Installation and Maintenance Instructions

Vanessa Series 30,000

Installation and Maintenance Instructions

Vanessa Series 30,000 - Basic Configuration
Body Style Double Flanged, Wafer, Lug and Buttweld

Applicable Product Range

• Series 30,000 Basic Configuration, Double Flanged Body Style, which can be installed
between two flanges or stud-bolted to either flange.
• Series 30,000 Basic Configuration, Lug-Single Flange Body Style, which must be bolted
to either flange.
• Series 30,000 Basic Configuration, Wafer Body Style, which can be installed between two
flanges.
• Series 30,000 Basic Configuration, Buttweld ends, which must be welded to the line.

SECTION 1
Valve Storage

1.1 Preparation and Preservation for Shipment

All valves are properly packed in order to protect the parts that are subject to deterioration
during transportation and storage on site. In particular, the following precautions should be
taken:

1 The valves must be packed with the disc in the closed position. The flange sealing
surfaces (raised faces) of the valves will be protected with suitable protective grease. The
end faces of the valve must be protected with plastic or wooden discs fixed with straps.

2 Bare Shaft Valves: the ends of the shaft must be protected with plastic tubes.

3 Valves with Actuators: in case of “Fail open” pneumatic - hydraulic actuators with manual
override, the manual override shall be used to manually close the valves and to lock them
in position. If there is no manual override, cut outs are made in the flange protectors for
the disc, and the disc is securely protected.
All actuated valves must be securely palleted or crated with particular attention, in order to
ensure that parts of actuator (especially pneumatic piping or accessories) do not extend
beyond the skid/crate.

4 The type of packing must be defined in the Customer’s Order and will be appropriate to
ensure safe transportation to final destination and eventual conservation before
installation.

1.2 Handling Requirements

A - Packed Valves
Crates: Lifting and handling of the packed valves in crates will be carried out by a fork lift
truck, by means of the appropriate fork hitches.

Cases: The lifting of packed valves in cases will be carried out in the lifting points and in the
center of gravity position which have been marked. The transportation of all packed
material must be carried out safely and following the local safety regulations.

B - Unpacked valves
1 The lifting and the handling of these valves has to be carried out by using appropriate
means and by respecting the carrying limits. The handling must be carried out on pallets,
protecting the machined surfaces to avoid any damage.

2 With large dimension valves, the sling and the hooking of the load must be carried out by
using the appropriate tools (brackets, hook, fasteners, ropes) and load balancing tools in
order to prevent them from falling or moving during the lifting and handling.

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Installation and Maintenance Instructions
Vanessa Series 30,000

Lifting and Handling of Valves Installed in Horizontal Pipeline 1.3 Storage and Preservation before
Installation
In case the valves have to be stored before
installation, the storage has to be carried out
in a controlled way, and has to be performed
in accordance to the following criteria:

1 The valves have to be stocked in a closed,

clean and dry storage room.
2 The disc must be in the closed position,
and the end faces must be protected with
plastic or wooden discs fixed with straps. If
possible, keep the original protection.
3 Periodical checks have to be carried out in
the storage area to verify that the above
mentioned conditions are maintained.

Note
Storage in an open area for a limited period
can be considered only in case the valves
have appropriate packing (packed in cases
lined with tarred paper, and contents well
protected with barrier sacks).

Caution
For valve handling and/or lifting, the lifting
equipment (fasteners, hooks, etc.) must be
sized and selected while taking into account
the valve weight indicated in the packing list
and/or delivery note.
Figure no. 1a Lifting and handling must be made only by
qualified personnel.
Lifting and Handling of Valves Installed in Vertical Pipeline
Fasteners must be protected by plastic
covers in sharp corner areas.

Caution must be taken during the handling to

avoid that this equipment passes over the
workers or over any other place where a
possible fall could cause damage. In any
case, the local safety regulations must be
respected.

Note
Solutions A and C are applicable when the
protrusion of the bottom hub from the flange
or body is sufficient to position securely the
lifting strap.
Solutions B and D are applicable when the
protrusion of the bottom hub from the flanges
is NOT sufficient to position securely the lifting
strap.
In presence of solution B, insert a stud bolt
and fix it securely with nuts as indicated in the
drawing detail.
In presence of solution D, insert a lifting eyelet
in the flange threaded holes close to the
bottom hub and fix it securely as indicated in
the drawing detail.

Figure no. 1b

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 Installation and Maintenance Instructions
Vanessa Series 30,000

SECTION 2
Installation

2.1 Valve Inspection

1 Carefully remove the valve from the shipping package (box or pallet) avoiding any damage to
the valve or, in case of automated valves, to the electric or pneumatic/hydraulic actuator or
instrumentation.
2 The valves are shipped with the ends protected with caps and a thin layer of protective grease.
Before installing the valve, remove the caps and clean carefully, then de-grease both surfaces
with a solvent. Clean the inside of the valve using an air line. Ensure that there are no solid
objects such as pieces of wood, plastic or packing materials within the valve or on the valve
seat.
3 Inspect the seal ring to ensure that it was not damaged during handling. This is especially
important in case of valves shipped with the disc in the open position and with “fail-open”
actuators.
4 Confirm that the materials of construction listed on the valve nameplate are appropriate for the
service intended and are as specified.
5 Ensure that the packing gland adjusting nuts against the packing gland flange cannot be
rotated by hand.

2.2 Valve Installation

Figure 2 Vanessa recommends that the optimum valve installation is with the shaft in the horizontal plane,
after which it is preferable to have the shaft at an angle so as to minimize any problem associated
with solid particles present in the fluid that otherwise could deposit in the lower bearing area.

The Vanessa valve is designed to withstand design differential pressure in both directions.

Isolating applications
The valve operating torque affects the sealing performances. Vanessa attached the indication
plate ∆P (figure 2) on the upstream flange as a reference for the direction of the installation.
The best sealing performance, also for bi-directional service, will be maintained when pressure
acts on the shaft side of the valve, which is recommended when the service tightness
requirements are more stringent in one specific direction.

Control applications (uni-directional, where perfect sealing is not required)

The plate could be fixed on either flange indicating the preferred direction. Please respect the
direction of installation indicated on the relevant flange. The selection of the actuator has been
made for that specific direction of installation.

Unless otherwise recommended by Vanessa, the valve should be installed with the disc in the
closed position to ensure that the seal ring in the disc is not damaged during installation. Particular
care should be taken with those valves equipped with ‘fail-open’ actuators.

For operating temperatures above 200°C (392°F) thermal insulation of the valve body is
recommended.

If the valve has threaded tapped holes in the hub areas, Vanessa recommends to use hexagonal
head bolts or shorter studs to connect the valve in this zone. The depth of the tapped holes in the
bodies of all Series 30,000 valves is specified in the technical literature. Failure to use correct
bolts/studs may result in damage to the valve.

If the valve has welded ends, perfectly clean and degrease the ends to be welded (of both valve
and pipe), using a cloth with acetone or similar product. Insert correctly the valve between the
edges of the pipe to be welded, taking care of the plate that indicates the preferential side for
Important
sealing. Carry out an initial accurate spot welding verifying the perfect alignment of the edge and
It is recommended to perform piping axis of the valve. Carry out the welding of the edge proceeding in alternate way on both sides to
flushing before installation of valve. reduce the tensions introduced by the welding. It is important to respect the interpass
If this is not possible, the valves must be temperature which must not go above 150°C (302°F).
set with the disc in full open position
before starting with flushing. Handling and lifting of the valves during installation MUST be performed following the same criteria
and instructions described in previous points “1.2 Handling Requirements” and “1.3 Storage and
Preservation before Installation”.
Cautions
When the pipe is lined, be careful that the
disc does not come into contact with the
lining during its stroke, especially in Lug and
Wafer body styles. This verification is very
important to avoid any damage to the valve.

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 Installation and Maintenance Instructions
Vanessa Series 30,000

2.3 Valve Verification

1 Tighten the packing just enough to prevent stem leakage. Over-tightening will decrease packing
life and increase operating torque.
2 Check the operation of the valve by stroking it to “full open” and “full close”. To verify the valve
orientation, the disc position indicator mark on the shaft (during the normal open to close cycle)
should rotate clockwise from a position in line with the pipe (see figure 3a) to a position parallel
to the pipe flanges (see figure 3b).

lose
ise to c
Clockw

ey
Shaft k
sition
Disc po
r mark
indicato

osition y and
open p haft ke
Disc in Disc - s plane
r mark
sition indicato
po
ey
Figure no. 3A Shaft k

sition
Disc po
r mark
indicato
position
closed
Disc in

lose
ise to c
Clockw

y and
haft ke
Disc - s ark pla
ne
ion indicator m
posit

Figure no. 3B

Important

If piping system is pressurized with water for testing, and in case the piping system has been
shut down after testing for a long time, the following recommendations should be adopted:

a. Use corrosion inhibitor with water to pressurize the piping system.

b. After testing, the piping system should be depressurized and the test water completely
drained.
c. After testing, valves must be maneuvered through a complete opening/closing cycle
and disc left in half-open position. Apply a film of protective oil in the packing area by
means of a paintbrush. The protective oil must fill the area between shaft and
packing bushing.

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 Installation and Maintenance Instructions
Vanessa Series 30,000

2.4 Troubleshooting Guide

Symptom Possible Cause Resolution

Valve won’t rotate 1. Packing is too tight 1. Loosen gland nuts

2. Actuator has failed 2. Replace or repair
3. Valve packed with debris 3. Flush or clean valve to remove debris
4. Stem key has sheared 4. Determine cause of shearing and correctly replace stem key
5. Fluid solidification between bearings 5. Flush bearings by flushing holes (if present)
and shaft

Stem packing leaking 1. Gland flange nuts too loose 1. Tighten gland flange nuts
2. Packing damaged 2 Replace packing - See Paragraph 3.1

Bottom flange gasket leaking 1. Bottom flange bolting loose 1. Tighten bottom flange bolting
2. Spiral wound gasket damage 2. Replace gasket - See Paragraph 3.3

Valve leaking 1. Valve not fully closed 1. Close valve

2. Debris trapped in valve 2. Cycle and flush (with valve open) to remove debris
3. Actuator mechanical stops improperly set 3. Remove the stop for closure and reset properly
4. Seal ring damaged 4. Replace seal ring - See Paragraph 3.2

Jerky operation 1. Packing is too tight 1. Loosen gland nuts, cycle valve, retighten
2. Air supply inadequate 2. Increase air supply pressure and/or volume
3. Actuator/stem adapter misaligned 3. Remove actuator mounting and realign.

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 Installation and Maintenance Instructions
Vanessa Series 30,000

SECTION 3
Maintenance Warning!

The Vanessa Series 30,000 has been designed to require a minimum of maintenance.
Depressurize the line before starting any
3.1 Packing Maintenance maintenance. Failure to do so may cause
If shaft leakage is observed through the packing, tighten the gland nuts slowly and evenly until the serious personal injury and/or equipment
leakage stops. damage.

Caution
Do not over-tighten packing gland nuts. Over-tightening will increase the torque required to
operate the valve.
When tightening the gland nut, use half-turn increments until leakage has stopped.
Please refer to the Figure no. 4.
To replace the packing proceed as follows:
1 Remove the gear/actuator and relevant connecting keys (4f). Please note the actuator position
relative to the valve position for reassembly of gear/actuator later.
2 Remove gland nuts (5d). If present, remove bellevilIe springs (5n), taking care of noting their
assembly configuration to reassemble them correctly (point 7).
3 Remove packing gland flange (5f), anti blow-out ring if present (5g), and gland bushing (5c).
4 Remove packing (5a). If valve is with packing flush option, remove lantern ring also (5h).
5 Carefully clean packing cavity and shaft (4a).
6 Apply a thin film of lubricant on each new packing ring (5a) surfaces (lubricant should be in
accordance with Table IV). Insert new packing rings, paying attention to insert the two braided
rings at the bottom and top of the entire packing. If valve is with packing flush option, insert the
lantern ring (5h) in the same sequence as previously removed (or as indicated in figure 4). If the
packing rings are of the split variety, install with splits staggered at 180° from each other.
7 Reassemble gland bushing (5c), anti blow-out ring if present (5g), and gland flange (5f). If
present, assemble the belleville springs (5n), following the assembly configuration noted in the
previous point 2, then assemble by hand the gland nuts (5d) without tightening (after applying
a thin film of lubricant on the threads of the stud bolts, in accordance with Table IV).
8 Reassemble keys (4f) on the upper stem end.
9 Reassemble gear/actuator and close the valve.
Caution
Do not force actuator on the stem! This should be a free moving fit.
10 Tighten gland nuts (5d) in accordance to Table I (Torque values for gland nuts).
11 Cycle the valve.
12 Pressurize again the line.
13 If a leakage is detected, tighten the gland nuts slowly and evenly until the leakage stops.

Figure no. 4

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 Installation and Maintenance Instructions
Vanessa Series 30,000

3.2 Sealing Elements Maintenance 5 Carefully remove the retainer ring screws (2c) with security washers (2d), then remove the seal
retaining ring (2b).
To replace the sealing elements proceed as 6 Remove seal ring (3a) and spiral wound gasket (3b).
follows (please refer to figure no. 5): 7 Inspect the body seat. Clean it, if necessary, with fine abrasive cloth (No. 600 or finer), after
having cleaned it perfectly with solvent.
8 Inspect and clean the disc seal ring area and spiral wound gasket groove. No foreign particles
Warning! must be present before spiral wound gasket and seal ring assembly.
9 Apply a thin film of lubricant on the surface area of the disc (2a) where seal ring (3a) and spiral
Depressurize the line before starting any wound gasket (3b) will be located (lubricant should be in accordance with Table IV).
maintenance.
Failure to do so may cause serious Caution
personal injury and/or damage to the valve. Apply only a thin film of lubricant where indicated. Failure to do so will hinder the assembly and
may cause damage to the valve.

1 Remove the valve with the disc in the 10 Assemble the new spiral wound gasket (3b) in the disc groove, without forcing and taking care
closed position from line. Clean the valve not to damage it.
according to proper cleaning procedure 11 Replace seal ring (3a) on the disc through the shaft side of the body. To properly locate the seal
as outlined by the plant or according to a ring, there are two different solutions:
recommended procedure. • solution 1 - ref. to figure no. 6a - align the internal slot of the seal ring (3a) to the reference pin
2 Open the valve a few degrees. (F).
3 Loosen the seal retainer ring screws (2c). • solution 2 - ref. to figure no. 6b - align the reference mark (C) on the seal ring (3a) with the
4 Open valve to full open position. relevant reference mark (D) on the disc.
12 Assemble the seal retainer ring (2b). There are two different solutions as per previous point 11:
Note • solution 1 - ref. to figure no. 6a: make sure that the slot on the edge of the seal retainer ring
In small size valves it may be easier to (B) is in correspondence with reference pin (F).
unbolt the actuator and rotate the disc • solution 2 - ref. to figure no. 6b: ensure to locate the hole (E) of the seal retainer ring with the
beyond the full-open position to provide relevant marks on the disc (D) and seal ring (C).
more space to work with components. 13 Hand tighten all the fastening screws (2c), with relevant lock washers (2d) after applying
Loctite® 270 or equivalent on the bottom side of the threads (they have to be perfectly cleaned
with solvent before applying Loctite®). Then, verify that the seal ring can be moved freely by
hand without rotating it.
14 Apply a thin film of lubricant to the body seat and to the external edge (sealing conical surface)
of the seal ring (3a). Lubricant should be in accordance with Table IV.
15 Seat and unseat the valve twice.
16 Keep the valve in the closed position without applying torque. Tighten at least two retaining
screws (2c) to avoid the seal ring moving from the position found.

Figure no. 5

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 Installation and Maintenance Instructions
Vanessa Series 30,000

17 Open the disc a few degrees and tighten, using a torque wrench, all screws (2c). Use a torque
value from Table III for valves according to solution 1 (ref. to figure no. 6a). Use instead a torque
value from Table II for valves according to solution 2 (ref. to figure no. 6b).
It is recommended to use the crossover method to tighten all retaining screws.

Important!

• Solution 1- ref. to figure no. 6a:

The seal ring is supplied with an index marking (A). After the complete assembling, verify that the
index marking (A) can be seen in the slot (B) of the seal retainer flange.
Slot (B) and marking (A) have to be perfectly aligned.
If not visible or not aligned, loosen the retaining screws, re-align the index marking and start again
the procedure from point 12.

• Solution 2 - ref. to figure no. 6b:

The seal ring and the disc are completed with two reference markings, (C) and (D).
After the complete assembling, verify that both markings can be seen through the hole (E) of
the seal retainer flange. The two markings have to be perfectly aligned.
If not visible or not aligned, loose the retaining screws, re-align the index markings and start
again the procedure from point 12.

3.3. Bottom Flange Gasket Maintenance

If necessary to replace the bottom spiral wound gasket, proceed as follows (see fig. no. 7):

1 Remove the bottom flange (6a).

2 Remove the spiral wound gasket (6c).
3 Inspect and clean the groove of the spiral wound gasket in the body and in the bottom flange.
4 Apply a thin film of lubricant on the bottom spiral wound gasket (6c), then insert it on the
bottom flange (6a), centering and positioning all on the body bore (lubricant should be in
accordance with Table IV). Rotate the bottom flange to accommodate the correct position and
center the holes with the threaded holes on the body.
5 Apply a thin film of lubricant on the threads of the screws (6b), then introduce and tighten them
using a torque value from Table III (lubricant should be in accordance with Table IV).

Figure no. 7

Figure no. 6a Figure no. 6b

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 Installation and Maintenance Instructions
Vanessa Series 30,000

SECTION 4
Standard Options

This section (4) is referred only to Vanessa products configured with the following options:
- bearing & packing flushing,
- live loaded packing.

4.1 Bearing & Packing Flushing

4.1.1 Bearing Flushing

The bearing flushing option is obtained by adding two tapped holes, one in the bottom flange and
one in the neck of the valve (see fig. 9). This option includes the introduction of a lantern ring at
the bottom of the valve packing. Bearing flushing is recommended when the valve is installed in a
service where the particles present in the fluid or the line fluid itself can migrate into the
shaft/bearing area causing problems. A typical example is sulphur recovery services, where the
sulphur in a liquid or gaseous state may enter this area and crystallise as a consequence of the
plant shutdown.

This crystallisation may result in an increase in

the torque requirement of the valve. Another
Upper flushing inlet example may be a fluid that contains particles
(e.g. catalyst) that may cause similar problems
Flush pressure = P + 5% to those highlighted above.
In these types of situations the bearing
flushing may be used to introduce an inert
fluid compatible with the process via the
bearing flush taps (see fig. 8) so as to create a
pressure barrier which prevents the
introduction of the unwanted products from
the line into the shaft/bearing area. The
pressure of the flushing fluid must be slightly
higher than the line pressure (i.e. P1 + approx
Disc Shaft 5%). This both acts as a safety measure and
side side is a positive step in increasing the lifetime of
the valve, as well as maintaining the constant
torque requirement and hence operability of
the valve.
The bearing protector The bearings may be continuously flushed,
minimizes the consumption this is recommended by Vanessa for critical
of the clean fluid services such as described above. Periodic
flushing may be used for less critical services
in order to clean the bearing/shaft interface or
in order to prepare the valve for a shutdown
Lower flushing inlet of the process.
The bearing flush taps may also be used to
Figure no. 8 introduce a lubricant compatible with the
process to the bearing areas for high cycle or
dry gas service. The presence of the bearing
protector drastically reduces the consumption
of the flushing or lubricant by reducing the
amount of fluid required to give efficient
service (see fig. 8).
Further information is available from Vanessa
on request.

flushing
bearing
Upper
tion
connec g flushin
g
Packin
tio n
shing connec
er be aring flu
Figure no. 9 Low
tion
connec

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 Installation and Maintenance Instructions
Vanessa Series 30,000

4.1.2 Packing Flushing

The packing flushing option is obtained by the introduction of a tapped hole that communicates
directly to the packing set in the neck of the valve via a lantern ring. This option can be used to
monitor the rate of emission of the line fluid toward the atmosphere (it is important to point out
that the packing of the Vanessa valve fully complies with TA Luft and EPA requirements). This flush
tap may also be used to capture and evacuate line fluid so as to prevent any atmospheric loss,
with the lantern ring and split packing configuration acting as a double block and bleed unit.

A suitable fluid may also be introduced via the packing flush tap into the packing area so as to
eliminate any possible fugitive emissions (see fig. 9). By keeping the fluid pressurised at a pressure
that is higher with respect to the line pressure, the passage of any line fluid towards the
atmosphere can be effectively blocked giving the valve excellent fugitive emissions control.
However, the fluid used must be compatible with the line fluid as it may have the possibility of
finding its way into the line as well as toward the atmosphere.

As with the bearing flushing option this may also be used to introduce a lubricant compatible with
the process.

The type of lubricant used for flushing is at the clients’ care. Vanessa may be contacted to supply
further detailed, process specific information.

4.3 Live Loaded Packing

The live loaded packing option is designed to supplement the already excellent characteristics of
the Vanessa valve packing. This option guarantees a constant compression of the packing set
giving a further guarantee of the fugitive emissions control of the Vanessa valve. The fact that the
packing is subject to a near constant force supplied by the Belleville washers reduces the
maintenance cycle required by the packing (see fig. 10).

Care should be taken in replacing the Belleville springs as their order (parallel or series) should be
noted.
The packing nuts should be tightened in accordance with Table I.

At this point it is worth mentioning that the TA Luft test has shown that the Vanessa Series 30,000
std. Packing is more than adequate in passing its stringent requirements.

The live loaded packing option should be considered in valves that are subject to severe cycling
duty or valves that are subject to severe thermal cycles.
The drawing shows typical set ups for the live loaded packing option.

Figure no. 10

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 Vanessa Series 30,000
Storage, Installation and Maintenance Manual

Table I: Torque Values for Gland Nuts

ND Trim A Trim B Trim C Trim D Trim E
in. mm Nm FT-LB Nm FT-LB Nm FT-LB Nm FT-LB Nm FT-LB
3 80 - - 15 11 15 11 30 22 - -
4 100 - - 15 11 15 11 30 22 - -
6 150 - - 15 11 20 15 35 26 50 37
8 200 - - 15 11 20 15 60 44 105 78
10 250 - - 25 18 20 15 70 52 135 100
12 300 - - 25 18 25 18 75 55 240 177
14 350 - - 30 22 30 22 75 55 240 177
16 400 - - 30 22 35 26 100 74 175 129
18 450 - - 35 26 40 30 205 151 480 354
20 500 - - 35 26 45 33 320 236 195 144
24 600 - - 45 33 55 41 420 310 605 446
28 700 30 22 85 63 100 74 465 343 - -
30 750 30 22 105 78 135 100 485 358 - -
32 800 30 22 105 78 165 122 505 372 - -
36 900 30 22 110 81 220 162 545 402 - -
40 1000 30 22 110 81 225 166 - - - -
42 1050 30 22 110 81 230 170 - - - -
48 1200 30 22 110 81 235 173 - - - -
54 1350 50 37 155 115 - - - - - -
60 1500 65 48 160 118 - - - - - -
64 1600 65 48 - - - - - - - -
72 1800 65 48 - - - - - - - -
84 2100 65 48 - - - - - - - -
Note: The torque values are those suggested for the hydraulic test of the body.

Table II: Tightening Torque Values Table III: General Torque Values
for Bolts & Screws for Bolting
Bolt Dimensions Torque Values Bolt Dimensions Torque Values
(mm) Torque (Nm) Torque (Ftlb) (mm) Torque (Nm) Torque (Ftlb)
8 12 9 6 10 7
10 24 18 8 20 15
12 41 30 10 45 33
14 66 49 12 70 52
16 103 76 14 110 81
18 142 105 16 175 129
20 201 148 18 235 173
22 274 202 20 335 247
24 348 257 22 370 273
24 460 339
27 595 439
30 760 561
33 785 579
36 1010 745
39 1315 970
42 1625 1199
45 2035 1501

Table IV: Lubrication

Type Component to Lubricate

Light mineral oil 1. Packing Rings (5a)
2. Disc Surface areas (2a) for Seal Ring and
Spiral Wound Gasket location
3. Spiral Wound Gasket (6c)

Molykote® - P74 (grease) 1. Stud Bolts/Nuts (5d)

or equivalent 2. Screw (6b)

Molykote® Spray - 321 R (dry lubricant) 1. Seal Ring (3a)

or equivalent 2. Body Seat

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