T6435-CM-MMC-010.pdf

T6435-CM-MMC-010

PUBLISHED BY DIRECTION OF COMMANDER MILITARY SEALIFT COMMAND

0910-LP-104-2823

TECHNICAL MANUAL

QUICK CLOSING VALVES, FUEL OIL & LUBE OIL

FOR

USNS LEWIS AND CLARK (T-AKE 1) CLASS

INSTALLATION, OPERATION, MAINTENANCE AND REPAIR INSTRUCTIONS

( YOUNG & CUNNINGHAM, LTD.)

STEPHENSON INDUSTRIAL AREA, NEWCASTLE UPON TYNE, NE12 ORY

N00024-02-C-2300

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

PUBLISHED BY DIRECTION OF COMMANDER MILITARY SEALIFT COMMAND

19 AUGUST 2005

0910-LP-104-2823

TECHNICAL MANUAL

QUICK CLOSING VALVES, FUEL OIL & LUBE OIL

FOR

USNS LEWIS AND CLARK (T-AKE 1) CLASS

INSTALLATION, OPERATION, MAINTENANCE AND REPAIR INSTRUCTIONS

( YOUNG & CUNNINGHAM, LTD.)

STEPHENSON INDUSTRIAL AREA, NEWCASTLE UPON TYNE, NE12 ORY

N00024-02-C-2300

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

A

List of Effective Pages Date of original pages is:

Original . . . . . . 19 AUGUST 2005

Total number of pages in this publication is 35 consisting of the following:

Page No. * Change No. Page No. * Change No.

Title/A

Index

Section 1

Section 1, Pages 1 through 6

Section 2

Section 2, Pages 1 through 13

Section 3

Section 3, Pages 1 through 8

* Zero in this column indicates an original page

INDEX

SECTION 1: INSTALLATION/PRESERVATION MANUAL PG 1-6

SECTION 2: OPERATION, MAINTENANCE AND REPAIR MANUAL PG 1-13

SECTION 3: DRAWINGS AND PARTS LIST PG 1-8

SECTION 1

INSTALLATION/PRESERVATION MANUAL

NASSCO

T-AKE PROJECT

INSTALLATION / PRESERVATION MANUAL

YOUNG & CUNNINGHAM LIMITED

SECTION 1 1

CONTENTS

1. GENERAL 3

2. HANDLING / STORAGE BEFORE INSTALLATION 3

3. INSTALLATION 3

4. INDIVIDUAL VALVE INSTALLATION INFORMATION 4

5. AFTER INSTALLATION 5

6. OPERATION / MAINTENANCE 5

7. PERIODIC INTERNAL EXAMINATION 5

SECTION 1 2

PARA DESCRIPTION PAGE

1. GENERAL

1.1 This manual applies to all standard valves.

1.2 Valves/equipment must be installed and operated in service conditions suitable to their design and construction and only in accordance with applicable codes, standards and generally accepted good construction and operating practice.

1.3 No special tools are required for the installation, disassembly, maintenance and reassembly of these products.

1.4 Replacement of minor components including stem packing and bonnet gaskets may be done under field conditions provided proper procedures are followed.

1.5 Replacement of major components including stem and disc should only be done in a properly equipped workshop.

2. HANDLING / STORAGE BEFORE INSTALLATION

2.1 The valves should be stored in a warehouse or weatherproof compound in a clean environment and as dry conditions as possible.

2.2 Care should be taken to ensure that the end flange faces and bores are adequately protected and properly secured.

2.3 The valve stem should be generously greased.

2.4 It is recommended that the valves be examined and operated periodically to avoid the deterioration in the protection indicated above. During the operating of valves the internals should be oiled if necessary. Replace end protectors after inspection of valves internals.

2.5 If the valves are to be stored for long periods:-

(a) Gland packing should be removed

(b) Valve should be kept dry.

(c) All machined surfaces should be greased, i.e. flanges etc.

(d) Periodically the valves should be inspected internally and externally and re-greased where necessary (approx. once per year).

3. INSTALLATION

3.1 We recommend that bonnet and gland fasteners are checked for tightness prior to pressurising and also offer a short period of service.

This is particularly important if the valves have been subjected to severe changes in temperature.

SECTION 1 3

Tightening should be done alternatively from one side of the bonnet to the other to prevent distortion.

3.2 Unless stated in the purchase order or approved by supplier, equipment should be installed in position shown on relevant general arrangement drawings.

3.3 Valves should be located in positions with adequate clearance to open / close.

3.4 Valves should be installed in the pipework to prevent undue stress and should be independently supported when valve weight determines.

3.5 Where applicable valves should be installed in the pipeline with the flow direction arrow in line with the flow.

3.6 Correct jointing material must be used to suit application.

Valves with screwed ends must have threads thoroughly cleaned. Jointing compound or PTFE tape should be used. Care should be taken not to overtighten screwed connections.

3.7 Operation – Gates and Globes – The valve is operated by rotating the spindle via the handwheel:-

Clockwise to CLOSE Anti-clockwise to OPEN

3.8 The valve should only be operated by the handwheel and WITHOUT the use of a wheel key or any similar device to increase the force exerted to the valve stem.

3.9 Fully opening Gate and Globe valves will allow the back seating to operate, preventing undue strain on the packing (where a backseat is fitted).

4. INDIVIDUAL VALVE INSTALLATION INFORMATION

4.1 Globe and Angle Globes:-

Globe and Angle valves should be installed with stems in a vertical position, where possible. Valves operate most efficiently with pressure flow under the disc. Install with direction arrow in correct position for proper flow direction.

4.2 Gate Valves:-

Gate valves operated best when standing upright, usually valves can be installed with either face to the inlet side. Gate valves should be in the fully open position before installation.

4.3 Lift Check Valves Straight and Angle Pattern:-

Check valve flow marking on the valve body – install correct flow ensuring the disc OPENS with the flow and re-seat by backflow.

Horizontal Check valves need installing in a level horizontal position ensuring the internal discs rise and fall vertically, unless spring loaded. Angle pattern checks installed with FLOW upwards and under disc.

SECTION 1 4

4.4 Swing Checks:-

Install with valve flow marking arrow in the correct direction of flow. Swing Checks may be installed in vertical position with upward flow. Avoid installation of Swing Checks with pulsating flow.

5. AFTER INSTALLATION

5.1 General – Before putting a new piping installation into service, lines should be tested and flushed with clean water, steam or other clean media. Valves should be fully OPEN before flushing so that any scale or foreign matter can be completely flushed away before valve seating can be damaged.

5.2 After flushing check valves for correct operation. Never force a valve if it does not close tight.

5.3 Check valve and joints for leakage at operating pressure. Tighten joint fasteners where necessary.

6. OPERATION / MAINTENANCE

6.1 Refer to specific valve Operating, Maintenance & Repair Manuals for detailed information.

7. PERIODIC INTERNAL EXAMINATION

(a) Ensure valve is isolated from pressure / flow.

(b) Loosen bonnet fasteners and remove bonnet assembly.

(c) Remove any foreign matter from seat faces, well of body and lower spindle (or hinge pin assembly).

(d) Check seat faces for wear or damage.

(If satisfactory continue to (e), if not satisfactory refer to 5.3 before continuing).

(e) Remove old gasket from body/bonnet flange.

(f) Slightly grease new gasket and locate on body/bonnet flange.

NOTE:

We strongly recommend that whenever the cover is removed/ disturbed a new gasket is fitted.

(g) Replace bonnet assembly taking care not to damage seating faces.

SECTION 1 5

(h) Tighten down bonnet fasteners evenly.

SECTION 1

SECTION 2

OPERATING, MAINTENANCE AND REPAIR

MANUAL

QUICK CLOSING VALVE SYSTEMS

OPERATING, MAINTENANCE, & REPAIR

MANUAL

YOUNG & CUNNINGHAM LTD.

CONTENTS

Page

1. INSTALLATION 3.

2. SAFETY 4.

3. OPERATING INSTRUCTIONS 5.

A. MANUAL OPERATION (HANDWHEEL)

B. TRIPWIRE OPERATION

C. HYDRAULIC OPERATION

D. FUSIBLE RELEASE CYLINDER OPERATION

4. MAINTENANCE 7.

A. QUICK CLOSING VALVE

B. CONTROL PANEL

5. REPAIR 9.

A. VALVE SEAL REPLACEMENT

B. CONTROL PANEL SEAL REPLACEMENT

C. VALVE SEATING FACE REPAIR

D. REMOVAL OF WEDGE JAMMED IN VALVE BODY SEAT

E. ADJUSTING CONTROL PANEL RELIEF VALVE

F. DEAERATING QUICK CLOSING SYSTEM

G. TECHNICAL DATA SHEETS

1.

INSTALLATION

Prior to commencing, equipment should be visually checked, using relevant general arrangement drawings and parts lists for possible damage during storage.

WARNING

The Quick Closing Mechanism can cause personal injury when in operation or if accidentally activated.

(A) VALVE

Protective covers should be removed from valve bores, and internals checked for cleanliness. Any visible foreign matter must be removed. The valve should be installed vertically in a horizontal pipeline and in the manually closed position.

(B) CONTROL PANEL

Wherever possible, piping from Quick Closing Valve to panel should be a continuous inclination to assist in deaeration. We recommend ¼ inch bore tube having cleanly cut joints to avoid obstructions in bore which will cause restriction to flow.

After installation, add recommended oil to reservoir and, maintaining reservoir level at approximately 2/3 capacity, prime system to de-aerate.

(Recommended Oil: Shell Tellus T32 fire resistant or equivalent).

A functional test of the system should be carried out after installation is complete (refer to Operating Instructions).

2.

SAFETY

The design of the Quick Closing Valve, ie. spring loaded, means that personal injury is possible if safety precautions are ignored. READ THE MANUAL CAREFULLY AND

ADHERE TO INSTRUCTIONS CONCERNING SAFETY.

Although the majority of installation and maintenance tasks for Quick Closing Valves can be accomplished by one person, it is always preferable that tasks are not carried out alone. The immediate presence of someone capable of rendering aid is preferred.

The manual contains headings to attract attention to essential or critical information throughout this manual as follows:

An operating or maintenance procedure, practice, condition, or statement, which, if not strictly observed, could result in injury to or death of personnel.

CAUTION

An operating or maintenance procedure, practice, condition, or statement, which, if not strictly observed, could result in damage to or destruction of equipment or long term health hazards to personnel.

3.

OPERATING INSTRUCTIONS

A. MANUAL OPERATION (VIA HANDWHEEL)

1. Ensure locking lever assembly is engaged with wing collar.

The Quick Closing Mechanism can cause personal injury when in operation or if accidentally activated.

2. Turn handwheel counter-clockwise to open

3. Turn handwheel clockwise to close.

B. OPERATION OF TRIPWIRE ACTUATED QUICK CLOSING VALVES

Do not trip Gate Valves when seating faces are dry to avoid jamming of wedge.

To shut Quick Closing Valve

1. Apply 80 pounds minimum pull to tripwire.

To re-set Quick Closing Valve (return to open position)

1. Rotate handwheel clockwise to raise wing collar.

2. Engage locking levers to wing collar.

The Quick Closing Mechanism can cause personal injury when in operation or if accidentally activated.

3. Open valve by rotating handwheel counter clockwise.

(Gate Valves only) If handwheel cannot be rotated easily, do not apply excessive force, refer to Repair Section (wedge jammed in body seating)

C. OPERATION OF HYDRAULICALLY OPERATED QUICK CLOSING VALVES

AND HYDRAULIC DIRECT DISPLACEMENT CONTROL PANEL.

Do not trip Gate Valves when seating faces are dry to avoid jamming of wedge.

To shut Quick Closing Valve

1. Close vent cock and all selector cocks on control panel.

2. Open appropriate selector cock.

3. Open handpump using extension lever to trip quick closing valve.

NOTE

Minimum one full downstroke of the handpump is required to displace sufficient oil and intensify pressure to 120 pounds per square inch at pressure gauge to ensure valve is tripped shut.

4. Repeat 2 and 3 to close other valves.

To re-set Quick Closing Valve/Panel

1. Open vent cock on control panel.

2. Depress piston in release cylinder using resetting lever.

3. Rotate handwheel clockwise to raise wing collar.

4. Ensure locking levers are engaged to wing collar.

The Quick Closing mechanism can cause personal injury when in operation or if accidentally activated.

5. Open valve by rotating handwheel counter clockwise.

6. Open all selector cocks on control panel.

When not in use, vent cock and all selector cocks must be in open position to prevent thermal expansion of oil causing premature closure of valves.

D. AUTOMATIC FUSIBLE RELEASE CYLINDER ACTIVATION

When temperature in vicinity of valve reaches 135°C. (approx) release cylinder will activate and close valve.

If valves close automatically due to fire, release cylinder O-rings and valve O-rings must be replaced.

4.

MAINTENANCE

A. QUICK CLOSING VALVE

6 Monthly Procedure

1. Check valve for leakage through seals or internally past valve seating faces, (refer to Repair Section if necessary).

2. Lubricate valve as per Lubrication Chart.

12 Monthly Procedure (in addition to 6 monthly procedure)

1. Carry out functional test (refer to Operating Instructions).

2. Replace all seals (refer to Repair Section).

VALVE LUBRICATION CHART

Part Lubricant Application Stem Thread Lithium Grease Directly to threads

Locking Lever Assembly Pivot Points

Lithium Grease Back and front of locking lever (both pivot points)

Fasteners Anti-Sieze Compound Directly to threads during re-assembly (or to exposed threads only when assembled)

Bearing point of Locking Lever/Wing Collar

Lithium Grease Fine smear only

(See page 12)

(See page 12)

(See page 13)

CONTROL PANEL

6 Monthly Procedure Lubricate control panel as per Lubrication Chart

12 Monthly Procedure (in addition to 6 monthly procedure) Check reservoir level (top up to 2/3 full if necessary).

Check vent hole in filling port is not obstructed.

Close all selector cocks and vent cock and intensify pressure to250 PSI to check relief valve setting (refer to Repair Section for adjustment procedure if necessary).

Carry out functional test (refer to Operating Instructions).

Check for sponginess of handpump during operation, refer to Repair Section for de-aeration procedure, in necessary.

CONTROL PANEL LUBRICATION CHART

Part Lubricant Application

Handpump Lever Pivot Point

Lithium Grease Directly to pivot point

Handpump Linkage Bolts Pivot Points

Anti seize Compound

Directly to exposed thread

(See page 13)

5.

REPAIR

A. VALVE SEAL REPLACEMENT

To replace valve seals:

1. Close valve.

2. Disengage locking levers from wing collar.

3. Rotate handwheel counter clockwise to lower wing collar and extend spring.

4. Remove cover fasteners.

5. Remove valve head assembly and lid from body.

6. Remove lid from spindle.

7. Slide spindle out of gland box.

8. Clean gland box.

9. Fit new ‘O’ rings and smear internally with grease.

10. Clean spindle and recess in cover.

11. Replace valve cover gasket.

12. Reassemble.

To replace release cylinder seals:

1. Close valve.

2. Disengage locking levers.

3. Rotate handwheel counter clockwise to lower wing collar and extend spring.

4. Remove locking lever assembly.

5. Withdraw piston from release cylinder.

6. Fit new ‘O’ rings.

7. Reassemble.

B. CONTROL PANEL SEAL REPLACEMENT

To replace control panel handpump seals:-

1. Remove upper fasteners from handpump links.

2. Using lever as tee handle pull gently to extract piston from barrel.

3. Replace seals on piston.

4. Completely fill handpump barrel with oil.

5. Insert piston into barrel.

Slight spillage will occur as piston is inserted.

6. Press piston into barrel.

7. Replace upper fasteners to handpump links.

To replace control panel sight gauge/gasket:

1. Drain system by removing filler plug, drain plug and 2 tubing plugs.

Ensure selector cocks are shut.

2. Remove sight gauge.

3. Replace sight gauge gasket.

4. Fill reservoir with oil to recommended level.

5. Deaerate system.

C. VALVE SEATING FACE REPAIR

1. Mix abrasive lapping compound with olive oil and evenly distribute over cast iron lapping plate.

2. Move wedge in circular direction on the plate using light, even pressure regularly lifting to remove accumulated particles in one area and allow proper distribution of the lapping compound.

3. Turn lapping plate every few strokes to maintain flat surface.

4. Lap component until seating face has smooth finish – this may be time consuming due to the erosion resistant surface but too much lapping must be avoided as this will alter original seating angle.

5. On completion, compound must be cleaned off with suitable cleaning solvent such as acetone or alcohol.

6. Blue test the seating face to confirm full circumferential contact.

If defects cannot be removed by lapping, replacement components must be installed.

D. REMOVAL OF WEDGE JAMMED IN VALVE BODY SEATING

Note: Only applicable to Gate Valves size 2-1/2” (65mm) and above.

1. Remove plug and washer from base of body.

2. Apply wedge jacking screw (tool kit) to base of body.

3. Rotate jacking screw slowly using spanner to free wedge (if necessary, at same time rotate handwheel counterclockwise ).

4. As soon as resistance is overcome, rotate handwheel clockwise to close valve, while removing jacking screw by turning clockwise.

5. Replace plug and washer in base of body.

E. ADJUSTING CONTROL PANEL RELIEF VALVE

1. Locate 2 stem elbows on downstream side of relief valve.

2. Loosen bottom tubing nuts on each stem elbow by turning counter-clockwise.

3. Lift assembly comprising 2 stem elbows and interconnecting tube out of pipeline.

4. Remove straight adaptor by turning counter-clockwise.

5. Insert 5/32” hexagon key wrench into locking screw.

6. Break locking screw counter-clockwise until the hexagon key wrench slides into the adjusting screw.

7. Turn both screws to the desired cracking pressure (clockwise increases opening pressure).

8. Retract hexagon key wrench into the locking screw.

9. Lock against adjusting screw by turning clockwise.

Slight spillage of oil will occur when relief valve ‘blows’. Increase pressure gently as gauge approaches ‘blow off’ pressure.

F. DEAERATING QUICK CLOSING SYSTEM

1. Remove piston from handpump barrel.

2. Fill handpump barrel with oil.

3. Insert piston into barrel.

Slight spillage of oil will occur as piston is inserted.

4. Slacken off hydraulic connection into release cylinder.

5. Operate handpump until flow of oil contains no air.

6. Tighten connection whilst handpump is being operated.

Start at valves operated by selector cocks nearest to reservoir.

SECTION 2 12

SECTION 2 13

SECTION 3

DRAWINGS AND PARTS LIST

Drawing A3.4000 1 Drawing A3.4002 2 Drawing A3.4002S 3

Drawing 2876-A 4 Drawing 3808-18 5 Drawing 3808-12 6 Parts List 7

DRAWING NUMBER PAGE

S E

C T

IO

N ns505234

SECTION 3

ns505234 ns505234

C T

IO

N ns505234

SECTION 3

ns505234

C T

IO

N ns505234

SECTION 3

ns505234 ns505234

SECTION 3

ns505234

SECTION 3

ns505234

SECTION 3

Young & Cunningham Ltd.

ns505234

SECTION 3

Young and Cunningham Inc.

438-1975YA

FUEL OIL AND LUBE OIL

QUICK CLOSING VALVES

SPARES

NASSCO T-AKE

471-342-7385

Recommended

Optional DESCRIPTION PART NUMBER Price

Qty of Valves per ship recommended spares qty Extended

1 1/2" Gate Valve 3 O locking lever assembly A3-4000-1.5-item 10 $134.40 1 $134.40 O spring A3-4000-1.5-item 7 $41.89 1 $41.89 O wing collar A3-4000-1.5-item 9 $57.12 1 $57.12 R o-ring set of (3) A3-4000-1.5-item 6 $22.40 2 $44.80 R bonnet gasket A3-4000-1.5-item 14 $28.00 2 $56.00

2" Gate Valve 1 O locking lever assembly A3.4000-2-item 10 $150.08 1 $150.08 O spring A3.4000-2-item 7 $41.89 1 $41.89 O wing collar A3.4000-2-item 9 $57.12 1 $57.12 R o-ring set of (3) A3.4000-2-item 6 $22.40 1 $22.40 R bonnet gasket A3.4000-2-item 14 $28.00 1 $28.00

2" Gate Valve - SS 2 O locking lever assembly A3.4002S-2-item 10 $150.08 1 $150.08 O spring A3.4002S-2-item 7 $41.89 1 $41.89 O wing collar A3.4002S-2-item 9 $57.12 1 $57.12 R o-ring set of (3) A3.4002S-2-item 6 $22.40 2 $44.80 R bonnet gasket A3.4002S-2-item 14 $28.00 2 $56.00

2 1/2" Gate Valve 3 O locking lever assembly A3.4002-2.5-item 10 $150.08 1 $150.08 O spring A3.4002-2.5-item 7 $41.89 1 $41.89 O wing collar A3.4002-2.5-item 9 $57.12 1 $57.12 R o-ring set of (3) A3.4002-2.5-item 6 $22.40 2 $44.80 R bonnet gasket A3.4002-2.5-item 14 $28.00 2 $56.00

3" Gate Valve - SS 8 O locking lever assembly A3.4002S-3-item 10 $150.08 1 $150.08 O spring A3.4002S-3-item 7 $41.89 1 $41.89 O wing collar A3.4002S-3-item 9 $57.12 1 $57.12 R o-ring set of (3) A3.4002S-3-item 6 $22.40 4 $89.60 R bonnet gasket A3.4002S-3-item 14 $33.60 4 $134.40

4" Gate Valve 2 O locking lever assembly A3.4002-4-item 10 $150.08 1 $150.08 O spring A3.4002-4-item 7 $41.89 1 $41.89 O wing collar A3.4002-4-item 9 $57.12 1 $57.12 R o-ring set of (3) A3.4002-4-item 6 $22.40 3 $67.20 R bonnet gasket A3.4002-4-item 14 $33.60 3 $100.80

4" Gate Valve - SS 2 O locking lever assembly A3.4002S-4-item 10 $150.08 1 $150.08 O spring A3.4002S-4-item 7 $41.89 1 $41.89 O wing collar A3.4002S-4-item 9 $57.12 1 $57.12 R o-ring set of (3) A3.4002S-4-item 6 $22.40 3 $67.20 R bonnet gasket A3.4002S-4-item 14 $33.60 3 $100.80

6" Gate Valve 2 O locking lever assembly A3.4002-6-item 10 $150.08 1 $150.08 O spring A3.4002-6-item 7 $50.40 1 $50.40 O wing collar A3.4002-6-item 9 $98.00 1 $98.00 R o-ring set of (3) A3.4002-6-item 6 $22.40 2 $44.80 R bonnet gasket A3.4002-6-item 14 $56.00 2 $112.00

Young and Cunningham Inc.

H02-05-1975YA

FUEL OIL AND LUBE OIL

QUICK CLOSING VALVES

NASSCO T-AKE

471-342-7385

Recommended

Optional DESCRIPTION PART NUMBER Price

Qty of Valves per ship recommended spares qty Extended

Release Cylinder - One on each Valve 23 O spring 2876-A-item 4 $16.58 4 $66.30 R fusible element 2876-A-item 6 $34.72 10 $347.20 R o-ring set of (2) 2876-A-item 7 $8.96 10 $89.60

Hydraulic Control Panel 2 O selector cock 3803-3 $32.03 4 $128.13 R hand pump o-ring 3803-8 $21.50 2 $43.01 O non-return valve 3803-12 $188.83 1 $188.83 O sight glass 3803-14 $26.66 2 $53.31 R sight glass gasket 3803-15 $14.11 1 $14.11 O relief valve 3803-19 $146.94 1 $146.94

TOTAL PER SHIPSET $4,173.46