Installation and Operating Instructions Инструкция за
Contents
1. as the result of non adherence to warning instructions as well as transport damage and improper use e g as a climbing aid etc will render the manufacturer s guarantee null and void and release him from any responsibility 21 3 Maintenance Measure Interval Clean valve and actuator spindle with a soft cloth depending on degree of contamination Tighten if stuffing box leaks Caution Do not over seal the stuffing box Check spring tension and tighten if necessary Standard stuffing boxes subjected to normal operating conditions every 10 000 strokes Standard stuffing boxes subjected to difficult operating conditions packing exposed to aggressive medium major temperature change during operation occurrence of vibrations e unfavourable installation position every 5 000 strokes Spring loaded stuffing box systems and normal operating conditions every 100 000 strokes atleast once per year Spring loaded stuffing box systems and every 10 000 strokes difficult operating conditions Pneumatic linear actuators maintenance free Electric linear rotary actuators Check spindle gear largely maintenance free if required lubricate every 200 000 up and down strokes Electric linear rotary actuators Grease grease nipple at least once per year 4 Repair If afault or defect occurs which according to the list of measures below requires the customer services2. department or contract partner to be contacted the manufacturer s guarantee shall be rendered null and void and the manufacturer released from any responsibility unless the customer services department or contract partner is duly notified If the customer performs the repairs himself these operating instructions and the respective disassembly assembly instructions must be followed to the letter and carried out in a competent manner Original replacement parts must be used in every case 22 Control valves are pressure vessels Improper opening of the actuator or fitting may result in bodily injury 4 1 Trouble shooting damaged trim Defect No Possible causes Remedy Spindle does not move 1 1 no aux energy supply pneumatic e pneumatic actuators check supply line for leaks air or electrical power to actuator check pressure usually 6 bar and accessories solenoid valve filter reducing station electrical actuators check power supply positioner limit switch and special connections circuit breakers voltage accessories 1 2 the fitted accessories do not work see maintenance and operating instructions of accessories manufacturer 13 the pneumatic actuator is contact customer services department or defective contract partner 14 the electrical actuator is defective see maintenance and operating instructions of actuator manufacturer 1 5 excessive tightenin
3. Villach Operation M FLOWSERVE we Operation Instructions Montage und Betriebsanleitung Installation and Operating Instructions m T VHCTpyKUMA 3a MOHTAXK M ekcrinoaTauna N vod k mont zi a pouzit p amp m PS Monterings og driftsvejledning LA ra t a Odnyiec eykATACTAONC KAI Ae roupyiac Instrucciones de montaje y de servicio Montaazi ja kasutusjuhend Asennus ja k ytt ohjeet Notice de montage et mode d emploi Szerel si s zemeltet si utas t s Istruzioni per il montaggio e l utilizzo Montavimo ir naudojimo instrukcija Mont Zas un ekspluatacijas pam ciba Manwal ta l Apparat Montage en Handleiding Instrukcja monta u i obs ugi Instru es de Instala o e Utiliza o Instructiuni de montaj si utilizare VHCTpyKUNA no MOHTaXY M pyKOBOJICTBO No akcnnyaTayMn Navod na mont z a obsluhu Navodila za montazo in obratovanje Monterings och bruksanvisning Montaj ve Kullanma kilavuzu Montage und Betriebsanleitung Installation and Operating Instructions VHCTpyKUMA 3a MOHTax M eKcnnoaTauma N vod k mont zi a obsluze Monterings og driftsvejledning Odnyiec eykar oraonc Kal Aerroupyia Instrucciones de montaje y de servicio Montaazi ja kasutusjuhend Asennus ja k ytt ohjeet Notice de montage et mode d emploi Szerel si s zemeltet si utas t s Istruzioni per il montaggio e l utilizzo Montavimo ir naudojimo instrukcija Mont Zas un ekspluat cijas pam ciba Ma
4. a guarante Modifications without notice in line with technical progress Ol 133414 11 09 Control Valves eu Y FLOWSERVE s j Villach Operation 900 Flowserve Austria GmbH 9001 Control Valves Villach Operation Kasernengasse 6 A 9500 Villach E Telephone 43 0 4242 41181 0 Cena Facsimile 43 0 4242 41181 50 or 51 e mail villach_operationO flowserve com www flowserve com 248 SAEUOIVALV 04 11 09
5. ces department or seat or plug contract partner 4 2 foreign particles in seat area contact customer services department or contract partner 4 3 plug does not close fully e referto 3 1 to 3 5 Leaking stuffing box system 54 e compression force on packing too slightly re tighten stuffing box packing low Caution make sure the valve spindle can still move 5 2 worn packing Slightly re tighten stuffing box packing Caution make sure the valve spindle can still move if the packing does not stop leaking contact customer services department or contract partner 5 3 dirty spindle clean spindle with suitable cleaning agent 54 damaged spindle contact customer services department or contract partner Leaking top or lid seal 6 1 pressing force on seal s too low properly re tighten top or lid nuts crosswise 6 2 e seals s defective contact customer services department or contract partner Leaking housing 7 1 e medium or flow related damage contact customer services department or contract partner No limit switch signal 8 1 power supply to limit switch check power supply connections circuit interrupted breakers voltage 82 e limit switch misadjusted readjust limit switch operating distance see limit switch data sheet Vibrating positioner 9 1 defective positioner see maintenance and operating instructions of positioner manufacturer If the problem is not solved by taking the above measures c
6. contractually agreed specifications To ensure a faultless and reliable operation of this product please read and observe these installation and operating instructions before using this product Failureto comply with these installation and operating instructions will render the manufacturer s guarantee and liability null and void Unless otherwise agreed the manufacturer s General Terms and Conditions of Sale shall apply 15 Scope Product description 1 Installation These operating instructions shall apply to Single seated control valves PN 10 160 Class 150 900 Lined single seated control valves PN 10 40 Three way control valves PN 10 160 Class 150 600 Double seated control valves PN 10 160 Special valves with fitted pneumatic or electrical linear actuator with fitted linear unit and electrical rotary actuator with or without accessories Control valves control gases vapours or liquids and change the flow conditions of a process The control valves consists of the body valve bottom and the actuator which depending on the control signal changes the position of the closure member plug relative to the seat The bodies have been arranged in logical kits allowing the user to assemble the highest possible number of variants from a minimum of components to match each individual application Our range also includes a series of peripheral units such as positioners boosters filter reducing stations or solen
7. d base in a closed room Until its installation the valve must be protected from the weather dirt and other potentially harmful influences Under no circumstances should the valve remain in storage for more than 6 months as the impregnation in the stuffing box packing evaporates and leaks may develop Do not remove the plugs protecting the flanges and the inside of the control valve until it has arrived at its place of installation 1 2 Preparation for installation into the piping The pressure leak and operation tests performed in the factory and the quality management system introduced by the manufacturer ensure that the execution of the control valve complies with the specifications set forth in the contract The series number and the vital valve actuator data are found on the rating plate The travel indicator shows the position of the closure member relative to the seat Before installing the valve carefully clean the piping 17 Rating plate As the information on rating plates reflects the special features ofthe type they describe their appearance may differ The rating plate contains the following data a Kennzeichnung Tag No Fabrikations Nr Serial No Typ Type Antrieb Typ Actuator Type DN PN Hub Stroke Sitz Seat Zuluft min max Supply min max Kvs Cv Federlaufbereich Spring Range Kegel Plug Sicherheitsstellung Failure Position Kennlinie Characteristic Umgegungstemp Ambient Te
8. d to comply with national and international environmental regulations install suitable protective measures to ensure workplace requirements are satisfied and to instruct his employees accordingly 20 Due to the risk of injury it is prohibited to work between the yoke columns while the valve is in operation Once these hazards have been averted by adopting appropriate protective measures the valve can be installed and connected in the piping The following points should be noted Flange connection Connection material gaskets bolts nuts are not part of the scope of supply Locate gaskets in the centre of flanges failure to do so can result in leaks and increased noise levels If a completely installed piping is to be flushed or blown through for cleaning replace the control valve with a matching piece Welded connection Welded connections have to be made in compliance with applicable welding regulations After welding carefully clean the piping again Open control valves properly and remove any accumulated foreign particles Advise the manufacturer in writing that the fitting has been opened When the control valve is installed in the piping connect instrument air to the actuator or installed accessories applies to pneumatic linear actuators connect according to the wiring diagram in the removable actuator cover or according to manufacturers actuator documentation applies to electrical rotary l
9. g of the stuffing e loosen stuffing box packing nuts until valve box packing operates properly Caution make sure there are no leaks 1 6 valve trim worn stuck contact customer services department or contract partner Jolting spindle movement 2 1 the electrical actuator is defective clean spindle with suitable cleaning agent 2 2 damaged spindle contact customer services department or contract partner 2 3 actuator not powerful enough compare actuator specs on the rating plate with operation specifications of the facility if incompatible contact customer services department or contract partner Spindle travel 3 1 air supply pressure too low provide air at the pressure stated on the rating less than full stroke plate 0 to 100 stroke 3 2 pneumatic actuators bad hand move hand wheel to limit position or flow rate is too low wheel position hand wheel emergency operation 3 3 electrical actuators limit switch readjust limit switch to actuator manufacturer s misadjusted specification 3 4 badly adjusted or defective readjust positioner to positioner manufacturer s positioner specifications 3 5 foreign particles in valve seat contact customer services department or contract partner 23 Trouble shooting continued Defect No Possible causes Remedy Excessive valve seat leakage 4 1 damaged sealing edges at valve contact customer servi
10. inear actuators Continuously increase load until operation parameters are reached Sudden exposure of the control valve to the full working pressure and working temperature may cause stress cracks After the first loading trial run in depressurised and cool conditions evenly tighten screw connections of sealing components crosswise if required Be careful to prevent damage to the high quality spindle surface finish A damaged spindle surface finish may be detrimental to the smooth operation of the stuffing box Excessive levels of noise and vibration during operation indicate critical operating conditions and must be avoided at all costs Impermissible continuous operation of control valves under critical conditions can damage the valves as they are not designed to cope with this situation Avoid frequent system start ups and shutdowns Experience has shown that critical operating conditions which can damage the control valve are often encountered when starting up or shutting down the system Keep the operating medium free of foreign particles Foreign particles can damage the control valve this can be prevented by fitting a suitable dirt trap The instrument air must conform to at least the ISO 8573 1 class 2 or the requirements of the accessory manufacturer Contaminated instrument air can damage the accessories and valve or cause them to fail Bodily injury or damage to the control valve and its accessories
11. itzk hlventile H n Injection nozzle valves Type V901 Selbstt tige Regler H Self acting regulators Type 5801 5610 Pneumatische Antriebe Pneumatic actuators Y Type FlowAct Valtek Piston Actuator 1 F r den Europ ischen Markt for European Market Benannte Stelle f r die Kontrollen Notified Body for the Inspections DGRL 97 23 EG PED 97 23 EC T V CERT Zertifizierungsstelle f r Druckger te der T V Anlagentechnik GmbH Kennummer der Benannten Stelle Am Grauen Stein D 51101 K ln Number of Notified Body 0035 Richtlinie 90 396 EWG Directive 90 396 EEC DVGW Zertifizierungsstelle Technisch wissenschaftlicher Verein Kennummer der Benannten Stelle Josef Wirmer Stra e 1 3 D 53123 Bonn Number of Notified Body 0085 Management System Management System OHSAS 18001 2007 ISO 14001 2004 ISO9001 2008 DNV Zertifizierung und Umweltgutachter GmbH Schnieringshof 14 D 45329 Essen Bevollm chtigter des Herstellers in der EG Authorized representatives of the manufacturer in the EC Villach 09 11 2009 H Aa 4 Mad Luca fino All vun Dipl Ing Arnold Muschet Ing Herbert Schiffer Technischer Leiter Technical Director QM Leiter QM Manager 247 Villach Operation FLOWSERVE p Operation Instructions TM Indicates a trade mark of Schmidt Armaturen Information given in this leaflet is made in god faith and based upon specific testing but does not however constitute
12. mp Mat Geh use Mat Body Ap Antrieb Ap Actuator Innenteile Trim Einbaulage Arrangement Packung Packing Betriebstemperatur Working Temperature V Betriebsdruck Working Pressure 1 3 Before installation check the following items The operator is required to carefully check the suitability of the control valve for its intended use in the system in advance Any use not in compliance with the regulations specifications can lead to serious damage to the control valve or may lead to failure of the facility Does the nominal operation data on the rating plate match the operational data of the facility A mismatch may cause considerable damage to the valves At the point of installation is there enough space to fit and remove the valve A lack of space can cause considerable problems and in the some cases necessitate expensive rerouting of the piping Was the piping flushed and cleaned prior to the installation Foreign particles can damage the control valve and accessories this can be avoided by fitting a suitable dirt trap Was the protective coat removed from the control valve and was the valve cleaned The preservative Mipa Abziehhaut blue and the spray Castrol Safecoat DW 32 can contaminate the operating medium and must be removed before installation Unsuitable cleaning agents that attack the PTFE and graphite sealing sets can cause damage and leaks Pay particular attention to the relevant chemical re
13. nwal ta l Apparat Montage en Handleiding Instrukcja monta u i obs ugi Instru es de Instala o e Utiliza o Instructiuni de montaj si utilizare Seite 5 Page 15 crpaHuua 25 Strana 35 Side 45 2edida 55 P gina 65 Lehek lg 75 Sivu 85 14 24 34 44 54 64 74 84 94 Pages 95 a 104 105 114 oldal Pagina 115 124 p 125 134 135 144 lappuse Pagni 145 Pagina 155 Strona 165 P ginas 175 Paginile 185 UHcTpyKuna NO MOHTAXYy M PYKOBOACTBO NO 3KCriyaTalMM crp 195 N vod na mont z a obsluhu Navodila za montazo in obratovanje Monterings och bruksanvisning Montaj ve Kullanma Kilavuzu Strana 205 Stran 215 Sidan 225 Sayfa 235 154 164 174 184 194 204 214 224 234 244 Contents Page Preface 15 Scope 16 Product description 16 1 Installation 16 1 1 As delivered status 17 1 1 1 Transport 17 1 1 2 Storage 17 12 Preparation for installation into the piping 17 Rating plate 18 13 Installation of the control valve 18 4 19 Recommended installation 19 2 Commissioning 20 Flange connection 20 Welded connection 21 3 Maintenance 22 4 Repair 22 4 1 Troubleshooting service and repair centres 23 24 This control valve was manufactured to the strict standards of our ISO 9001 certified quality management system lt was tested for compliance with all applicable regulations and guidelines and fully conforms with all
14. oid valves Positioners and solenoid valves can be assembled directly or according to NAMUR recommendations Refer to the relevant manufacturer s instruction manual for information regarding peripheral equipment The valve must be installed and commissioned by qualified staff Qualified staff is defined as personnel who are familiar with the installation commissioning and operation of this product and possess the relevant qualifications in their field of activity 1 1 As delivered status Control valves are generally delivered as tested and 1 1 1 Transport 1 1 2 Storage assembled units with the actuators fitted Parts of the body and actuator subjectto corrosion are protected by a coat of paint Unpainted components are greased and the openings of the housings are closed with plugs High grade steel housings are delivered without a protective coat of paint pickled or blasted Careful loading and transport arrangements are required to avoid the product suffering impact and jolting movements Under no circumstances should lifting gear be attached to the valve spindle travel indicator and any peripheral units if applicable We recommend the use of a length of rope that is looped around the valve head underneath the yoke or the transportation eyelet s The maximum permitted carrying capacity must be observed Promptly touch up any damage to the corrosion protection Upon arrival on site store the control valve on a soli
15. ontact the customer services department or contract partner Service hotline Austria 443 0 664 341 8 616 24 Service hotline Germany 49 0 2157 8176 29 or 49 0 163 8176 014 245 246 EG Konformit tserkl rung EC Declaration of Conformity gem DGRL 97 23 EG acc to PED 97 23 EC gem Richtlinie 90 396 EWG acc to Directive 90 396 EEC gem ATEX 94 9 EG acc to ATEX 94 9 EC gem Richtlinie 2006 42 EG acc to Directive 2006 42 EC Hersteller Manufacturer FLOWSERVE Austria GmbH Control Valves Villach Operation Kasernengasse 6 A 9500 Villach Richtlinien Directives Produkte Products DGRL PED 97 23 EG Mod Richtl Dir 90 396 EWG ATEX 94 9 EG Richtl Dir 2006 42 EG EN 161 DIN 3394 EN 264 DIN 32725 SIL IEC 61508 ISO 15848 VDI 2440 Autom Absperrarmaturen f r gasf rmige Brennstoffe u Sicherheitsabsperreinrichtungen f r fl ssige Brennstoffe Automatic shut off valves for inflammable gases and B D Safety shutoff devices for inflammable liquids Type D726 D738 D740 Stellger te FlowTop Control valves FlowTop H Type V726 V738 V740 Stellger te Control valves Type V724 V760 H a s Stellger te Control valves H m Type V725 V723 Stellger te Control valves H n 7 Type MarkOne Mark100 MarkSix Stellger te Control valves H 4 Sonderregelventile Special control valves 1 Einspr
16. sistance lists Remove covers Does the direction of flow arrow on the housing coincide with the direction of flow of the medium If not critical operating conditions can result that may damage the control valve as they are not designed to cope with this situation Are the piping flanges equiaxial and parallel and does the distance between pipe ends correspond to the valve length If not excessive tension valve malfunctions and leaks at the flange connections may result Is the piping routed correctly and is the valve free from additional piping forces If not leaks may develop and depending on the situation the valve may fail Is the installation position of the valve with vertical valve spindle achieved If not increased wear in the stuffing box packing leaks and depending on the situation rubbing may occur Contact the manufacturer if the prevailing installation conditions mean that the valve will have to be fitted horizontally Is there a suitable surge section upstream and downstream of where the valve is installed The absence of a surge section can create critical operating conditions and cause impermissible levels of noise and vibration Is appropriate equipotential bonding provided Impermissible electrical compensating currents across the valve and the actuator can generate static and cause electrical discharging In explosive atmospheres the only valves that may be used are those that comply wi
17. th the permitted group equipment category and temperature class requirements laid down in Directive 94 9 EC ATEX Recommended installation Successful use of the control valve is conditional on the availability of a suitable installation environment We suggest that the recommended values be adhered to as it is very important to take account of physical aspects when using the control valve Deviations can result in significant control deviations and in the worst case expensive rerouting of the piping will be necessary However some physical processes will permit a deviation from these values although in such cases system knowledge is required as is the express approval of the manufacturer Recommended installation for control valves Medium s Control valve Installation distance from valve 10 x DN at least 1m 19 2 Commissioning The medium and the valve can pose the following hazards Critical operating conditions can cause impermissible levels of noise and vibration Hearing loss vascular and nerve problems damage to joints and bones Incorrect maintenance can result in the emission of thermal cryogenic and toxic operating media Danger of burns freezing acid burns poisoning The temperature of the operating medium is transferred to the surface of the valve Danger of burns freezing explosion As these hazards can all be controlled by the plant operator the operator is oblige
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