Raimondi Ball Valves, Figure 5600
Contents
1. Fluid Shell test pressure Double Block and bleed N order Valve reference number Double piston effect Single piston effect Serie number TR_ATEX_01 xX 12GDe Information on the standard ATEX marking plate Ex TR_ATEX_01 X Specific mark Group ll Category 2 Can be used in gas athmosphere Can be used in dust athmosphere Ignition protection category Identification number See instruction manual for information Can be used for zone 1 21 and 2 22 Pentair reserves the right to change the contents without notice RAILT 0042 EN 1305 Ball valves fully welded Installation and Maintenance Instructions Section 2 Valve Storage 2 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 ball in the open position 2 The weld ends surface shall be protected with suitable protective like Deoxaluminite The end shall be closed with plywood or plastic disc fixed at the edge by straps 3 All actuated valves must be carefully securely palleted or crated in order to ensure that the 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 shall be appropriate to ensure safe transport2. gt PENTAIR RAIMONDI Rating and temperature limits Pressure rating ANSI Class 150 to Class 900 Temperature range 46 C to 150 C if standard design 200 C if modification material seat Insert Check the information in the marking plates placed on the valves www pentair com valves Ball valves fully welded Installation and Maintenance Instructions Installation and Maintenance Instructions Ball valves fully welded To ensure a correct use of our products check the information on the CE and ATEX if any marking plate fixed on the valve TYPE BODY STEM Pmax bar AT Tmin Pmax bar AT Tmax O PED CATEG SHELL TEST PRESS PO N TAG S N C E 0496 NPS DN FAB Y M OBTURATOR END TO END C FIRE SAFEL C NACE Bar _ DOUBLE B 8B _JDOUBLE P _ SELF REL MANUFACTURER RAIMONDI MFG PLANT RESCALDINA M ITALY raimondi FLUID Information on the standard CE marking plate Type Class NPS DN Fab Y M Body Seat Obturator Stem Seal End to end Pmax T min Fire safe Pmax T max NACE PED Categ Fluid Shell test press Double B amp B PO N TAG Double P Self Rel S N Type of valve Pressure class Diameter in inches mm Manufacturing date Body material Seat material Obturator material Stem material Seal material End to end length Max pressure at Min temp Fire Safe Max pressure at Max temp Complies with NACE PED category
3. the coupling flange pos 11 by means of the bolts pos 14 using the extraction holes 9 Remove the lantern ring pos 48 using the extraction holes Only for fig 2 and 2A remove the bonnet pos 12 by means of the bolts or screws pos 14 S using the extraction holes 11 Only for fig 2 and 2A remove the lip seal gasket pos 13b Make sure not to damage the sealing surfaces on the stem and body 12 Carefully clean all the sealing surfaces using proper remover products Visually check all the sealing surfaces if damaged they should be repaired Only for fig 2 and 2A for lip seal assembling use the conical ring special tool 13 Change the damaged gaskets and reassemble all parts following backwards the above mentioned steps 14 Close the vent valve Warning The stem has been designed as antiblow out to improve safety during the service This means that the stem cannot be disassembled D CS er SMe i Na Re GY J 4 LEL 4 S Figure no 2A Welded bonnet style i YNN KAYIN A SN Li LLL SAS D7 Dr NO Ee SOS OS SN Li bX UZLLLLLLLLL LN DYZ ZZZ AX SA Z SoS N N VY Figure no 3 Figure no 3A Pentair reserves the right to change the contents without notice Ball valves fully welded Installation and Mainten
4. ance Instructions Section 5 Valve Removal If the valve needs to be removed from the line for some extraordinary reason the user should ensure the following A N Warning Depressurize the line before starting any maintenance Failure to do so may cause serious personal injury and or damage to the valve 1 The valve is depressurized 2 The pipe shall be cut as far away from the valve as possible Section 6 Greases and Special Tools 6 1 Sealant Greases The suggested sealant grease is MOLYCOTE 111 valve lubricating and sealing silicone compound by DOW CORNING 6 2 Special Tools The only suggested tool is the conical ring suitable for the gasket assembly Pentair reserves the right to change the contents without notice
5. ation to final destination and eventual conservation before installation 2 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 should be carried out in the lifting points and at 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 valves of large dimensions 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 2 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 with the following criteria 1 The valves have to be stocked in a closed clean and dry storage room 2 The ball must be in the open position and the end faces must be protected with plastic or wooden discs fixed wit
6. h 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 For actuated valves in addition to the above please refer to the warnings in the relevant actuator manual 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 Do not place consignment packages directly on the ground Do not expose consignment packages to the weather or directly to the sun Check the packaging every two months Figure no 1 Pentair reserves the right to change the contents without notice 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 Lifting and handling must be made only by qualified personnel Do not use the lifting points located on the actuator if any to lift the valve These lifting points are for the actuator only 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 Ball
7. ion should be advised to allow for the right position of the drain plug Unless otherwise recommended by the manufacturing plant the valve should be installed with the ball in the open position to ensure that the seat rings are not damaged during installation Particular care should be taken with those valves equipped with fail close actuators For operating temperatures above 200 C 392 F thermal insulation of the valve body is recommended Handling and lifting of the valves during installation MUST be performed following the same criteria and instructions described in previous points 2 2 Handling Requirements and 2 3 Storage and Preservation before Installation Buttweld Valves Position the valve and check the alignment with the pipe Proceed with welding in accordance with the applicable welding procedure It is recommended to perform piping flushing before installation of the valve If this is not possible the valve must be set with the ball in full open position before starting with flushing For buttweld end valves To avoid any damage to the gaskets the temperature during the pipe welding and the heat treatment has to be monitored by a thermocouple placed in the seat grease Injector holes Make sure to limit the temperature at maximum of 200 C This instruction has to be carefully followed especially in case there are not any transition piece pup piece welded to the valve 3 3 Valve Verification Before Star
8. ment All the other repairs major repairs should be performed by the manufacturing plant or Nominated Service Company 4 1 Stem Bonnet Gasket Replacement Please refer to figures no 2 and 2A for bolted bonnet style and no 3 and 3A for welded bonnet style Note The following instructions are applicable to a fully welded valve completed with extension If the valve is supplied without any extension the related references are not applicable Warning Before starting any maintenance operations check that the vent valve is open The ball must be completely in open or close position with no pressure in the body cavity Failure to do so may cause serious personal injury and or equipment damage NI M ii U_VZZZZLZLILL SS SS WZ LY R SN L N LIN AR 4 LH ZS N E ANL tS VZ N 1 Place the valve in fully open or fully closed position cD 2 Open the vent and discharge the pressure The vent valve has to be in open position during all operations Remove the operator from the top flange of the extension if any Remove the coupling bushing to disassemble the stem actuator from the stem extension EZ if any gt U Nez LSS N N 5 Sling the extension if any N 48 6 Remove the bottom flange of the extension if any N X 7 Lift the extension using the proper lifting lugs mo X D 8 Remove
9. nsidered as an emergency operation to stop the leakage up to the next planned maintenance job If the leakage does not stop follow the maintenance procedure for the replacement of the gaskets in Section 4 2 For actuated valves in addition to the above please refer also to the warnings in the actuator manual B Preventive Actions 1 Every 3 months verify the tightness of bolts drain vent 2 For the actuator proceed as indicated in its maintenance manual 3 6 Troubleshooting Guide Symptom Possible Cause Solution Stem gasket leaking 1 Gasket damage 1 Sealant injection temporary 2 Gasket replacement see section 4 Body bonnet gasket 1 Gasket damage 1 Gasket replacement see section 4 leaking Valve leaking 1 Valve not fully closed 1 Close the valve 2 Debris trapped in valve 2 Cycle and flush with valve open to remove debris 3 Sealing surface damaged 3 Perform sealant injection Jerky operation 1 Not enough feed pressure 1 Increase the actuator feed pressure Check seat sealing by Opening the vent valve Opening or closing completely the ball and with pressure in the line Check that after a while there is not any more pressure coming out from the vent valve Pentair reserves the right to change the contents without notice Ball valves fully welded Installation and Maintenance Instructions PaM aA ponete This section describes on site repairs as Stem Bonnet Gasket replace
10. t Up 1 Verify the tightness of the drain plug and of the vent valve 2 Check the valve operability by stroking it to full open and full close 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 Pentair reserves the right to change the contents without notice Ball valves fully welded Installation and Maintenance Instructions 3 4 Operations Instructions 1 Make sure to perform periodic valve verification as described in paragraph 3 5 2 In case of actuated valves always follow the specific instructions given by the actuator s manufacturer 3 Never change the setting of torque and or limit switches which have been carefully set during the final test at our workshop 4 Never change the setting of the mechanical stops of the gearbox 3 5 Periodic Valve Verification During Service A Normal Check 1 Verify monthly that there is no leakage from the gaskets or through the seats If the leakage has been detected in the stem bonnet area inject the proper seal as it grease through the stem grease injector Use the seat injectors device to stop the leakage of the valve in close position The sealant injection is to be co
11. valves fully welded Installation and Maintenance Instructions Section 3 Installation 3 1 Preparation before installation 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 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 Confirm that the materials of construction listed on the valve nameplates service and temperature are appropriate for the service intended and are as specified 4 Define the preferred mounting orientation with respect to the system pressure If any see arrow on the body identify the upstream side high pressure and downstream side low pressure Warning e Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body Valves without the arrow are bi directional e See the actuator user manual for the actuator preparation e Verify the assembly of the overpressure relief device in case of liquid service and double piston effect option 3 2 Installation Instructions Ball valves are normally installed in horizontal pipe with vertical stem These valves can also be installed with no limitation regarding the pipe or stem orientation However in this case the actual pipe stem orientat
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