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Operating Instructions BA 1.0 - DGRL/MRL

1. EBROARMATUREN BA 1 0 DGRL MRL WAH Centric lined butterfly valves Series Z F M T TW BE Z011 Z014 F012 1211 T214 99094 Examples shown above not all possible type variants are shown Operating Instructions with technical Appendix in accordance with EG Machine Directive 2006 42 EG in accordance with EG Pressure Equipment Directive 97 23 EG Translation of the original instruction English version Revision 05 02 13 A A1 A2 A3 A4 B B1 B2 B3 B4 B5 C C1 C2 C3 D D1 D2 D3 DA D5 OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE Contents GENERAL EXPLANATION OF SYMBOLS INTENDED USE BUTTERFLY VALVE LABELLING TRANSPORT AND STORAGE FITTING THE VALVE INTO THE PIPE SYSTEM PRESSURE TESTING SAFETY ADVICE FOR FITTING OF VALVES REQUIREMENTS FOR FITTING INTO THE PIPE SYSTEM FITTING PROCESS PRESSURE TESTING BEFORE DURING OPERATION SUPPLEMENTARY INFO DISMANTLING THE VALVE OPERATING MANUAL SAFETY INSTRUCTIONS FOR OPERATION AND MAINTENANCE MANUAL OPERATION AUTOMATIC OPERATION TROUBLESHOOTING TECHNICAL APPENDIX PLANNING DOCUMENTATION TECHNICAL SPECIFICATION OF THE VALVE P T RATINGS DRAWING BILL OF MATERIALS REPLACEMENT PARTS FLANGE BOLTS FOR CENTRIC VALVES DECLARATION IN COMPLIANCE WITH EU DIRECTIVES page Ul mh BW W CON OO Ul Ul 10 11 11 11 13 13 13 14 More information and current addresses of our branch offic
2. for the full catalogue refer to the addresses in the table of contents D1 Technical Specification of the valve The butterfly valve type lt centric gt conforms to Design Standard gt EN 593 Butterfly valves with housing made from metallic materials D2 pr t Hatings Dependent on lt PS gt and the housing and lining materials the following maximum operating pressures are allowed dependent on the operating temperature Note The figures may vary depending on type and material for maximum pressure and temperature limits see section A2 and A3 Not all types and sizes are listed p t ratings for versions not shown can be obtained on request Type T211 A and Type T211 C System Pressure PS bar eo 40 20 0 20 40 60 80 100 120 140 160 180 200 System Temperature TS C Pressure Temperature Diagramm for valves with Silicone elastomer inserts Service limitation with EPDM elatomer inserts from 10 C up to 120 C Service limitation with Fluor carbon inserts FPM from 10 C up to 180 C Vacuum service to 1mbar absolute from 10 C up to 160 C Valve installation between flanges Type T212 A Sizes DN 350 600 special design 10 T E 3 e LL LH E Po 5 6 y4 Sizes DN 700 900 a installation between flanges 4 z Sizes DN 350 900 uU a gt e 0 40 20 0 20 40 50 80 100 120 140 160 180 200 System Temperature TS C Pressure Temperature Diagramm for valves with Silicone elastomer inserts Other e
3. gt the purchaser has made explicit reference to this Non compliance with this intended use constitutes an act of gross negligence and releases EBRO Armaturen from any product liability EBRO ARMATUREN Seite 3 ae OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE A3 Butterfly valve Labelling Each butterfly valve carries the following information on the housing or on the name plate for Code Remarks Manufacturer EBRO ARMATUREN Address see page 2 lt Content gt Valve type e g Z011 Housing model see overview page 1 Conformity CE Conformance with Pressure Equipment Directive 97 23EG ID Number 0036 Notified body according to EU Directive TUV S ddeutschl a Numbers 1 6 EBRO Com Nr Numbers 7 9 Order position RAPAREN E TAANA 3 Numbers 10 12 serial nr of an order position DN and figure Housing model e g DN80 PN PN JJeg PN16 The required PN level of the counter flange Temp limits TS and figure Figures for upper and lower operating limits Maximum pres PS and figure Figures in bars at Room temperature sure tolerance Material in the name plate Material of lining Note The year of manufacture is encoded in the factory nr The name plate should not be covered in order that the fitted valve remains identifiable A4 Transport and storage To transport correctly e Leave the Valve in the factory packaging until use assembly e Store the valve in a secure area
4. M T TW BE D3 Drawing bill of materials The drawings assigned to the valves and standard bills of materials can be downloaded from the EBRO Download menu www ebro armaturen com doku D4 Replacement parts In the bill of materials in the datasheets described under section D3 the replacement parts are highlighted by the note empfohlenes Ersatzteil recommended spare part Only EBRO Original parts can be fitted Request replacement parts and the necessary manual from EBRO Armaturen D5 Flange bolts for centric valves The flange bolts compatible with the valve and relevant assembly instructions can be found in the EBRO ARMATUREN Company standard sheets EW1806 to EW1810 and EW1830 ff This can be downloaded from the Download menu Address see Page 4 or Link below www ebro armaturen com doku Seite 13 EBRO ARMATUREN OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE Declaration in compliance with EU Directives The manufacturer EBRO Armaturen Gebr Broer GmbH Karlstrasse 8 58135 Hagen Deutschland declares that the valves EBRO butterfly valves in centric and excentric design Series Z F M T TW BE and Series HP Are manufactured in accordance with the requirements of the following standards EN 593 Product Standard Butterfly valves with metal housing EN ISO 12100 Safety of machines Basic terms general design guidelines Product documents are available on the follow
5. and CLOSED must be set correctly N Ensure that pressure is not applied to a butterfly valve like this before the actuator is fitted Warning e Butterfly valves can be fitted irrespective of the direction of flow of the medium EBRO ARMATUREN Seite 6 ae B4 OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE Valve with pneumatic lt fail safe gt actuator with opening spring A lt fail safe gt actuator with opening spring must be closed by means of a compressed air connection or alternative for insertion between the counter flanges The assembly instruction of the actuator must be followed and it must be ensured that the butterfly disc is not suddenly opened accidentally risk of injury After fitting the butterfly valve disc should be opened to flush the pipe to ensure that the pipe section is clean before the valve is closed the first time Before closing the first time hard abrasive dirt welding beads rust particles etc must be removed from the pipe section When fitting onto the end of a pipe section If the butterfly valve is mounted as an end fitting and pressure is applied it must be sealed with a blank flange in order to prevent damage to people or property through A gear mechanism or actuator is adjusted to match the operating data includ ed in the order The setting on the CLOSED end stop of a brand new valve should not be changed as long as the valv
6. and protect against dirt and damp e Attach lifting straps as in fig 1 to fig 3 Do not suspend large valves on gear or drive mechanisms Protect valve discs and flange mating surfaces against possible damage ISO 2230 described in detail the storage conditions for parts with elastomers complete valve and spares and determined the allowable duration of storage Valves which are supplied without an actuator The butterfly valve disc is not secured against displacement The disc must be trans ported in such a way that it cannot be opened from its transport position through outside factors e g vibrations RO ARMATUREN Seite 4 CES B B1 OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE Fitting the valve into the pipe svstem Pressure testin This instruction includes safety advice relating to foreseeable risks when fitting the valve into a pipe system It is the responsibility of the user to follow this advice with regard to other risks in particu lar those relating to local conditions All preconditions for the system should already be in place Safety advice for fitting of valves e Valves may only be fitted into the system by qualified persons Qualified in the context of this manual means persons who can correctly assess and carry out the tasks assigned to them and can recognise and eliminate any risk on the basis of their training specialist knowledge and professional experience
7. is normally not necessary The mating surfaces on the butterfly valve housing are lined with elastomer or polymer and are designed for sealing the flange joint To seal the joint the counter flanges must be smooth and have full faced mating surfac es e g Form A or B in line with Standard EN 1092 1 or EN 1759 1 Other types of flange must be used only with the agreement of the manufacturer B3 Fitting process The lining of the housing must not come into contact with lubricants cleaning agents or any other substances whose suitability has not been proven or confirmed by EBRO Arma turen Unsuitable substances can lead to soiling swelling or damage e Inspect Valve and actuator for transport damage Damaged butterfly valves or actuators may not be fitted e The preferred assembly position of the valve is with a horizontal shaft The gear mechanism should if possible not be housed directly below the valve Leaks on the shaft may damage the gear mechanism or actuator e Butterfly valves for fitting between flanges must be carefully centred when fitting with flange bolts Follow the advice on flange bolts in Section D5 e fa valve is supplied without an actuator device in special cases it must be fitted closed and left like this until the actuator is retrofitted An assembly instruction for this must be supplied by the actuator manufacturer The nominal torque must be adjusted to match the valve and the end stops OPEN
8. e The intended function of a valve after fitting must correspond to the intended use described in Section A2 e Pressure may not be applied to a valve which is not locked into a any position on actuation e An actuator fitted onto a valve may only be actuated if the valve is surrounded on both sides by the pipe or valve section any actuation before this point constitutes a crush hazard and is solely the responsibility of the user e A valve which closes a pipe section as an end fitting under pressure from within the pipe must be secured with a blank flange in such a way that no leaks can oc cur Requirements for fitting into the pipe system Ensure that only butterfly valves whose pressure classification and materials correspond to the op erating conditions are fitted See corresponding information on the name plate Section A3 Normally the butterfly valve must be either adjusted with the hand lever geared hand wheel or fit ted with an actuator and adjusted ready for operation A valve will only be supplied without an actuator in special cases for retrofitting purposes The butterfly valve should be left in the factory packaging for storage and transport and only un packed immediately before fitting into the pipe section AN The outer edge of the disc is very finely machined in order to ensure that a closed butterfly valve is sealed Please ensure that this surface is not damaged when handling during fitting Caut
9. e is sealed when closed Only for butterfly valves with electrical actuators Ensure that the actuator is switched off in the end settings by the microswitch signal The torque switch signal should be used for a fault indicator The fault should be rec tified as quickly as possible see section C3 Troubleshooting For more advice refer to the Electrical actuator manual To complete the fitting a function test must be carried out Using the lever or hand wheel a but terfly valve should be actuated by hand as quickly as possible to the full opening angle An actuator fitted on the butterfly valve must be moved smoothly into the OPEN or CLOSED positions using the control data indicated and following the control commands Incorrectly executed control commands may cause a hazard and may damage the pipe system Any functional faults found must be rectified immediately before full operation See also Section C3 Troubleshooting Pressure testing before during operation All butterfly valves have undergone a final inspection by the manufacturer ex factory in accordance with EN12266 1 The test conditions for the pipe section apply when pressure testing a valve in the system with the fol lowing provisos The test pressure of a valve may not exceed 1 5x PS according to the name plate of the valve The butterfly valve disc must also be open at this test pressure If pressure exceeding 1 1x PS is applied to a closed butter
10. em Ensure that the pipe flanges are aligned and plane parallel and or change the lining of the housing Follow Section B1 Safety instructions gt and re quest replacement parts and the necessary manual from EBRO Armaturen Leaking from the shaft f the shaft seal is not tight seal Repair needed Replace shaft seal Follow instructions from sections B1 and C1 Safety instructions and request replacement parts and the necessary manual from EBRO Armaturen Check whether the valve is 10096 closed with full actuation torque If the valve is still not tight when closed Open close valve several times under pressure Leak in the passage Bearer seer linia valves Suinotiont Repair needed Replace Housing lining sleeve Follow instructions from sec tion C1 lt Safety instructions gt and request replacement parts and the neces sary manual from EBRO Armaturen Dismantle valve follow instructions from sections B1 and C1 Safety instruc tions gt and inspect Functional problems If the valve is damaged Repair needed request replacement parts and the necessary manual from EBRO Armaturen Seite 10 EBRO ARMATUREN OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE D Technical Appendix Planning documentation Note This appendix is not an integral part of the assembly and operating manual and is only an extract of the catalogue pages of EBRO Armaturen for this valve type
11. es and resellers can be found under www ebro armaturen com EBRO ARMATUREN GmbH Karlstrake 8 D 58135 Hagen 4 02331 904 0 Fax 02331 904 111 Seite 2 EBRO ARMATUREN bu 4 OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE A General A1 Explanation of Symbols Notes in these instructions are indicated by symbols Hazard Caution Warning draws attention to a dangerous situation which may cause death or serious in juries to people and or damage to the piping system Attention draws attention to an imperative instruction Information provides useful tips and recommendations If these notes cautions and warnings are not followed hazards may result and the manufacturer s guar antee may become void A2 Intended Use After fitting between flanges of a piping system butterfly valves belonging to Series Z F M T TW and BE are designed to shut off and convey media within the maximum pressure and temperature tolerances or to regulate its flow The maximum pressure and temperature tolerances dependent on the housing lining materials are in dicated in the name plate of the valve by TS and PS see section A3 The valve may only be operated after reference to the following documents e Declaration according to EU Directives see above e This assembly operating manual which is supplied with the valve The valve may only be used in amp hazardous environments if
12. fly valve there is a risk of the in terior sections of the valve being overstressed This must be avoided at all costs EBRO ARMATUREN Seite 7 pur OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE B5 Supplementary Info Dismantling the valve Follow the same safety rules as for the pipe system and valve see section B1 e Check whether the pipe is disconnected empty and at normal pressure e Fully close the valve remove the flange bolts Prise apart the flange with a tool e Remove the valve do not damage the flange mating surface when removing the valve and store away in a well protected place Protect the mating surfaces e Refer to Section A4 for attaching lifting straps If a fitting is dismantled from pipes containing dangerous substances and needs to be removed from the system The sections of the valve which come into contact with the product disc shaft and seat ring must be properly decontaminated before repair After dismantling the valve The lining of the housing must not come into contact with lubricants cleaning agents or any other substances whose suitability has not been proven or confirmed by EBRO Armaturen Unsuitable substances can lead to soiling swelling or damage EBRO ARMATUREN Seite 8 ae OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE C Operating Manual Under the provisions of MRL 2006 42 EG the system planner must conduct a full ris
13. ich the valve is fitted has been declared by the persons responsible A separate declaration is supplied for the actuator named above 3 EBRO Armaturen has conducted and documented the required risk analyses the EBRO Armaturen employee re sponsible for this documentation is Bernhard Mitschke Hagen 4 12 2009 Dirk Mischnick anaging Director YEN uu Seite 14 EBRO ARMATUREN OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE The manufacturer EBRO ARMATUREN Gebr Broer GmbH D58135 Hagen declares that the valve fitting EBRO Butterfly valve in centric and excentric design complies with the following provisions Requirement according to Annex I of the Machine Directive 2006 42 EG 1 1 1 g Intended use see Assembly Operating manual 1 1 2 c Warnings against incorrect use see Assembly Operating manual Exactly as per the pipe section into which the valve is fitted No special tool required for changing consumable parts All materials coming into contact with media are specified in the type datasheet and in the order 1 1 2 c Required protective equipment 1 1 2 e Accessories 1 1 3 Parts in contact with media confirmation The user is required to conduct an appropriate risk analysis Met through the instructions in the Assembly Operating manual Responsibility of the user in accordance with the Assembly Manual of the actuator For pressure retaining parts of the valve Certified thro
14. ing Planning documentation Technical datasheets catalogue pages These products comply with the following directives Pressure Equipment Directive 97 23 EG DGRL applies if Art 3 Paragraph 1 3 or Art 3 Paragraph 3 is appli cable The valves comply with this directive The conformity rating procedure used according to Annex IIl of the Pressure Equipment Directive 97 23 EG is For Category Module A For Category Il and II Module H For Category IV Module B D Name of notified body T V S d Industrie Service GmbH Reg Nr 0036 Machine Directive 2006 42 EG MRL applies if the valve is not actuated manually 1 The products are a partly completed machine under the terms of Art 2 g of this Directive 2 The table overleaf lists whether and how the requirements of this Directive are met 3 This declaration is the Declaration of Incorporation under the terms of this Directive To comply with the directive above the following applies 1 The user must comply with the intended use defined in the Original Assembly and Operating Manual BA 1 0 DGRL MRL or BA 3 0 DGRL MRL supplied with the valve and must follow all instructions in this manual If this manual is not followed the manufacturer may in serious cases be released from his product liability 2 The valve must not be put into operation and the fitted actuator if applicable until the conformity to all applicable EU directives above of the system into wh
15. ion Flanged valves must be fitted on or between flanges according to EN 1092 1 or EN 1759 1 with mating surfaces according to form A or B which must be machined plane parallel and must be aligned The use of other flanges and or other forms of sealing faces must have been verified in the order confirmation from EBRO Armaturen The clearance of the counter flange must leave sufficient space for the butterfly valve disc when opening so that the disc is not damaged when opening out thus becoming unusable See Table Dimensions may vary depending on type EBRO ARMATUREN Seite 5 ua OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE Minimum Pan Ts inner diameter D of the counter flange 196 560 e All interior surfaces of the valve must be free of dirt especially hard sharp particles The pipe sections on both sides must be also be clean Follow the advice in Section B3 to flush out a pipe with a fitted valve If dirt Welding beads rust particles etc is not removed the mating surface on the butter fly valve disc may be damaged The valve may leak and at worst will become unusable e The butterfly valve is supplied almost closed and must also be fitted as such in order to protect the mating surface on the disc against damage e The ends of the pipes must be aligned and have plane parallel joint planes Flange seals must not be used for centric valves The use of additional flange seals
16. ity of the user Crush hazard C2 Manual operation automatic operation The valve closes in a clockwise direction when actuated and opens in an anti clockwise direction A butterfly valve with manual actuation only requires normal manual force to actuate it do not use any extensions to the hand wheel Valve wheel hook or similar tool A butterfly valve with actuator must be actuated by the controller signals Butterfly valves which have been supplied with an actuator ex factory are set precisely ex factory this setting in the gear mecha nism actuator should not be reset as long as the valve works properly The only maintenance required is a visual inspection at appropriate intervals of the tightness of the flange connection for media leaving the valve if any leakage occurs see Section C3 Troubleshoot ing We recommend that you actuate butterfly valves which remain permanently in one position at regular in tervals in order to ensure continued free movement EBRO ARMATUREN Seite 9 ae OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE C3 Troubleshooting Type of problem Seal the flange connection between the housing and pipe system Follow instructions in the Operating manual for the pipe system and the instal Leaking from the flange lation instructions see Section D5 for the corresponding fitting connection to the pipe If the leak cannot be stopped by retightening the flanges syst
17. k analysis For this purpose EBRO Armaturen provide the following documentation e This assembly and operating manual e The attached Declaration of EU Directives This manual contains safety instructions for foreseeable risks when using the valve for industrial applications The planner operator is responsible for supplementing these instructions for other risks specific to the machinery used C1 Safety instructions for operation and maintenance e he function of a valve must match the Intended Use described in Section A2 e he operating conditions must correspond to the information on the name plate of the butterfly valve e Any required work on the valve may only be carried out by qualified persons Quali fied in the context of this manual means persons who can correctly assess and carry out the tasks assigned to them and can recognise and eliminate any risk on the basis of their training specialist knowledge and professional experience e Before loosening a lock screw or screw on the housing cover or before dismantling the entire valve from the pipe system the pressure in the system or pipe section must be reduced on both sides of the valve so that the medium does not escape uncontrolled from the pipe An actuator fitted onto a valve may only be actuated if the valve is surrounded on AN both sides by the pipe or valve section any actuation before this point constitutes a crush hazard and is solely the responsibil
18. lastomer inlays on request Vacuumservice for Sizes DN 350 600 to 200mbar absolut depending on medium and temperature Valve installation between flanges Vacuumservice for Sizes DN 700 900 to 500mbar absolut depending on medium and temperature Valve installation between flanges a lL AAT Seite 11 EBRO ARMATUREN Differential pressure bar System Pressure PS bar 18 16 14 12 10 OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F M T TW BE Type T214 A and Type T214 C Sizes 50 150 special design Sizes DM 50 300 oO rn o 40 20 0 20 40 60 BO 100 120 140 150 180 200 System Temperature TS C Pressure Temperature Diagramm for valves with Silicone elastomer inserts Service limitation with EPDM elatomer inserts from 10 C up to 120 C Service limitation with Fluor carbon inserts FPM from 10 C up to 180 C Vacuum service to 1mbar absolute from 10 C up to 160 C Valve installation between flanges PRESSURE TEMPERATURE DIAGRAM Type Z011 A Z014 A DN50 DN300 for versions with EPDM sleeve EBRO Standard black 10 0 20 40 80 90 100 110 120 System temp rTS C Z011 A Z014 A Pressure rating of disc bar between flanges o 6 O 1 2 6 3 o 10 LTOS 4 116 A 3106 X 3 Seite 12 EBRO ARMATUREN OPERATING MANUAL FOR CENTRIC BUTTERFLY VALVES SERIES Z F
19. quired for special actuators see order confirmation 3 20 6 1 inherently safe design Analysis according to 4 5 and 6 Since valves with an actuator work automatically according to the commands of the controller 6 4 5 Operating manual those aspects which are typical to the valve are described in the operating manual and must be made available to the manufacturer of the pipe system The conducted risk analysis has been carried out according to Annex VII B by EBRO Armaturen 7 Risk analysis and is documented according to MRL Annex VII B Seite 15 EBRO ARMATUREN
20. sis for the valve actuator is conducted from the perspective of a partly completed machine The analysis has been based upon Product Standard EN593 lt Butterfly valve with metal housing gt with an actuator according to EN15714 2 or EN15714 3 Class A 15 This is also based on industrial application and on average gt 20 years experience in using the Scope above valve types This has resulted in the instructions and warnings in the above assembly man ual and operating manual Note It is a prerequirement that the user conduct a risk analysis tailored to the application for the pipe section includ ing the valves used in accordance with Sections 4 to 6 of EN ISO 12100 this cannot be done for EBRO Arma turen for standard valves The butterfly valves are designed according to the principle of lt inherently safe design gt The lt intended use gt is a prerequirement Based on knowledge of malfunctions recorded by the manufacturer and misuse within the context of a claim for damages Documentation according to ISO9001 wu The limits of the partly completed machine have been set according to the intended use of the 5 3 Machine limits valve as well as of the actuator 5 4 Decommissioning disposal Not within the responsibility of the manufacturer Since the valve and the actuator enclose the function parts if used as intended this section does 6 2 2 Geometric Factors not apply 6 3 Technical protection equipment Only re
21. ugh Declaration of Conformity with DGRL 1 3 2 Preventing risk of breakage 97 23 EG 1 1 5 Handling 1 2 and 6 2 11 Control For functional parts Guaranteed through intended use of actuator Requirement met 1 3 4 Sharp corners and edges Requirement met through intended use Maintenance and repair only when valve actuator is not in operation Responsibility of user See also Assembly manual of actuator see Warnings in Assembly Operating Manual Section lt Intended Use gt 1 3 7 8 Risk of injury through moved parts 1 5 1 1 5 3 Power supply 1 5 5 Permitted temperature exceeded x protection required Must be stated explicitly in Purchase Contract 1 5 7 Explosion In this case Only use as directed on the valve Not applicable see Operating manual Discuss keeping stock of consumables with EBRO Armaturen Valve According to assembly manual Actuator According to assembly manual Any supplementary information required for the full manual of the lt completed machine gt are summarised in the Operating Manual document see Section C of the Assembly Operating manual The valve is not a lt complete machine gt No CE Mark for conformance to the MRL 1 5 13 Emission of hazardous substances 1 6 1 Maintenance 1 7 3 Labelling 1 7 4 Operating Manual Requirements according to Annex Ill Requirements according to Annex Ill and Annex VIII XI Not applicable Requirement according to EN ISO 12100 The risk analy

Operating Instructions BA 1.0 - DGRL/MRL

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