OPERATI ON & M AI N TEN AN CE M AN UAL

FOR
1 2 0 0 M M SPH ERI CAL VALVE

CUSTOM ER : M / s B FOURESS ( P) LTD .

P.O. N O

: 3 5 9 / BM / 3 2 8 3 8

D ATE

: 30/ 10/ 2012

PROJECT

: CH AN JU- I H YD RO POW ER PROJECT.

FOURESS CON TRACT N O

: 13846

FOURESS
ENGINEERING (INDIA)LIMITED

In

the

business

of f l o w w

Plot No.2, PhaseII, Peenya Industrial Area, Bangalore-570058. India

Phone: 2839 5734, Fax : 90-80-2389 5175/76
E-mail: info@fouressindia.com Website: http://www.fouressindia.com

OPERATI ON & M AI N TEN AN CE M AN UAL

FOR
1 2 0 0 M M SPH ERI CAL VALVE

I N D EX
CH APTER N O.

D ESCRI PTI ON

01.

GEN ERAL I N TROD UCTI ON

02.

D ATA SH EET FOR VALVE & ACCESSORI ES

03.

BOD Y & ROTOR

04.

SERVO M OTOR

05

M AI N TEN AN CE

06.

UN PACKI N G, H AN D LI N G,
I N STALLATI ON & STORAGE

07.

ERECTI ON PROCED URE

08.

COM M I SSI ON I N G

09.

LI ST OF RECOM M EN D ED SPARES

10.

CATALOGUES FOR BOUGH T OUT I TEM S

11.

D RAW I N GS & EN CLOSURES

CH APTER 0 1

GEN ERAL I N TROD U CTI ON

GEN ERAL I N TROD UCTI ON

GEN ERAL FUN CTI ON OF VALVE
Spher ical valve is basically used t o isolat e it s t ur bine fr om t he penst ock w hen t he
t ur bine is shut dow n. I t is opened and closed by a double act ing ser vom ot or , using
pr essur ized oil fr om t he pow er pack operat ing fluid. I n bot h inst ances, t he flow of oil t o
t he ser vo is cont r olled by solenoid oper at ed dir ect ion cont rol valve. The oper at ion of t he
valve is nor m ally par t of t he oper at ing sequence of t he t ur bine.
The valve funct ions ver y sim ilar ly t o a conv ent ional ball valve, except t hat t her e is a
gap bet w een t he spher ical rot or and t he body. To seal t he valve, t his gap m ay be closed
at eit her end f t he valv e by st ainless st eel seal r ings, w hich slide ax ially in t he body under
hydr aulic cont r ol. The dow nstr eam r ing is the ser vice seal and is engaged, or disengaged
m aint enance seal and is engaged, or disengaged. I t usually r em ains open, only being
closed for isolat ion pur poses. These seals m ust never be engaged unless t he r ot or is
closed; avoid dam age t he seals ar e fir st disengaged. To avoid dam age t o t he seals or
r ot or, and seals can only be oper at ed if t hese condit ions pr evail.
Nor m ally, t he valve oper at es in a balanced condit ion, i.e. at zero flow w it h t he
t ur bine needle valves closed. How ever , in an em ergency it is capable of closing against
full flow .

CH APTER - 0 2

D ATA SH EET FOR VALVE & ACCESSORI ES

D ATA SH EET FOR VALVE & ACCESSORI ES

1 .1

1 .2

GEN ERAL
Cu st om e r

M / s B FOURESS ( P) LI M I TED

P.O. N o.

3 5 9 / BM / 3 2 8 3 8

Date

30-10-2012

Pr oj e ct

CH AN JU- I H YD RO POW ER PROJECT

TECH N I CAL D ATA

Valve Manufact ur er

M/ s. Four ess Engineer ing ( I ndia) Lt d.

Year of Manufact ur ing

2013

Valve Size

1200 m m

G.A. Dr g .No.

SV- 48001- H/ R4

I nst allat ion Dr g. No.

SV- 48001- 10/ R4

Plat for m Drg. No

SV- 48001- 100/ R1

Design

Split Body

Type

Spher ical Valve

Fluid Handled

Wat er

Design Pr essur e

32 BAR.

Tem per at ur e

Am bient

End Connect ion

Tapped Holes on Bot h I nlet &

Out let Pieces of Body

Wt . of valve and it s
Accessor ies

20000 Kgs ( Appr ox)

Valve Oper at ing Tim e

30- 60 Sec

Body Test Pr essur e

51 Kg/ cm 2. durat ion : 15m in

Seat Test Pr essur e

37.4 Kg/ cm 2. durat ion : 15m in

Valve I s Designed t o
Open Under

Balanced Head Condit ion

( Wit h By Pass Ar rangem ent )

Flange Dr illing

Manufact ur er s St d.

Dut y of valve

on/ off

Type of Rot or

Thr ough flow t ype

Lever Locking Ar rangem ent

Pr ovided
:

Yes at closed posit ion of valve

Hydraulic cylinder pr ovided

for Valve Opening/ Closing :

Yes

By pass arr angem ent

pr ovided

Yes

Dism ant ling j oint pr ovided :

Yes

Dow n st r eam pipe pr ovided :

No

Air Release valve pr ovided :

Yes

Dr ain valve pr ovided

Yes

Hydraulic Pow er Pack

Pr ovided

No

Elect r ical cont r ol panel

pr ovided

No

Lim it Sw it ches pr ovided

Yes

Valve Foundat ion det ails

pr ovided

Yes

1 .3

ACCESSORI ES
I.

H YD RAULI C CYLI N D ER

a)

Make

I sland Hydraulics ( I ndia) Pr ivat e Lim it ed.

b)

Type

Double Act ing

c)

Size

200m m bor e x 1162m m St r oke

d)

Cylinder pr essur e r at ing

160 Bar

e)

Cylinder Qt y/ valve

01 No.

f)

Cylinder Mount ing St yle

Rear clevis w it h spher ical ey e.

g)

Por t connect ion

1 BSP ( Type)

h)

Fluid handled

Miner al Oil Ser vo Syst em 68

II.

H YD RAULI C CYLI N D ER FOR N EED LE VALVE

a)

Make

I sland Hydraulic

b)

Type

Double Act ing

c)

Cylinder pr essur e r at ing :

160 Bar

d)

Cylinder Qt y/ valve

01 No.

e)

Cylinder Mount ing St y le :

Fr ont flange m ount ing

f)

Pist on r od Dia

110m m

g)

Por t connect ion

1 BSP ( Bot h ends)

h)

Fluid handled

Miner al Oil Ser vo Syst em 68

I I I . BY- PASS GATE VALVE ( M an u ally Ope ra t e d)

a)

Manufact ur er

Four ess Engineer ing ( I ) Lt d

b)

Pr essur e class

Class- 300

c)

Type of oper at ion

Manual w it h hand w heel

d)

End connect ion

Flanged w it h r aised face

CH APTER - 0 3

BOD Y & ROTOR

BOD Y & ROTOR

The body consist s of t w o cast st eel hollow hem ispher ical cast ings secur ed t oget her
by st uds and nut s. The upst r eam face

of t he body connect ed t o a cast st eel flange

int egr al w it h pipe, w hich is w elded t o t he dow nst r eam flange of t he penst ock .
The dow n st r eam face of t he body ( out let piece) is connect ed t o a ser vice flange
int egr al w it h cast pipe & t erm inat ed by dism ant ling j oint flange. Fur t her t he fabr icat ed
pipe piece ends w it h a t er m inat ion flange w hich is going t o be connect ed t o t he flange of
t he t ur bine inlet pipe w or k. The dism ant ling j oint is of j acking t ype incorpor at ing j acking
st uds, & it s design per m it t he r em oval of t he assem bly for m aint enance t o t he ser vice seal
w it hout dist ur bing t he valve body.
The r ot or is a one piece spher ical cast st eel cast ing suppor t ed by bolt ed t r unnions.
These t r unnions r un in self- lubr icat ed bear ings locat ed in bear ings housings m achined in
inlet body cast ing. Bolt ed and dow elled t o t he end one t r unnion is an oper at ing lever ,
w hich is act uat ed by t he ser vice seal and m aint enance seal w hich ar e secur ed in r ecesses
in.t he.r ot or .by,.socket .head.cap.scr ew s.

CH APTER - 0 4
SERV O M OTOR

SERVOM OTOR
The ser vom ot or is of t he double act ing type using pr essur ized oil fr om hydraulic pow er
pack.

The ser vom ot or is suspended from a m ounting br acket bolt ed t o anot her br acket , w hich is
w elded t o t he inlet piece of body. The r od end is connect ed t o t he valve oper at ing lever
ar m , so t hat axial m ovem ent of t he ser vom ot or pist on is conver t ed t o angular m ovem ent
of t he valve r ot or .

CH APTER - 0 5

M AI N TEN AN CE

M AI N TEN AN CE
REN EW I N G I N LET VALVE SERV I CE SEAL D & O RI N GS
1)

Close t he inlet valv e, engage t he m aint enance seal t hen dew at er t he valve and
t ur bine inlet pipe w or k.

N OTE: The air r elease valves m ust be open dur ing t he dew at er ing.
2)

Rem ove dr ain, scour and air r elease valve piping and all indicat ing equipm ent fr om
t he valve, aft er car efully m at ch- m ar king t o assist in r eplacem ent .

3)

Release and r em ove t he bolt s and nut s secur ing t he sealing r ing t o t he pipe piece,
t hen inser t t he j acking scr ew s and j ack the sealing r ing along t he pipe fr ee of
dow nstr eam pipe piece.

4)

Scr ew an eyebolt int o t he lift ing boss on t he dow nstr eam flange & pipe and
anot her in t o t he sealing r ing.

5)

Release and r em ove t he bolt s secur ing t he flange and pipe t o t he inlet pipe w or k
flange, t hen r em ove t he pipe, com plet e w it h sealing r ing.

6)

Scr ew eyebolt s int o t he t apped holes on t he upst r eam flange & pipe and eyebolt s in
t o t he t apped holes on t he dow nst r eam flange of dow nstr eam pipe piece.

7)

Release and r em ove t he nut s from t he st uds secur ing t he dow nst r eam pipe piece t o
t he valve body. Rem ove t he dow nst r eam pipe piece, t aking car e not t o dam age t he
ser vice seal.

8)

Rem ove t he ser vice seal t aking car e t o avoid dam aging t he highly finished sliding
sur faces

9)

Rem ove, and dest r oy, t he old D r ings and fit new r ings.

N OTE: These r ings ar e pr ecisely gr ound to suit t he individual r ing gr ooves and ar e not
int er changeable.
10)

While t he ser vice seal is r em oved, oppor tunit y should be t aken t o exam ine t he
m at ing faces of t he seat ing r ing and t he service seal and t her eaft er t o r efurbish , or
r enew , t hem as necessar y.

11)

Renew all t he O r ings in t he flanges and t he sealing r ing t hen r eassem ble t he
ser vice seal and dism ant ling j oint in r ev er se or der t o t hat descr ibed above.

N OTE: The nit r ile r ings should be lubr icat ed only w it h soft - soap or silicon based gr ease,
as ot her com pounds m ay have a det r im ent al effect on t he r ing.
12)

Replace all piping and cont r ol equipm ent s.

CH APTER 0 6
UN PACKI N G, H AN D LI N G, I N STALLATI ON & STORAGE

UN PACKI N G, H AN D LI N G, I N STALLATI ON & STORAGE

The follow ing pr ocedur e is adopt ed w hile r em oving t he t ur bine inlet spher ical valve and it s
accessor ies fr om t he package sent befor e it is t aken up for assem bly and inst allat ion.
1.

Please check t he m ar kings on t he package and aft er confir m ing t at t his package is
having t he ext r act valve, it can be opened as explained below .

2.

Rem ove t he t op and side cover s of t he w ooden package in w hich

valve has been cr at ed.

3.

Rem ove t he bolt s pr ovided t o fix t he valv e in posit ion.

4.

Aft er ascer t aining t hat t he valve is fr ee fr om all it s fixt ur es, t he unit is t aken out
car efully fr om t he bot t om plank of t he package.

5.

Check and confir m t hat all t he openings if any in t he equipm ent and it s accessor ies
ar e proper ly plugged w it h plast ic cover plugs t o avoid ingr ess of dust / m oist ur e.

6.

Befor e t aking up assem bly and er ect ion of t he valve, m ake sur e t hat t he it em s of
t he valve have not undergone any dam age w hile in t r ansit and handling, and w hile
unloading.

7.

As far as possible, im m ediat e ar rangem ents m ust be m ade t o inst all t he valve and
it s com ponent s w her e it is m eant for and not j ust be kept for a long w it hout use a
t her e is ev er y possibilit y for all finished sur faces coat ed w it h oil t o dr y and get
cor r oded t her e by r educing t he nor m al life/ useful w or king per iod of t he valve and
it s accessor ies.

t he par t icular

I n case t her e is any possibilit y of t he it em s not being used im m ediat ely and have t o be
st or ed for a long t im e t he follow ing ar r angem ent s have t op be m ade t o keep t he it em s of
valves and it s accessor ies in a t r im / fit condit ions w it hout any dam age / w ear .
a.

All t he ext er nal bear ing sur face of cylinder s, and finely finished sur faces of t he
valve and it s accessor ies ar e given a good coat ing of gr ease and ar e cover s w it h
r ust pr oof polyt hene paper .

b.

The ent ir e openings ar e plugged ver y effect ively t o avoid dir t , dust w at er / m oist ur e
or any ot her contam inat ion t o ent er and dam age t he it em s.

c.

Sm all it em s like O r ings and r ubber seals ar e cover ed w it h Fr ench chalk and ar e
packed in gr ease/ oil coat ed polyt hene bags and sealed.

d.

All packages/ loose supplies ar e kept cover ed w it h polyt hene plast ic sheet s t o avoid
dam age due t o dir t / dust , m oist ur e, fungus or any ot her corr osive gaseous
at m ospher e.

e.

All t he it em s ar e st or ed in a cool and clean at m ospher e fr ee of dir t , dust heat

hum idit y acid and corr osive gaseous fum es and or any ot her cont am inat ion.

CH APTER 0 7
ERECTI ON PROCED URE

ERECTI ON PROCED URE

Befor e t aking up t he er ect ion w or k of t he spher ical valve, please check t he availabilit y of
all t he it em s at sit e as per t he dispat ch docum ent s, if not t ake needful act ion t o m ake up
t he nonavailable it em s. Also check and confir m t hat t her e is no dam age/ det er iorat ion of
valve and accessor ies due t o t r anspor t at ion, long/ bad stor age , wr ong handling et c.

Re fe r e n ce D r a w in gs
Gener al ar rangem ent of 1200m m spher ical valve
I nst allat ion ar r angem ent of 1200 m m spherical valve
Hydraulic cylinder200m m bor e x 1162 m m St r oke
Test pr ocedur e for 1200m m spher ical valve
Check and pr ovide connect ing pipe line / ax is m ar king as r efer ence m ake t o car r yout
fur t her er ect ion w or k.
1.

I f U/ S and D/ S pipes ar e alr eady inst alled check and ensur e t hat
pr ovided t o inser t t he spher ical valves and t he accessor ies.

cor r ect gap is

2.

Wit h r efer ence t o t he I nst allat ion dr aw ing ( SV- 48001- 10) m ar k t he foundat ion plan.
Cast t he spher ical valve foundat ion leaving pocket s for foundat ion bolt s as per
foundat ion layout draw ing ( 1 st st age concr et e) dur ing second st age concr et e of
foundat ion t he foundat ion bolt s and sole plat es ar e inser t ed and gr out ed as per t he
above foundat ion dr aw ing.

3.

Wit h t he available opening of t he spher ical Valve is t o be low er ed inside t he pit

ver t ically. The spher ical valv e and t he assem bly is t o be m ade hor izont al inside t he
valve pit and t hen inst all t he above assem bly t o t he pipe line as per t he inst allat ion
dr aw ing.

N ot e :- Suit able handling ar r angem ent of adequat e capacit y is r equir ed inside t he valve
pit and t he sam e is t o be arr anged by cust om er .
4.

5.

Check t he dim ensions of t he cavit y/ opening provided on t he pow er house floor /

r oofing for t aking t he spher ical valve t o it s locat ion in t he piping syst em . I f t he
spher ical valve w it h U/ S and U/ S assem bly cannot
be t aken t hr ough above
available opening, t hen one side pipe piece w ill have t o be dism ant led fr om t he
spher ical valve befor e it is t aken t hr ough t he opening ( in a t ilt ed fashion) and
r eassem bled a t he locat ion.
Lift and locat e t he valve on t he foundat ion and m at ch U/ S pipe U/ S cust om er pipe
for carr ying out U/ S w elded j oint . Aft er com plet ing edge pr epar at ion and alignm ent
of spher ical valve and pipe piece assem bly, align D/ S pipe piece w it h dism ant ling
j oint aligning all t he above as per t he dr aw ing, com plet e U/ S w eld j oint and D/ S
com panion flange w elding. Com plet e D/ S flange j oint .

Com plet e assem bly of ser vo cylinder as per t he dr aw ing.

N ot e : - ensur e t o m aint ain flow dir ect ion for t he spher ical valve as per t he inst allat ion
dr aw ing.
6.

Com plet e assem bly of bypass line along w it h gat e valve, needle valve as per
inst allat ion dr aw ing.

7.

Com plet e dr ain line piping along w it h T- j oint s as per t he draw ing.

8.

Ar r ange concr et e pedest al/ foundat ion as per t he dr aw ing or at a convenient

locat ion t he hydr aulic pow er pack, elect r ical cont r ol panel, wat er panel et c. Ensur e
t hat sufficient w or king space is pr ovided/ available w hile locat ing all t he above
panels.

9.

Keep and secur e t he hydr aulic pow er pack on it s foundat ion and com plet e t he
hydr aulic oil piping bet w een ser vo cylinder s and t he pow er pack, t he pow er pack
t ank t o be cleaned pr oper ly, old oil, if any, t o be discarded befor e filling up t he
cor r ect gr ade hydraulic oil. The oil lines should be cleaned proper ly and flushed
befor e charging w it h oil.

10.

Keep and secur e t he wat er panel on it s foundat ion/ suppor t and com plet e t he w at er
line piping as per t he piping schem at ic dr aw ing / or as per t he sit e condit ions for
convenience of laying t he piping.

N ot e : a.
Aft er laying t he hydr aulic oil line and w at er line piping suit able suppor t s is t o
be pr ovided for t he piping wor k.
b.
Aft er cleaning and flushing, t he open ends of piping ar e t o be kept plugged/
Closed suit ably dur ing t he idle per iod t ill t he lines ar e char ged.
11

Place and secur e t he elect r ical panel on it s foundat ion / suppor t s and com plet e
cabling w or k bet w een t he elect r ical panel, pow er supply sour ce and t he var ious
elect r ical accessor ies as per t he elect r ical schem at ics dr aw ing. Pr oper suppor t s like
cable t r ays, conduit s et c is t o be pr ovided for t he cabling as per sit e condit ions.

N ot e : a.
For handling t he spher ical valve and accessor ies dur ing er ect ion/ local
t r anspor t at ion pr oper lift ing and handling accessor ies of adequat e capacit y should
be used st r ict ly ( cr ane, w ir e r opes/ slings, D- Shackles et c)
b.
St d safet y m easur es used for sit e w or k should be follow ed sincer ely t o avoid
accident s.
Aft er com plet ing t he er ect ion w or k, check t he w hole syst em once again befor e
doing any t r ial operat ion. Then car r y out t r ial operat ion as per t he operat ing
sequence/ pr ocedur e.

CH APTER - 0 8
COM M I SSI ON I N G

COM M I SSI ON I N G

1.

These com m issioning not es ar e based on t he Four ess involvem ent w it h t he supply
of Spher ical valves for Boving Four ess Lim it ed, t hey only m ake r efer ence t o
equipm ent supplied by ot hers and have been w r it t en in r esponse t o a r equest for
com m issioning checks and pr ocedur es t o assist in t he underst anding of
com m issioning r equir em ent s for t he pr oj ect s.

2.

PRE- PEN STOCK FI LL ACTI VI TI ES

2 .1

Or ifice siz in g a n d posit ion

As a fir st appr oxim at ion , m inim um sized or ifice should be fit t ed and w e suggest a
2m m dia or ifice at all point s. These or ifices shall be em bedded in t he pipe fit t ings so
t hat in t he event of pipe fr act ur e, t he or ifice w ill sur vive and r at e of ser vom ot or
m ovem ent w ill not be radically changed. A num ber of or ifices in ser ies, dr opping
t he pr essur e in st ages is bet t er t han a single or ifice.

2 .2

SERVO M OTOR

The ser vo m ot or is t o be fit t ed w it h flex ible pipes t o allow for t he change in posit ion
dur ing valve st r oke. These pipes should be t est ed t o at least 1.5 t im es m axim um
w or king pr essur e in posit ion so t hat t he fit t ings ar e also t est ed. These fit t ings
should include st eel bends w her e t he or ifice is fit t ed t o allow oil t o im pinge on st eel
and not t he flexible pipe.

2 .3

Ope r a t ion of M I V ( pr ior t o pe n st ock fill)

Wit h m aint enance seal and ser vice seal w it hdr aw n, ser vom otor is operat ed. I t
should be possible w it h m inim um oil pr essur e t o st r oke spher ical valve by t his
m et hod.
3.

STATI ON COM M I SSI ON I N G

3 .1

Pe n st ock fill

Wit h spher ical valve closed and all pipe w ork r einst at ed, connect t he pum p t o ser vo
cylinder . Build up pr essur e by pum p hold t he m aint enance seal and ser vice seal in
ON condit ion.
I t is advisable t o have t he t ur bine in t he st at e r eady t o r un at t his st age.
Adm it w at er int o t he penst ock and com m ence t o fill. Obser ve any leakage wat er
and if appr opr iat e st op, dewat er and rect ify. The m aint enance seal w ill be
aut om at ically held on as t he w at er pr essur e builds up.

3 .2

I n it ia l fill of t u r bin e

Oper at e t he bypass of t he valve. The upstr eam penst ock w at er is dir ect ed t o t he
dow nstr eam side. The dow nst r eam side is filled gr adually by cont r olling t he needle
valve cylinder m ovem ent , w hich cont r ols t he r at e of filling.
Filling of t he t ur bine should be done car efully m aking sur e air escapes fr om t he
t ur bine t hr ough t he air r elease valve. Allow pr essur e t o build up in t he t ur bine
slow ly. Once dow nst r eam side is filled, close t he valv e.
Ensur e t hat t he ser vice seal is applied on it s seat dur ing filling and m aint enance
seal is aw ay fr om it s seat .
I f no w at er ham m er exist s w hen t he seal is opened at m axim um rat e obtained t hen
it is lik ely t hat no or ifice is r equir ed. I f in any doubt , t he rat e should be lim it ed by
int r oducing or ifice of say, 3 m m dia at t he st ar t of t hese t est s. This w ould have t o
be r educed t o give a slow opening is a problem .

3 .3

Ope r a t ion of Sph e r ica l v a lv e

The valve is now held closed by oil fr om pow er pack. The m aint enance seal is kept
open. Operat e t o open t he ser vice seal. See t hat t his act ion is sm oot h and t urbine
pr essur izes w it hout any w at er ham m er . Oper at e t o open t he MI V ser vom ot or . Tim e
t he opening r at e. Oper at e t o close t he MI V ser vom ot or . Tim e t he closing r at e.
Adj ust or ifice sizes t o obt ain t he r at e specified.
Obser ve t he cor r ect funct ioning of lim it sw it ches. Connect t he elect r ical supplies
and pr ove t he oper at ion of t he valve fr om t he cont r ol panel.

CH APTER- 0 9
LI ST OF RECOM M EN D ED SPARES

LI ST OF RECOM M EN D ED SPARES FOR VALVE & I TS ACCESSORI ES

I

SPH ERI CAL VALVE

1. Bear ing bush
2. End cover plat e O r ing
3. shaft seals
4. Hex scr ew & spr ing w asher for r ot or seat
5. pr oxim it y sw it ches

II

H YD RAULI C CYLI N D ER
1. Pist on seal/ bear ing
2. End cover O r ing
3. Pist on r od O r ing
4. Rod seal
5. Rod w iper seal
6. Pist on r od bear ing

CH APTER 1 1
CATALOGUES FOR BOUGH T OU T I TEM S

ISLAND
HYDRAULIC CYLINDER

JAI BALAJI
LIMIT SWITCH

CH APTER 1 2
GA D RAW I N GS

D RAW I N GS & EN CLOSURES

SL
NO
1

D RAW I N G N O
Gener al ar rangem ent
of 1200m m Spher ical
Valve.
I nst allat ion
ar rangem ent of
1200m m Spher ical
Valve.

Plat for m dr aw ing

TI TLE OF D RAW I N G

REV.
N O.

N O OF
SH EETS

SV- 48001- H

R4

03

R4

03

R1

03

SV- 48001- 10

SV- 48001- 100

N OTE:
All dr aw ings included in t his m anual ar e reduct ions fr om full size or iginals and ar e for
r efer ence only. For gr eat er det ail and clarit y dur ing m aint enance operat ions, r efer ence
should be m ade t o t he Cont ract Dr aw ings.

GENERAL ARRANGEMENT
DRAWINGS

SPHERICAL VALVE

FOURESS
ENGINEERING (INDIA)
LIMITED

SPECIFICATION FOR GATE VALVE

(MANUALLY OPERATED)

PREPARED

AGR

CHECKED

GAR

APPROVED

HVR

DATE

25.01.13

REV. No.

R0

SHEET

1 OF 1

FD

BOI-913

BANGALORE

CUSTOMER: M/s. B FOURESS Ltd.

VALVE SIZE: 1200MM SPHERICAL VAVE.
CONTRACT No: 13846.
QUANTITY: 01 No. PER VALVE.
1.

SIZE

100 mm (4).

2.

RATING

CLASS 300.

3.

FLANGE DRILLING

ANSI B16.5 CL 300.

4.

END CONNECTION

FLANGED WITHOUT RAISED FACE.

5.

FLANGE FINISH

AS PER MFRS STD.

6.

FACE TO FACE

305mm

7.

OPERATOR

MANUAL WITH HAND WHEEL.

8.

MATERIAL

CAST STEEL (ASTM A216 Gr. WCB)

9.

VALVE CONFIRMS TO

API-600

10.

MAKE

FOURESS, PEE/EQUI

11.

LOCATION

ISOLATING VALVE.

SL.
NO.

REVISION

APPROVED BY

DATE
DGN-F-40A

FOURESS
ENGINEERING (INDIA)
LIMITED

SPECIFICATION FOR GATE VALVE

(MANUALLY OPERATED)

PREPARED

AGR

CHECKED

GAR

APPROVED

HVR

DATE

25.01.13

REV. No.

R0

SHEET

1 OF 1

FD

BOI-914

BANGALORE

CUSTOMER: M/s. B FOURESS Ltd.

VALVE SIZE: 1200MM SPHERICAL VAVE.
CONTRACT No: 13846.
QUANTITY: 01 No. PER VALVE.
1.

SIZE

150 mm (6).

2.

RATING

CLASS 300.

3.

FLANGE DRILLING

ANSI B16.5 CL 300.

4.

END CONNECTION

FLANGED WITHOUT RAISED FACE.

5.

FLANGE FINISH

AS PER MFRS STD.

6.

FACE TO FACE

403mm

7.

OPERATOR

MANUAL WITH HAND WHEEL.

8.

MATERIAL

CAST STEEL (ASTM A216 Gr. WCB)

9.

VALVE CONFIRMS TO

API-600

10.

MAKE

FOURESS, PEE/EQUI

11.

LOCATION

IN BY PASS LINE.

SL.
NO.

REVISION

APPROVED BY

DATE
DGN-F-40A

FOURESS

SPECIFICATION FOR HYDRAULIC

CYLINDER

ENGINEERING (INDIA)
LIMITED

BANGALORE

PREPARED

AGR

CHECKED

GAR

APPROVED

HVR

DATE

31.12.12

SHEET

1 of 1
BOI-915
R0

DOC.NO.
REV.NO.
CUSTOMER

M/ s. B FOURESS LTD.

VALVE SI ZE

1 2 0 0 MM SPHERI CAL VALVE.

CON TRACT No

13846.

QUANTI TY

0 2 NO PER VALVE.

TYPE

DOUBLE ACTING

CYLINDER PRESSURE RATING

160 BAR

BORE OF CYLINDER

200 MM

STROKE OF CYLINDER:

1162 MM

PISTON ROD DIAMETER

110 MM

END CUSHIONING:

BOTH ENDS CUSHIONED 5%

PORT CONNECTION:

1 BSP

CYLINDER CONSTRUCTION:

TIE ROD CONSTRUCTION.

CYLINDER SHALL BE SUPPLIED

YES ,

WTH THREADED CONNECTION

WITH SPHERICAL BEARING.

+5
0

PISTON ROD, ROD EYE.

10

CYLINDER FOR USE WITH MINERAL OIL

11

MOUNTING METHOD:

12
13
14
15

YES, SERVO SYSTEM 68

REAR END ROD EYE.
(WITH SPHERICAL BEARING)

CYLINDER OPERATING TIME:

OPEN

- 30-60 - SEC ,

CLOSE 30-60 - SEC {FOR REF}

MINIMUM PRESSURE REQUIRED TO

MIN. 1BAR AT NO LOAD CONDITION.

MOVE CYLINDER SHALL BE

{FOR REFE. ONLY}

PAINTING

EPOXY ZINC RICH PRIMER

TESTING
a ) STAGE INSPECTION

AS PER MANUFACTURERS STANDARD

(WITNESSED BY M/S. FOURESS,
THEIR LIENTS INSPECTION AGENCY)

b) FINAL INSPECTION

WITNESSED BY US/ OUR CLIENT

CYLINDER BODY TO BE TESTED AT

160 x 1.5 = 240 bars

(DETAIL TEST PROCEDURE TO BE SUBMITTED FOR APPROVAL)

SL.
NO.

REVISION

APPROVED BY

DATE
DGN-F-40A

FOURESS
ENGINEERING (INDIA)
LIMITED

SPECIFICATION FOR HYDRAULIC

CYLINDER

BANGALORE

PREPARED

AGR

CHECKED

GAR

APPROVED

HVR

DATE

31.12.12

SHEET

2 of 2
BOI-915
R0

DOC.NO.
REV.NO.

c) PISTON AND SEAL LEAKAGE at

160 bars, GLAND leakage at 160 bars.

d) PERFORMANCE CHECK AT

160 bars

e) CUSHIONING CHECK.
f) PRESSURE TEST CERTIFICATE
g) MATERIAL TEST, GUARANTEE
CERTIFICATE.
h) GENERALLY TESTING SHALL BE
AS PER IS: 10585 STANDARD

16

INSTRUCTION AND MAINTENANCE:

CROSS SECTIONAL DRAWING WITH PART

LIST, ASSEMBLY, DISASSEMBLY
PROCEDURE ,ROUTINE & MAINTANANCE
DETAILS TO BE SUPPLIED ALONG WITH
CYLINDER.

17

NOTE:
a) QUOTATION SHOULD INCLUDE OVERALL,
OVERALL DIMENSIONS, CROSS SECTIONAL,
DRAWINGS INDICATING CONSTRUCTION
AND MATERIAL SPECIFICATION.
b) MANUFACTURING SHALL BE TAKEN UP
AFTER APPROVAL OF G.A. DRAWING AND
OTHER DETAILS.
c) CYLINDER SHOULD BE FITTED WITH
BLEED POINTS FOR AIR RELEASE AND
CUSHIONING ADJUSTMENTS, PORT
SHALL BE PROVIDED. THESE SHALL BE CLEARLY
SHOWN IN G.A. DRAWING FOR APPROVAL

18

APPLICATION

19

CYLINDER OVERALL DIMENSIONS SHALL BE

20
21

SL.
NO.

AFTER APPROVAL OF SUPPLIERS DRG.

(BY M/S FOURESS) THE SAME
VELLOGRAPH TO BE SUPPLIED FOR RECORDS.
MAKE

REVISION

YES

YES

YES

FOR OPERATION OF SPHERICAL VALVE,

OPENED BY HYDRAULIC PRESSURE,
CLOSED BY EXTERNAL COUNTER
WEIGHT & VALVE SELF CLOSING
TORQUE, CYLINDER TO CLOSE FULLY
INCLUDING CUSHIONING ZONE WITH
COUNTER WEIGHT.
AS PER DRG.NO. IH-210111-588.
SOFT COPY OF DRAWING TO BE
FURNISHED.
ISLAND.

APPROVED BY

DATE
DGN-F-40A

FOURESS

SPECIFICATION FOR BY PASS

HYDRAULIC CYLINDER

ENGINEERING (INDIA)
LIMITED

BANGALORE

PREPARED

AGR

CHECKED

GAR

APPROVED

HVR

DATE

25.01.13

SHEET

1 of 1
BOI-916
R0

DOC.NO.
REV.NO.
CUSTOMER

M/ s. B FOURESS LTD.

VALVE SI ZE

1 2 0 0 MM SPHERI CAL VALVE.

CON TRACT No

13846.

QUANTI TY

0 1 NO PER VALVE.

TYPE

DOUBLE ACTING

CYLINDER PRESSURE RATING

160 BAR

BORE OF CYLINDER

125 MM

STROKE OF CYLINDER:

180 MM

PISTON ROD DIAMETER

56 MM

END CUSHIONING:

BOTH ENDS CUSHIONED 5 %

PORT CONNECTION:

1 BSP

CYLINDER CONSTRUCTION:

TIE ROD CONSTRUCTION.

CYLINDER SHALL BE SUPPLIED

9

WTH THREADED CONNECTION

+5

NO

PISTON ROD, ROD EYE.

10

CYLINDER FOR USE WITH MINERAL OIL

YES, SERVO SYSTEM 68

11

MOUNTING METHOD:

FRONT FLANGE

12

CYLINDER OPERATING TIME:

13
14
15

OPEN

- 30-60 - SEC ,

CLOSE 30-60 - SEC {FOR REF}

MINIMUM PRESSURE REQUIRED TO

MIN. 1BAR AT NO LOAD CONDITION.

MOVE CYLINDER SHALL BE

{FOR REFE. ONLY}

PAINTING

EPOXY ZINC RICH PRIMER

TESTING
a ) STAGE INSPECTION

AS PER MANUFACTURERS STANDARD

(WITNESSED BY M/S. FOURESS,
THEIR LIENTS INSPECTION AGENCY)

b) FINAL INSPECTION

WITNESSED BY US/ OUR CLIENT

CYLINDER BODY TO BE TESTED AT

160 x 1.5 = 240 bars

(DETAIL TEST PROCEDURE TO BE SUBMITTED FOR APPROVAL)

c) PISTON AND SEAL LEAKAGE at

SL.
NO.

REVISION

160 bars, GLAND leakage at 160 bars.

APPROVED BY

DATE
DGN-F-40A

FOURESS

SPECIFICATION FOR BY PASS

HYDRAULIC CYLINDER

ENGINEERING (INDIA)
LIMITED

BANGALORE

PREPARED

AGR

CHECKED

GAR

APPROVED

HVR

DATE

25.01.13

SHEET

2 of 2
BOI-916
R0

DOC.NO.
REV.NO.

d) PERFORMANCE CHECK AT

160 bars

e) CUSHIONING CHECK.
f) PRESSURE TEST CERTIFICATE
g) MATERIAL TEST, GUARANTEE
CERTIFICATE.
h) GENERALLY TESTING SHALL BE
AS PER IS: 10585 STANDARD

16

INSTRUCTION AND MAINTENANCE:

CROSS SECTIONAL DRAWING WITH PART

LIST, ASSEMBLY, DISASSEMBLY
PROCEDURE ,ROUTINE & MAINTANANCE
DETAILS TO BE SUPPLIED ALONG WITH
CYLINDER.

17

NOTE:
a) QUOTATION SHOULD INCLUDE OVERALL,
OVERALL DIMENSIONS, CROSS SECTIONAL,
DRAWINGS INDICATING CONSTRUCTION
AND MATERIAL SPECIFICATION.
b) MANUFACTURING SHALL BE TAKEN UP
AFTER APPROVAL OF G.A. DRAWING AND
OTHER DETAILS.
c) CYLINDER SHOULD BE FITTED WITH
BLEED POINTS FOR AIR RELEASE AND
CUSHIONING ADJUSTMENTS, PORT
SHALL BE PROVIDED. THESE SHALL BE CLEARLY
SHOWN IN G.A. DRAWING FOR APPROVAL

YES

YES

YES

18

APPLICATION

IN BY PASS.

19

CYLINDER OVERALL DIMENSIONS SHALL BE

AS PER STD. CATALOGUE.

AFTER APPROVAL OF SUPPLIERS DRG.

(BY M/S FOURESS) THE SAME
VELLOGRAPH TO BE SUPPLIED FOR RECORDS.
MAKE

SOFT COPY OF DRAWING TO BE

20
21

SL.
NO.

REVISION

FURNISHED.
ISLAND.

APPROVED BY

DATE
DGN-F-40A