EN Original Operating Instructions
Contents
1. FLOWSERVE ERVE High pressure Ball Valves HPH HPI HPK HPR HPT HPZ a FLOWSERVE Contents WNT OCUCHION as ieee ec cee sSinee sen aaa esc ctv ana vse duce a NANAK vanediscucaweeanasaxddodes entvavansvecedbieeess 3 Availability erie ine e EAN iii ee ee ae ee Ses 3 Types of valve illustrated and described 0 eee eeeeeeeeeeeeeeeneeeseeeeeeeenaeeeeeenaeeeeeenaees 3 Design features in the text c c cc coni ieee cues pno eaa aE aa ANTE n eaa 4 Saleh ye iasevienstnee dened ceacenepie rRNA EAKA edi heceniedevvenvasauaentelavevasgunndentaiaveesmtebneevtenstventls 4 Proper US eerren er Ah ne ei Sa he Sh bei ee ee 4 Basic safety iNStructions si csccccsascteccsestienesdetey thentteesecates sthestueesscunahcthenttensbdebneadhestueeneaten 5 Potential causes of damage and malfunction ieee eeeeeeeeeeneeeeeeneeeeeeeeeeenaeeeeees 7 Qualification Of PErsOMMel c cc ccccc cesgccdeceeneeeptescetdneeseevenessegedeeneuesesstenddeeneneveneetecedaenes 7 Protective Cloning oo eictcn se thet ev a a ton tea pet ates Liat nodes meet Lb cated 7 Design features of warning instructions in the text eeeeeeeeeeeeeereeeeeeeneeeeeneeeeee 8 Design features of instructions about damage to property eeceeesseeeeeereeeeenneeeeees 8 Deshpande seeds ved coed are a A a a 9 Scope of supply and description of the Unit eee ee eeeeeeeeneeeeeeneeeeeeeaeeeeeenaeeeeeeeaees 9 USOS ANGHTUNCIION repre aiara Eeer Eaa UE cs Aa EAEE se EE aa ised E AEEA2. HPI HPR HPT HPZ natural gas mineral oil HPH hot water gt HPK brine caustic potash lime water or mineral laden liquids Use of these ball valves with other media is only permissible with the manufactur er s approval For other media consult the manufactur er about the application The units shall only be used within the permissible pressure and temperature limits taking chemical and corrosive influences into account Observing and complying with all data and details in these Operating Instruc tions in particular the safety instructions is implicit in proper use 4 Instructions and data in the document supplied with the unit are considered to be an integral part of these Operating Instructions The operating authority must ensure that only the following activities are carried out bd The maintenance operations de scribed in these Operating Instructions see page 27 Opening and closing the ball valve Pressure testing Air bleeding optional Draining optional Emergency sealing of the valve stem optional Changing valve stem seals Emergency sealing of the secondary sealing system optional Any other activities shall only be carried out by personnel who have been special ly trained and authorised by the manufac turer Any other use of the unit is considered to be improper use In particular the use of ball valves to regulate the rate of flow is improper use If an uns
3. Make sure the unit has been fully decontaminated before gt Replace the bearing bush 45 working on it gt Replace the circlip 46 gt During such work follow the instructions for handling the media concerned Specialist personnel must have knowledge and experience of the follow ing legal regulations covering the handling of hazardous substances that apply where the unit is installed special instructions for handling the hazardous substances that occur use of the specified protective cloth ing 35 FLOWSERVE ATTENTION Environmental damage may be caused by residues of poisonous media gt Before disposal make sure the unit has been cleaned and is free of media residues gt Dispose of all materials in accordance with the legal re quirements that apply where the unit is installed Removing the unit gt gt 36 Remove all residues from the unit Dispose of all residues in accordance with the legal requirements that apply where the unit is installed AN DANGER When working on pipelines very serious injuries or death can be caused by burns high pressure in the system or poisoning gt Make sure there are no hot or hazardous media in the unit or pipelines Make sure there is no residual pressure in the valve cavities Make sure the unit and pipe lines connected to it are pres sure free Make sure the plant is switched off and secured a
4. N The torque to tighten the screw or screws depends on their size The tightening torques in the following table Nm should be considered as a guide because in practice the coefficient of friction may vary substantially The data here are based on a coefficient of friction of 0 12 If different screw materials are used ask the manufacturer for the correct tighten ing torque gt Tighten the screw or screws to the torque specified for their size Stainless steel Steel screws with strength grade 20 Thread A4 70 B7 5 6 8 8 10 9 12 9 M8 16 24 11 25 35 42 M10 30 49 23 50 69 83 M12 52 84 40 86 121 145 M14 83 130 64 138 194 232 M16 126 205 100 214 302 362 M16x1 5 108 230 324 390 M18 174 310 138 296 416 500 M20 245 395 195 419 590 708 M20x1 5 220 470 660 790 M22 328 525 270 573 806 968 M24 423 675 340 725 1020 1224 M27 617 1000 500 1066 1499 1799 M30 845 1430 677 1444 2031 2437 NPT G he 115 120 1 350 370 Connecting the unit AN DANGER An incorrectly connected unit can cause an accident that results in very serious injuries or death gt Make sure the unit is only connected to the pipeline by suitable specialist personnel gt Make sure the direction of flow in the pipeline corresponds to the direction of the arrow on the valve body FLOWSERVE N AN CAUTION Danger of burns from hot surface
5. suitable for the flow medium wear faster This can result in leakage of the medium Make sure the material is suitable for the flow medium The unit can be damaged by pressure surges even when the permissible nominal pressure PN is not exceeded Make sure the unit is not exposed to pressure surges Qualification of personnel The operating authority shall only author ise qualified specialist personnel to carry out work on the unit These persons must as a result of their training and experience have knowledge of the rele vant regulations to ensure safe operation of the unit that apply at the location where it is installed These include in particular the following regulations Legal requirements Standards Accident prevention regulations Recognised rules for safety and cor rect working Special instructions issued by the operating authority These persons must be able to recog nise assess and avoid potential hazards FLOWSERVE Specialist personnel must have knowledge and experience in the follow ing sectors Valid legal regulations concerning protection against fire and explosions and work safety that apply where the unit is installed Working on pressurised equipment Making connections to pipelines Working with hazardous media hot or under pressure Lifting and transporting loads All instructions in these Operating Instructions and other co val
6. EE 13 Storing and transporting the ValVe s ccccceeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeseeeeeeeeeeeneegs 15 Storing theValv sienai a a a a a a a aa 15 Transporting theUnit isi iia tear id oie eas 16 Installing and connecting the Unit cccseeceseeeeceeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeeeeeeeeeaees 17 Preparing tor installation cia eae cecasdetcatages E E aani aT ses EDE SE TAE a S RRA 17 Mounting the actuator issi n naa a a a a aaa 18 Connecting the unit stake a see eee ea 21 ODPESALION EE ETT a 23 Correcting faults and distUrbDaNnCes cccccceeesssenieeeeeeesssseenseeeeeeesssseeeaeeeeneeees 24 Eliminating leaks with the emergency Sealing SYStEM cecceeeeeeeeesteeeeeereeeeeeneees 25 After operation ar cts lai ele ie ee ee eee Rate ee Rie cece 27 Cleaning to remove external Citt ec eeeeeeeneeeeeeneeeeenneeeeeeaeeeseeeaeeetneeeesenaeeeeeeneees 27 Maintenance of the Unity iieiea a ae aa 27 Repairing the unit and fitting spare Parts 0 eee cece eeeeeneeeeeeeeeeeeetaeeeeeenaeeeeeneeees 32 Taking the unit out Of service cccccceessssereeeeeeeeesssseeeeeeeeeeesssneeeeeeeeeeessssseeaaees 35 Remove hazardous SUDStANCES iiiver ee enneeeeeeaeeeeeeeaeeeeaeeeeeeaeeeesenaeeeeeenaees 35 REMOVING THELUNIE esinin pe eiad nah ethan eaii eenaa 36 Reusing the unit after Storage sssri riie iiiter iiie iiaii kiadta veui draia evda 37 Disposal Of the unitas i a a a a eaten 37 Technical DE ee Ea EA E A
7. ET 38 Application limits miesni a aa EE nein eee ene 38 Manufacturer s declaration cccccccccseececcesesenceeeeeeeceueeneueueeneeseeeneeeeeeneceueeneeetens 39 Introduction These Operating Instructions will help you achieve the proper safe and eco nomical use of the following types of AUDCO Ball Valves HPH HPI HPK HPR HPT HPZ In the text below a valve will be referred to as a unit These operating instructions are intended for all persons who commission operate maintain clean or dispose of one or more of these units The Operating Instructions are intended in particular for customer service fitters trained specialist person nel and qualified and authorised operat ing personnel Each of these persons must have read and understood the contents of these Operating Instructions Following the instructions contained in these Operating Instructions helps rec ognise and avoid potential hazards and increase the reliability and useful life of the units In addition to the instructions in these Operating Instructions it is essen tial to observe and follow the valid bind ing accident prevention regulations and recognised technical rules for safe and technically correct working that apply in the country and at the location where the valve is installed and used oe FLOWSERVE Availability Always keep these Operating Instructions with the plant documentation Make sure that these Ope
8. depends on their size gt See the table on Page 20 for the cor rect tightening torque gt Tighten the screw or screws to the specified torque To relieve pressure in the cavity open the air bleed Remove the dowels 36 Remove the screws 35 around the valve stem first loosening them pro gressively Remove the flange 37 Remove the sleeve 38 with the bear ing bush and O rings Remove O rings 39 43 44 Remove the sealing ring 40 Remove the pressure ring 42 Remove the graphite ring 41 Make a note of the sequence an ring types Insert a new graphite ring 41 Insert a new pressure ring 42 Fit new sealing rings 39 40 to the sleeve 38 Fit new O rings 43 44 to the grooves in the sleeve Place the sleeve 38 with the bearing bush in the flange 37 FLOWSERVE N Changing the seal on the HPZ Taking the unit out of service Remove hazardous substanc es AN DANGER For units installed in contaminated areas there is a danger of severe or lethal injury from hazardous substances on or in the unit gt Work on contaminated units shall only be carried out by gt To relieve pressure in the cavity open nae the air bleed specialist personnel gt Remove the circlip 46 gt Wear the specified protective gt Remove the bearing bush 45 clothing during all work in the gt contaminated area gt Remove the O ring 47 gt Fit a new O ring 47 gt
9. fall under Category Il III or IV of Pressure Equipment Directive 97 23 EC bear the CE marking and the number of the Notified Body Connection types The units can be supplied with the follow ing connection types Flanges Pipe welding ends ATEX The unit has no potential ignition sources and is not subject to the Equipment and protective systems intended for use in potentially explosive atmospheres Di rective 94 9 EC These units bear no EX markings The markings on the unit and declaration of conformity to Explosion Protection Directive 94 9 EC are not valid for any electric hydraulic or pneumatic actuator that may be fitted gt In this respect observe and follow the information given in the actuator man ufacturer s documentation Pressure Equipment Directive The units that comply with the require ments of Pressure Equipment Directive 97 23 EC can be used for the following media when tested by the manufacturer Media in Fluid Groups 1 or 2 Units without safety functions can carry a CE marking from DN 32 A declaration of conformity in accordance with Pressure Equip ment Directive 97 23 EG is in cluded with the unit For pressure and temperature limits please see the typeplate Exceptions to this are units that fall under Article 3 3 These units are not allowed to bear a CE marking FLOWSERVE N Uses and function Uses AUDCO ball valves of the types de scribed here a
10. is under pressure and may be hot Do not carry out work on the unit until the following conditions apply The pipelines and cavities must be pressure free bd The medium must have been com pletely emptied from the pipelines and the unit During any work on the unit the higher level plant must be switched off and secured against unauthor ised switching back on The pipelines and the unit must have cooled to about 20 C hand warm For units installed in contaminated areas there is a danger of severe or lethal injury from hazardous substanc es on the unit Do not work on the unit until it has been completely decontam inated Wear the specified protective clothing during all work in the contam inated area The unit shall only be used with media that do not attack the material the unit is made from or its seals Otherwise leaks of hot or poisonous substances may result The unit and its components shall only be assembled or dismantled by spe cialist personnel Specialist personnel must have knowledge and experience in the following sectors Making connections to pipelines The selection of lifting gear suitable for the unit and the safe use of such lifting gear Working with hazardous media contaminated hot or under pres sure FLOWSERVE The selection of unsuitable lifting gear or the incorrect use of lifting gear can result in the unit or parts of it falling Allow o
11. seal areas on the valve 21 a S FLOWSERVE gt After welding remove the temperature sensing strips gt Make sure the unit is securely mount ed and that all connections have been correctly executed When the unit is used in air conditioning cooling or refrigeration plant it must be insulated with diffusion resistant insula tion gt Insulate the unit with suitable material The choice of insulation material de pends on the temperature of the medium gt To receive information about suitable insulation materials please contact the manufacturer gt Connect the actuator correctly to the appropriate energy supply After installation you must flush the unit and carry out leak testing gt Flush the unit and pipeline with clear water or with the medium being han dled gt Make sure that contaminated water or medium does not enter the plant circu lation gt To check the function and leak tightness of the unit open and close it several times while flushing it gt Make a visual inspection to check the leak tightness of the unit gt For gaseous media check the unit with an appropriate measuring instrument gt Eliminate any leaks found gt Run the higher level plant under oper ating conditions You can determine the pressure loss at measuring instruments in the higher level plant gt Check that the ball valve is leak free under pressure 22 When any leakage occurs proce
12. aints made later FLOWSERVE Description of the unit No Designation No Designation 1 Valve stem 6 Secondary sealing pressure 2 Valve stem seals system 3 Valve stem emergency sealing 7 Typeplate 4 Cavity air bleed from DN 150 8 Drain valve from DN 50 5 Lifting eyes from DN 200 9 __ Body welded 10 Ball Optional components The ball valve can be opened and closed either manually with a valve wrench or by an actuator The following optional components are available for these units Drive unit dD electric hydraulic pneumatic Gearbox for manual operation Valve wrench Air bleed valve Drain valve Pressure relief valve standard equip ment on HPH gt Parts for underfloor installation The following types of unit can be sup plied with emergency sealing HPH HPK HPT HPZ On these units a leaking valve stem can be sealed without dismantling the actua tor In addition the units are equipped with nipples for applying lubricant under pres sure On these units this allows the user to compensate for wear of the seating ring seals and the valve stem seals On units for underfloor installation the control elements and leads are extended upwards FLOWSERVE N These underfloor units differ from stand ard in the following ways The valve stem is fitted with an exten sion 11 The
13. amage contact the manufacturer As delivered the connections may be closed with plugs gt Remove the plugs before installation gt Keep the plugs and packing materials in a safe place for subsequent use AN DANGER When working on pipelines very serious injuries or death can be caused by burning or poisoning gt Make sure there are no hot or hazardous media in the unit or pipelines gt Make sure the pipelines at the unit are pressure free gt Make sure the plant is switched off and secured against unauthorised switching back on gt Make sure the unit and pipe lines have cooled so that they are no more than hand warm gt Wear protective clothing suita ble for the medium and when necessary use suitable protec tive equipment 17 FLOWSERVE N For more information about suitable pro tective clothing and protective equipment see the safety data sheet for the medium being handled gt Empty the pipelines gt Make sure the pipelines are clean and free from media residues gt Switch the plant off and secure it against unauthorised switching back on 18 Mounting the actuator Mount either the valve wrench the gear box or the actuator on the valve stem of the ball valve Actuators supplied by the manufacturer have a drive coupling that fits the valve For other actuators the drive coupling must fulfil the requirements of DIN EN ISO 5211 gt For more infor
14. bed in the section Changing seals from page 32 Draining the unit In this section draining is de scribed and illustrated for a standard unit On units for underfloor installation the valves have other locations An optional drain valve may be fitted to the lower part of the valve body for drain ing it FLOWSERVE N gt Drain the valve body at regular inter vals The interval required depends on condi tions where the valve is installed gt Contact the manufacturer for precise instructions On units with the Double Block and Bleed function the drain valve is only used for safe shut off during repairs and maintenance For this purpose both the bleed valve and the drain valve must be open When the ball valve is closed this ensures that any medium that leaks is drained through the valve This allows work to be carried out on or in the pipeline downstream of the unit without the danger of contact with the medium at the work site AN DANGER The uncontrolled release of medi um can result in very serious injuries or death caused by burns high pressure in the system or poisoning gt Make sure the unit and pipe lines connected to it are pres sure free gt Make sure that hot or hazard ous media are collected in a container that is suitable for those media gt Wear protective clothing suita ble for the medium and when necessary use suitable protec tive equipmen
15. ection Storing the valve from pa ge 15 C S FLOWSERVE N Reusing the unit after storage You can dismount the unit and reuse it at another location if you observe the follow ing conditions gt Make sure that all media residues have been removed from the unit in cluding from its cavities gt Ensure that the connections are in flawless condition gt If necessary welding connections must be reworked to return them to a flaw less condition gt Use the unit only for the same applica tion conditions as you would use a new unit Disposal of the unit ATTENTION Environmental damage may be caused by residues of poisonous media gt Before disposal make sure the unit has been cleaned and is free of media residues gt Dispose of all materials in accordance with the legal re quirements that apply where the unit is installed gt For details of the materials used in the unit please contact the manufacturer 37 a FLOWSERVE N Technical Data For details of all dimensions and weights please see the delivery note and the documentation supplied with the unit Working clearance To remove the actuator from an installed unit the following working clearance must be kept clear above the actuator Nominal bore Working clearance S mm DN 100 DN 150 500 DN 200 DN 400 750 Over DN 400 1000 Application limits Details of the application limits are
16. ed as follows gt When an emergency sealing system is fitted use it as described in the section Eliminating leaks with the emergency sealing systen from page 25 gt Otherwise replace the seals as de scribed in the section Changing seals from page 32 Operation AN CAUTION Danger of burns from hot surfaces or thermal radiation gt Wear protective clothing suita ble for the temperatures that occur in the plant You can recognise the position of the ball in several different ways With a valve wrench when the ball valve is open the valve wrench 28 will be parallel to the pipe Without actuator or valve wrench when the ball valve is open the key 27 in the valve stem is aligned with the direction of flow With an actuator the marking for the OPEN position depends on the actu ator For further information please see the actuator operating instruc tions _ _ FLOWSERVE gt To open the ball valve turn the valve stem a quarter of a turn anti clockwise so that the marking is in the Open position gt To close the ball valve turn the valve stem a quarter of a turn clockwise so that the marking is in the Closed po sition If required resealing of the valve stem and ball can be carried out while the valve is in operation For further infor mation about emergency sealing please see the section Eliminating leaks with the emergency sealing syst
17. en from page 25 During operation do not carry out any other activities on the valve 23 Correcting faults and disturbances AN DANGER A damaged unit can cause an accident that results in very serious injuries or death gt Replace defective units immediately Feature Cause Remedy Medium leaks The valve body has been damaged by corrosion or erosion Replace the unit immediately The unit has been damaged by frost Replace the unit When the plant is switched off make sure the pipelines and the unit are drained completely Insufficient flow The valve is not fully open Open the valve fully The transport plugs were not removed Dismantle the unit Remove the transport plugs Reassemble the unit The ball valve does not shut off the pipeline fully The valve is not completely closed Close the valve completely The seating ring seals are damaged or worn Have the operating authority seal the unit using the sealant connec tions Have the unit repaired by the man ufacturer Replace the unit Medium leaks The connections are not leak tight Seal the connections A seal in the valve body is defective Use the emergency sealing system to seal it There is leakage of medium at the valve stem The valve stem seal is defec tive Apply sealant using the optional emergency sealing system Replace the va
18. gainst unauthorised switching back on Make sure the unit and pipe lines have cooled so that they are no more than hand warm Wear protective clothing suita ble for the medium and when necessary use suitable protec tive equipment For more information about suitable pro tective clothing and protective equipment see the safety data sheet for the medium being handled AN CAUTION Danger of crushing injury if the unit falls or tips gt When dismounting the unit employ suitable measures to secure it against falling Suitable measures are for example gt For lighter units having a second person to support it gt Supporting heavy units with lifting gear with adequate load capacity gt Separating the unit s connections from the pipeline gt Laying the unit on a suitable surface AN WARNING Danger of injury from reaching into the unit gt Secure the unit during test runs and for large pipe bores When necessary remove the actuator from the unit gt Before removing the actuator make sure it is pressure free gt When doing this observe and follow the instructions supplied for the actua tor connection and the actuator gt When necessary remove the actuator connection from the valve body gt Separate the actuator from the actua tor connection gt Store the actuator and actuator con nection on a suitable surface gt Store the unit as described in the s
19. given on the unit s typeplate 38 ee FLOWSERVE Manufacturer s declaration The declaration of conformity supplied Any change made to the unit that has not with the unit is a part of the user docu been approved by us renders the decla mentation It must be kept safely with ration of conformity invalid these Operating Instructions If you have any questions about the declaration of conformity please contact the manufacturer at the address below 39 Ca N FLOWSERVE we For our representatives around the world go to www flowserve com Flowserve Flow Control GmbH Rudolf Plank Strasse 2 D 76275 Ettlingen Telephone 0049 0 72 43 103 0 Telefax 0049 0 72 43 103 222 E mail argus flowserve com Internet www flowserve com To ensure that your enquiry is dealt with as quickly as possible please provide the manufacturer with the following infor mation Unit type D Order number Serial number You can find the Operating Instruction also in other languages under following link http flowserve argus de produkte dokumentationen produktd atenblaetter Rev 00 Status 12 2014 40
20. hanging the valve stem seal are supplied in a kit gt For more details about how to order a replacement set please contact the manufacturer To ensure that your enquiry is dealt with as quickly as possible please provide the manufacturer with the following infor mation Unit type D Order number Dd Serial number For work on the unit you need the follow ing tools Torque wrench to DIN EN ISO 6789 Hexagon key to EN ISO 4762 ISO 272 Open ended spanner to EN ISO 4762 ISO 272 Grease gun The properties of the tools such as the size or measurement range depend on the type and size of unit gt Select tools suitable for the work to be carried out For work on the actuator it is necessary to have sufficient working clearance This depends on the type of unit its size and the options fitted For further details please see the Technical Data see also the notes on Page 38 Changing the seals When medium leaks from the valve stem you must reseal it On unit types HPH HPK HPT and HPZ there is an emergency sealing system gt On these units first seal the valve stem as described in the section Eliminating leaks with the emergency sealing syste from page 25 When you cannot reseal the valve stem in this way you must replace the valve stem seal To do this proceed as follows C FLOWSERVE N AN CAUTION Danger of burns from hot surfaces or thermal radiation g
21. hut off pipeline For pressure relief before mainte nance or repair work on the unit 14 Storing and transporting the valve Attention Incorrect storage or transport can damage the valve gt Close all openings with the covers supplied or similar co vers gt Make sure the unit is dry and protected from corrosive at mospheres where it is stored gt Contact the manufacturer for advice if you need to store or transport the unit under other conditions a FLOWSERVE Storing the valve gt Store the unit only under the following conditions Do not store it for more than 24 months Close all openings with the covers supplied or similar covers The connection surfaces and sealing surfaces must be protected against mechanical damage The unit and all its components must be protected from blows and shocks Secure the unit to prevent it falling or tipping The unit shall only be installed indoors under the following environmental conditions Relative humidity below 50 non condensing The room air must be clean and not contain salt or other corrosive sub stance Temperature 5 40 C The ball valve must be stored in its open position gt When storing make sure these condi tions apply at all times gt Contact the manufacturer for advice if you need to store the unit for longer or under other conditions 15 a FLOWSERVE T
22. id docu ments Making connections to the appropriate power source for the actuator Protective clothing The protective clothing required depends on the legal requirements where the unit operates and on the media being han dled For more information about suitable protective clothing and protective equip ment see the safety data sheet for the medium being handled Basic protective clothing has the follow ing components Hard hat to EN 397 Safety shoes to EN ISO 20345 Robust leather gloves to EN 388 Persons within one metre of the unit while it is in operation must wear ear defenders to EN 352 Depending on the media being handled and valid local regulations eye protection to EN 166 must also be worn FLOWSERVE N Design features of warning instructions in the text AN DANGER Instructions with the word DANGER warn of a hazardous situation that will result in death or serious injury AN WARNING Instructions with the word WARNING indicate a hazardous situation that could possibly result in death or serious injury AN CAUTION Instructions with the word CAUTION indicate a situation that could result in slight or moderately severe injuries Design features of instructions about damage to property Attention These instructions warn of a situa tion that will result in damage to property Description Scope of supply and descrip tion of the unit Sc
23. leaning the unit The unit can be cleaned internally by pigging Lubricating the unit As standard except for type HPT the units are filled with Sealant 735 K Units of the following types must be lubri cated once a year with Lubricant Sealant 735 K AUDCO Order Number 2473391 Size F at the secondary seals grease nipple unless some other sealant is expressly specified HPH HPK HPZ gt Force the lubricant sealant into the grease nipple with the grease gun supplied DA 400 Other valve types must not be lubricated The units have a nipple 6 on the side of the valve body for injecting sealant from DN 100 In the event of damage to seal 28 ing surfaces leakage can be eliminated by injecting sealant From the injection valve the sealant passes through a check valve and into the groove in the seating ring The grease nipple 6 can be replaced without danger during pipeline operation The sealant can be injected when the valve is either open or closed and injected against a pressure differ ential or when the valve is pressure free gt Connect the head of the AUDCO sealant gun to the injection valve gt Close the wing screw on the gun gt Operate the gun to generate a pres sure of about 800 bar gt Observe the pressure gauge If the pressure falls quickly the sealant is still flowing gt Operate the gun again to build up pressure and repeat until the pre
24. lve stem seal Replace the unit gt If you cannot correct the fault by following these instructions please contact the manufacturer 24 _ FLOWSERVE Eliminating leaks with the emergency sealing system AN DANGER When working on pipelines very serious injuries or death can be caused by burns high pressure or poisoning gt Be sure to avoid touching the unit or pipelines with your hands gt Make sure the ball valve is in either the open or closed posi tion gt Wear protective clothing suita ble for the medium and when necessary use suitable protec tive equipment gt Observe local safety regula tions For more information about suitable protective clothing and protective equip ment see the safety data sheet for the medium being handled AN CAUTION Danger of burns from hot surfaces or thermal radiation gt Wear protective clothing suita ble for the temperatures that occur in the plant The protective clothing must protect all body parts from heat and prevent contact between the skin and the medium This applies in particular to the hands 25 FLOWSERVE On the following valve types the valve stem has an emergency sealing system with an injection valve HPH HPK HPT HPZ This emergency sealing system can be used to seal the valve stem when neces sary To reseal the valve stem you need the following materials and
25. mation about available and possible actuators please contact the manufacturer gt The actuator must be correctly mount ed When you fit a valve wrench you must install it so that the position of the ball can be recognised from the position of the wrench When the ball valve is open the valve wrench should be parallel to the direction of flow gt Mount the valve wrench as described in the installation instructions supplied with it The connection between the actuator and the valve body should be either direct or by means of a special actuator connec tion When an actuator connection is required this will be mounted on the actuator at delivery The actuator con nection uses the same mountings on the valve body as the actuator The number of screws required to mount the actuator depends on the valve type Mounting an actuator on a type HPT DN 200 CL 600 is described here The type of mounting on your unit is shown on the drawings supplied gt Please contact the manufacturer if you need more information about mount ing an actuator a S FLOWSERVE N To mount the actuator on the valve body gt Tighten the screws 21 to the correct proceed as follows torque gt Make sure that the actuator connec gt Place the actuator 20 on the valve tion 22 is securely attached to the stem 1 or the extension 24 actuator 20 gt Tighten the screws 23 or 25 on the valve body 19 FLOWSERVE
26. nly specialist personnel to lift the unit or its parts Make sure that there are never per sons under suspended loads Make sure that lifting gear has ade quate load capacity for the load it has to lift and that such loads are properly attached Make sure that all valid local safety and accident prevention regulations are observed If the permissible application limits for the unit are exceeded the unit may be destroyed or hot or pressurised media released Make sure that the unit is always operated within the permissible application limits You will find data on the application limits on the typeplate and in the Chapter Technical Data observe al so the note on Page 38 Failing to use supports with adequate load capacity and sufficiently stable connections to the pipelines can result in damage to the unit Hot or pressur ised media may be released Allow only specialist personnel to install and connect the unit If the unit is not adequately supported during installation the unit may fall or tip over and cause serious injuries e g crushing Ensure that the unit is adequately supported against tipping and falling during installation Wear the protective clothing specified at the valve s location The unit can be equipped with several different types of actuator e g with an electric or pneumatic actuator De pending on the energy source for the actuator there is a danger of severe or le
27. ope of supply The following parts are included in the basic scope of supply Dd Ball valve These Operating Instructions The scope of supply may also include contract specific additional documents for example Inspection certificates Material certificates Operating instructions for the actuator Operating instructions for the gearbox For precise details of the scope of supply for your unit please see the delivery note As standard units up to DN 100 are supplied with a hand lever and units above DN 150 with a gearbox On re quest units up to DN 100 can be supplied with a gearbox ee FLOWSERVE The unit can be supplied in one of sever al different states Unit with actuator mounted Unit and actuator possibly with op tional actuator connections are sup plied separately Unit without actuator When the actuator is part of the scope of supply the manufacturer will have set it up already At the customer s request the unit can be supplied packed individually or in any of the following transport packages Transport box Wire mesh crate d Pallet gt On reception of the delivery compare the order number on the delivery note with the details on the typeplate gt Check that all parts are complete and in good condition gt Contact the manufacturer without delay if there are deviations or there is anything you are not clear about We will not accept compl
28. or those media gt Wear protective clothing suita ble for the medium and when necessary use suitable protec tive equipment gt Loosen only the safety screw plug on the unit For more information about suitable protective clothing and protective equip ment see the safety data sheet for the medium being handled gt Hold the bleed screw body 34 with a spanner to prevent it turning when you loosen the bleed screw C S FLOWSERVE N gt Loosen the safety screw plug 33 The safety screw plug is designed so that it cannot be opened too far The bleed screw body 34 is not secured against unintentional removal Air is bled from the valve body Medium may be ejected at the same time gt Dispose of the medium in accordance with legal requirements where the valve is installed gt Retighten the safety screw plug 33 31 FLOWSERVE The torque to tighten the screw or screws depends on their size Thread Torque Nm G NPT 1 113 G NPT1 150 gt Tighten the screw or screws to the specified torque Maintenance of the actuator gt Maintain the actuator as described in the manufacturer s operating instruc tions 32 Repairing the unit and fitting spare parts You can replace the following parts of the unit if they are worn or damaged For these units only the seal for the valve stem is available as a spare part All parts necessary for c
29. ransporting the unit gt For transport maintain the same con ditions as specified for storage gt Before transport fit plugs to the con nections If the plugs originally supplied are not available use comparable plugs and covers AN DANGER Danger of crushing injury if the unit or it components fall or tip gt During any work on the unit wear protective clothing gt Whenever lifting or moving the unit or its components to work on them use suitable lifting gear gt Make sure the unit cannot tip over gt When lifting the unit sling it only on the valve body or above DN 200 from the lifting eyes gt Make sure that there are never persons under suspended loads Protective clothing must comprise at least the following items Hard hat to EN 397 Safety shoes to EN ISO 20345 Robust leather gloves to EN 388 For more information about suitable safe ty clothing and protective equipment see the safety data sheet for the medium being handled 16 The lifting gear must have adequate load capacity for the unit including its actuator For more information about the weight of the unit please see the documentation supplied with it For more information about the weight of the actuator please see the manufacturer s documentation for it The lighter units can be carried by one person alone or with the aid of an assis tant For heavier units you will need suitable lifting gear
30. rating Instructions are available to the operator The Operating Instructions are consid ered to be a part of the unit If you sell the unit or pass it on in some other way these Operating Instructions must be handed over to the new owner Types of valve illustrated and described The valves described and illustrated in these Operating Instructions are variants of type HPT DN 200 CL 600 Where other types of valve are shown this will be expressly stated The standard units are described in these operating instructions Please contact the manufacturer for information about valve types not described here Possible actuators for the unit are not described and illustrated in detail in these Operating Instructions For more infor mation about an actuator please see the documentation supplied with it gt If you have any queries please con tact the manufacturer FLOWSERVE N Design features in the text Various elements in these Operating Instructions are furnished with predeter mined design features They make it easy to differentiate between the follow ing elements Normal text Cross references Listings Sub sections in listings gt Activity steps These tips contain additional information such as special data about economical use of the unit Safety Proper use The following types of AUDCO ball valves are for shutting off containers or pipelines containing the following media
31. re used to shut off contain ers or pipelines containing liquid or gase ous substances Function The valve stem 1 turns the ball 10 in the valve body Depending on the position of the ball the ball valve is open or closed In the closed position the ball in conjunc tion with the various seals prevents the flow of media Valve stem seals 2 Ball thrust washer 16 not on HPT Seating ring 17 Depending on the type of valve different sealing systems may be used On some units the seating ring may in corporate additional seals depending on the valve type 13 FLOWSERVE The seating ring creates a seal between the ball and the valve body When this seal wears additional sealing material may be introduced through the resealing system In addition the units are equipped with nipples for applying lubricant under pres sure On these units this allows the user to compensate for wear of the seating ring seals and the valve stem seals Pressure relief For pressure relief even while the valve is in service there are optional air bleed valves and drain valves that can be fitted to the valve body Pressure relief has the following objec tives To prepare for and carry out leak testing of the valve For safely cutting off the flow of media when the unit is used to shut off a pipeline When the drain valve is open media that has leaked leaves the valve and cannot enter the s
32. s or thermal radiation gt Wear protective clothing suita ble for the temperatures that occur in the plant The specialist personnel must have knowledge and experience of making connections of the appropriate type to pipelines Attention Seals may be damaged by heat from welding gt Make sure the seals are not damaged when welding con nections Attention If the connections are too weak the valve may be damaged gt Make sure the connections are strong enough to withstand the weight of the unit and the forc es to be expected in operation gt Make sure the pipeline system in the plant is clean gt Make sure there are no foreign mate rials in the valve gt Mount the unit so that the valve stem is vertically upwards On units for which the direction of flow is specified by the customer the direction of flow is marked on the valve body gt Install the valve so that the direction of flow corresponds to the marking You can monitor the effects of heat from welding by using temperature sensing strips At the positions 26 marked in the illustration below the temperature during welding must not exceed 180 C gt Apply temperature sensing strips at the specified positions gt Connect the unit to the pipeline Observe the temperature sensing strips during welding v gt If the temperature sensing strips indi cate that the area is becoming too hot cool the
33. s a risk of frost gt Remove external dirt from the unit with clean water and a lint free cloth gt To remove stubborn dirt use a clean ing agent suitable for the deposits and a lint free cloth Maintenance of the unit AN CAUTION Danger of burns from hot surfaces or thermal radiation gt Wear protective clothing suita ble for the temperatures that occur in the plant The unit requires little maintenance For work on the unit you need the follow ing tools _ Torque wrench to DIN EN ISO 6789 Hexagon key to EN ISO 4762 ISO 272 _ Open ended spanner to EN ISO 4762 ISO 272 Grease gun The properties of the tools such as the size or measurement range depend on the type and size of unit gt Select tools suitable for the work to be carried out For work on the actuator it is necessary to have sufficient working clearance This depends on the type of unit and the op 27 FLOWSERVE N tions fitted For further details please see the Technical Data see also the notes on page 38 When necessary you must carry out the following maintenance work gt Checking thatthe unit operates cor rectly if it is not regularly opened and closed gt Make a visual inspection to check the leak tightness of the unit gt For gaseous media check the unit with an appropriate measuring in strument gt Check for leaks by measuring the pressure in the plant during operation gt C
34. sealant lines 15 are extended The air bleed line 12 from the air bleed valve 4 is extended optional The drain line 13 from the drain valve 8 is extended optional The valves 14 for the extended lines are secured to the valve stem cover at the upper ends on the lines gt There may be further optional lines As an example the illustration shows a type HPZ DN 500 11 FLOWSERVE Typeplate The typeplate bears the following data Manufacturer Type designation Unit number Serial number Nominal bore Pressure rating Date of manufacture month year Order number Permissible operating pressure at 20 C or 38 C gt Permissible operating pressures at the minimum and maximum temperature limits Test pressure Materials CE marking only on units that comply with the Pressure Equipment Di rective Depending on the design code there may be further data on the typeplate CE marking depends on the pres sure classification according to the Pressure Equipment Directive The result is that there will not be CE marking on all unit types 12 In accordance with the Pressure Equip ment Directive classification there are the following options Units to which Pressure Equipment Directive 97 23 EC does not apply bear no CE marking Units which fall under Category of Pressure Equipment Directive 97 23 EC bear only the CE marking Units which
35. ssure no longer falls or falls only slowly The ring grooves are now filled The injection operation is complete gt Undo the wing screw on the gun gt Disconnect the head from the nipple For better distribution of the sealant on the sealing surfaces the ball can be moved several times in both directions by turning the handwheel On units that are installed under floor the sealant lines are ex tended up to the operating level Checking the pressure relief valve On units that are equipped with a pres sure relief valve the pressure relief valve must be checked at the Intervals speci fied by the manufacturer gt Have the pressure relief valve checked by personnel authorised by the manufacturer The maintenance interval may vary from the recommendation given here to com ply with local regulations gt When necessary specify a shorter maintenance interval in plant specific operating instructions Checking function and leak tightness gt Open and close the unit at least once every six months gt As you do so check the function and leak tightness of the unit When any leakage occurs proceed as follows gt When fitted use the emergency seal ing system as described in the sec tion Eliminating leaks with the emer gency sealing systen from page 25 or the grease nipple as described in the section Maintenance of the unit from page 27 gt Otherwise replace the seals as de scri
36. t gt Loosen only the safety screw plug on the unit For more information about suitable pro tective clothing and protective equipment see the safety data sheet for the medium being handled 29 FLOWSERVE gt Hold the drain screw body 31 with a spanner to prevent it turning when you loosen the drain screw gt Loosen the safety screw plug 32 The safety screw plug is designed so that it cannot be opened too far The drain screw body 31 is not secured against unintentional removal Condensate will be blown out gt Dispose of the medium in accordance with legal requirements where the valve is installed gt Retighten the drain screw body 31 gt See the table on Page 20 for the cor rect tightening torque 30 Bleeding air from the unit To bleed air from the valve body when handling liquid media or when pressure testing an optional bleed valve can be fitted to the upper part of the valve body In this section bleeding is de scribed and illustrated for a standard unit On units for underfloor installation the valves have other locations AN DANGER The uncontrolled release of medi um can result in very serious injuries or death caused by burns high pressure in the system or poisoning gt Make sure the unit and pipe lines connected to it are pres sure free gt Make sure that hot or hazard ous media are collected in a container that is suitable f
37. t Wear protective clothing suita ble for the temperatures that occur in the plant AN DANGER When working on pipelines very serious injuries or death can be caused by burns high pressure in the system or poisoning gt Make sure there are no hot or hazardous media in the unit or pipelines gt Make sure the unit and pipe lines connected to it are pres sure free gt Make sure the plant is switched off and secured against unauthorised switching back on gt Make sure the unit and pipe lines have cooled so that they are no more than hand warm gt Wear protective clothing suita ble for the medium and when necessary use suitable protec tive equipment The protective clothing must protect all body parts from heat and prevent contact between the skin and the medium This applies in particular to the hands ATTENTION It is important to remember that the residual pressure in the valve stem seal zone may be retained over a long period of time gt For this reason open the safe ty screw plug 33 gradually For more information about suitable protective clothing and protective equip ment see the safety data sheet for the medium being handled 33 a FLOWSERVE N Changing the seal on the HPT gt v v v VV VV WV v v 34 gt Replace the flange 37 gt Tighten the screws 35 gt Insert the dowels 36 The torque to tighten the screw or screws
38. thal injuries from a variety of causes Before starting any work on the unit make sure that the actuator is disconnected from the power supply and where applicable that there is no pressure in the pneumatic hydraulic system Observe and follow all hazard notes in the operating instructions for the actuator If you have any queries please contact the actuator manufac turer There is a danger of severe or lethal crushing by moving parts of the unit During operation make sure that no one can be in the vicinity of the mov ing parts or reach into them Before any work on the unit make sure the actuator is switched off and secured against unauthorised switching back on Danger of less serious injury Cut injuries are possible on the sharp edges of parts inside the unit During any work on the unit wear protective gloves If the unit is inadequately supported during installation crushing injuries are possible if the unit falls or tips During installation secure the unit to prevent it falling or tipping Wear ro bust safety shoes Potential causes of damage and malfunction If the unit is installed against the stat ed direction of flow or in the wrong po sition there is a risk of malfunction The unit or the higher level plant could be damaged Install the unit in the pipeline so that the direction of flow corresponds to the flow direction indi cated on the valve body Units made of material that are un
39. to transport them gt You can transport the unit over dis tances of a few metres without pack aging gt Use the original packing when trans porting the unit over greater distances gt If the original packing is not available pack the unit so that it is protected against corrosion and mechanical damage Transport is also possible at tem peratures below 0 C as long as the unit has been drained com pletely and dried gt Make sure the unit has been com pletely drained and flushed gt Attach lifting gear with adequate load capacity to the lifting eyes 19 The illustration below shows an example of how to lift the unit with the aid of a beam The units may also be lifted in other ways The illustration shows a DN 600 unit The lifting eyes illustrated are only present on DN 200 or larger units gt Attach smaller units to lifting gear with suitable slings gt Make sure the included angle between the legs of slings 18 is not more than 60 gt Contact the manufacturer if space is so restricted where the valve is locat ed that this type of transport is not possible FLOWSERVE Installing and connecting the unit Contact the manufacturer if you need help with the installation connections or commissioning of the unit Preparing for installation gt Take the unit out of its transport pack ing gt Check the unit for transport damage gt If you find transport d
40. tools Sealant sticks AUDCO order number 2473596 Open ended spanner 19 A F Allen key 5mm Torque wrench and suitable attach ment gt Hold the valve of the emergency seal ing system 29 with a spanner to pre vent it turning gt Remove the socket screw 30 from the injection valve gt Push a sealant stick into the injection valve gt To inject sealant into the valve body screw the socket screw into the injec tion valve gt Repeat the injection operation until the unit no longer leaks gt Tighten the socket screw ca 40 Nm 26 After operation AN DANGER For units installed in contaminated areas there is a danger of severe or lethal injury from hazardous substances on or in the unit gt Work on contaminated units shall only be carried out by specialist personnel gt Wear the specified protective clothing during all work in the contaminated area gt Make sure the unit including all its cavities has been fully decontaminated before work ing on it gt During such work follow the instructions for handling the media concerned C FLOWSERVE N Cleaning to remove external dirt AN CAUTION Danger of burns from hot surfaces or thermal radiation gt Wear protective clothing suita ble for the temperatures that occur in the plant Attention Risk of frost damage to plant that is not in operation gt Drain the unit if there i
41. uitable actuator is used to oper ate the valve this is also improper use Using a valve made of materials unsuita ble for the medium being handled is also improper use Basic safety instructions Explosion hazards An explosion hazard arises from using valves that are unsuitable for the envi ronmental condition Before use in an environment in which there is an ex plosion hazard observe the following points The surface temperature of the valve must not exceed that permis sible at the location where it is in stalled Dd If the unit is installed so that it is electrically insulated suitable measures must be adopted to dis charge static electricity between pipe connections dD If moving parts display extreme re sistance to movement frictional heat ing may cause an explosion Ensure that moving parts operate freely During welding operations to install or remove the unit there is a risk of ex plosion or fire being caused by open flames electric arcs and flying sparks Observe the valid legal regulations concerning protection against fire and explosions that apply where the unit is installed The unit and its components shall only be assembled or dismantled by spe cialist personnel FLOWSERVE N Danger of serious injury bd The unit can become hot during oper ation Only take the unit into service when insulation or guards prevent contact with hot surfaces During operation the unit
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