M24 12 150 115 610 420 550
300 M24 16 150 115 610 420 550
375 M27 16 170 150 900 610 810
450 M30 20 190 180 1190 810 1080 The information provided within is based on
500 M30 24 190 180 1190 810 1080 established engineering principles and is offered by
Tyco Water in good faith as a source of information
600 M33 24 210 230 1670 1140 1520 for its customers. Successful installation depends
on numerous factors outside the Company's control
750 M33 28 210 230 1670 1140 1520 and installers should be aware that these guidelines
might not be successful for every installation. Tyco
900 M36 32 230 270 2140 1460 1950 Water disclaims any liability to any person who
solely relies on this information for the purposes of
making a flange joint.
© Copyright by Tyco International Ltd
Tyco Water reserves the right to change product
designs and specifications without notice
Q-Pulse Id: VM479 Active: 10/07/2015 Page 8TWD_FJI1112
of 8