Emerson NEOTECHA NEOSEAL Installation Manual

NEOTECHA NEOSEAL BUTTERFLY VALVE

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

2 SAFETY

Please also read through these notes carefully.

2.1 General potential danger due to:

a. Failure to observe the instructions
b. Improper use
c. Insufficiently qualified personnel

2.2 Correct use

2.2.1 Area of application

Neoseal valves are fittings that are used for the
isolation, throttling and regulation of corrosive
and non-abrasive liquids, together with gases,
pastes and powdery products in pipelines,
vessels, apparatus etc.
The area of application of the fitting is the
responsibility of the system designer. Special
characteristics of the fitting must be taken

1 GENERAL INFORMATION ON THE
INSTALLATION AND MAINTENANCE
INSTRUCTIONS

These installation and maintenance
instructions contain the information necessary
for safe and correct installation and operation
of the fitting. If any difficulties are encountered
during installation or operation which cannot
be solved with the aid of the installation and
maintenance instructions, please contact the
supplier/manufacturer for more information.
These installation and maintenance
instructions comply with the relevant
applicableEN safety standards.
When installing the fitting, the operator or
the person responsible for the design of
the installation must ensure that applicable
national regulations are complied with.
The manufacturer reserves all rights to
make technical changes and improvements
atanytime.
The use of these installation and maintenance
instructions assumes that the user is qualified
to ‘Qualified Personnel’ level.
Operating staff must be given appropriate
training in the operating and maintenance
instructions.

intoaccount.
A very wide selection of product-wetted
components parts is available which allows
suitable combination for the optimal solution
toyour specific application.
Always consult the manufacturer when the
fitting is to be used with media that require
orpreclude the use of certain materials.

2.2.2 Method of operation

The valve is opened or closed by turning
theflap spindle. The angle of rotation is 90°.

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NEOTECHA NEOSEAL BUTTERFLY VALVE

INSTALLATION AND MAINTENANCE INSTRUCTIONS

2.2.3 Performance data

Pressure (bar) Liner DN 40-150 DN 200-600 DN 700/800-900 DN 750

10 PTFE/TFM -40 +180 °C -40 +160 °C

Butyl -30 +120 °C -30 +120 °C

Carboxyl nitril -20 +120 °C -20 +120 °C

EPDM -30 +140 °C -30 +140 °C
Hypalon -20 +140 °C -20 +140 °C
Silicone -30 +180 °C -30 +120 °C

FKM -20 +160 °C -20 +160 °C

UHMWPE -40 +80 °C -40 +80 °C

6 PTFE/TFM -40 +200 °C -40 +180 °C -20 +100 °C

Silicone -30 +200 °C -30 +180 °C

4 PTFE/TFM -40 +200 °C -40 +200 °C -20 +150 °C

Silicone -30 +200 °C -30 +200 °C

2.5 PTFE/TFM -40 +200 °C -40 +200 °C -20 +150 °C -20 +100 °C

1.5 PTFE/TFM -40 +200 °C -40 +200 °C -20 +150 °C -20 +150 °C

2.2.4 Usage restrictions

The product-wetted components must be
classified as resistant to the product to be
conveyed. Refer to appropriate literature or
consult the manufacturer or distributor for
advice on this.

2.2.5 Modification prohibition

Mechanical modifications to the valves or the
use of other manufacturers’ parts for repair
purposes is not permissible. Safety is not
guaranteed if this requirement is disregarded.
Repair work must only be carried out by the
manufacturer’s trained personnel.

2.2.6 Warning about foreseeable misuse

Valves and their accessories (e.g. operating
elements) must not be misused as
climbingaids.

2.2.7 Duty to comply with the instructions for
operation, maintenance and servicing

These instructions form part of the delivery
package and must be kept clean and made
accessible to the user.

2.3 Sources of danger

2.3.1 Chemical external

The valve body has a 2-part polyester coating.
The coating can be attacked externally by
strong solvents, leading to corrosion of
the body. If damage of this nature occurs,
the effects of the environment should be
investigated and the damage to the coating
made good.

2.3.2 Mechanical

When using the hand lever, it should be
ensured that there is still sufficient clearance
for the hands at the end position of the handle,
so that there is no risk of trapping.
Excessive oscillation and vibration should be
avoided, to prevent the bolts loosening.

2.3.3 Electrical

If static charges can lead to explosions, the
valve must be earthed by means of the earthing
accessory and mount it to the valve by using the
screw on the valve body neck. In addition, we
recommend the use of valves with electrically
conductive linings. Please contact your
supplier!

2.3.4 Thermal

Due to the range of operating temperatures
between -40°C and +200°C, surface
temperatures from -20°C to over +85°C can be
present on the valve body. Suitable precautions
should be taken to protect against burns due
to high or freezing temperatures. In particular,
insulated gloves should be worn when using
the hand lever, for example.
In case of fire, the mechanical strength of the
PTFE ring bellows is no longer guaranteed
above 200°C.

2.4 Requirements for the operator

This means people who are familiar with the
erection, installation, commissioning, operation
and maintenance of the product and have
appropriate qualifications relating to their
activities and functions, such as e.g.:

- Instruction in and duty to comply with all
installation-related, regional and internal
works regulations and requirements.

- Training or instruction in accordance with the
Safety Standards for personal care and use of
appropriate safety equipment and protective
workgear, like e.g. personal protection
equipment (e.g. insulated gloves), suitable
forthe operating conditions.

Furthermore, these people must have
readandunderstood these instructions.

3 TRANSPORT/STORAGE

The valve is supplied with protective covers.
Do not remove the protective covers until
immediately prior to installation. They protect
the PTFE surface from dust and mechanical
influences.

3.1 Transport

- Transport temperature -20°C to +65°C.

- Protect against external force(impact,
shock,vibration).

- Do not damage the coating.

3.2 Storage

- Storage temperature -20°C to +65°C,
dryanddust-free.

- A drying agent or heating is required in
damp storage areas to protect against
condensation.

- Keep the valve disc in a slightly open
position(5-10°).

3.3 Handling prior to installation

- With versions with protective covers, only
remove the covers immediately prior to
installation!

- Protect against the effects of weather,
e.g.dampness (or else use a drying agent).

- Proper treatment prevents damage.

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NEOTECHA NEOSEAL BUTTERFLY VALVE

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Manufacturer

Manufacturer’s

Customer request

Valve type

code

Year of manufacture

Serial number

Country of
manufacture

4-digit number of

CE-mark with

notified body

4 IDENTIFICATION

Additional identification on the valve in
accordance with DIN19, such as: DN, PN,
manufacturer’s logos of the Neotecha
AGcompany and . The valve
bodymaterial is cast onto the valve.

5 DIMENSIONS AND WEIGHTS

Refer to the product documentation
fordimensions and weights.

6 INSTALLATION

6.1 Preparation for installation

The dimensions of the NeoSeal valve have been
chosen so that, in the case of a wafer body,
itcanbe clamped between all current DIN,
ANSI and JIS flanges of the appropriate size.
Principal dimensions of the valves: refer to
thecatalog page for data.
The flanges must meet the following
requirements (see table below).

• Cleaned and undamaged mating surface.

• The internal diameter of the mating flange
must have the following dimensions:

Minimum: Y-dimension of the valve plus

sufficient clearance for the valve disc.

Maximum: if the flanges have a raised face,

the outside diameter of the raised face
must not be less than dimension ‘R’ of the
butterflyvalve.

• The appropriate flange bolt hole
arrangements in the various flange standards
and diameters allow the valve to be centered
by passing the flange bolts through the
holesin the mounting plate of the valve.

• The flange bolts must be centrally aligned
inthe holes in the valve mounting plate.

FLANGES REQUIREMENTS

DN øR X øY
mm inches mm mm mm

40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
700
750
800
900

1.5
2

2.5
3
4
5
6
8
10
12
14
16
18
20
24
28
30
32
36

80 4.5 23

95 5.0 31
120 11.5 52
132 18.5 69
153 26.0 90
183 35.5 114
209 48.5 143
259 72.5 196
309 92.5 244
364 112.5 293
412 126.0 321
475 149.0 387
525 162.0 423
578 186.0 484
680 218.0 570
780 272.0 686
728 280.0 728
887 305.0 783

1000 349.0 879

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NEOTECHA NEOSEAL BUTTERFLY VALVE

INSTALLATION AND MAINTENANCE INSTRUCTIONS

6.2 Installation in the pipeline

With the NeoSeal, the flow can be in any
direction. The recommended installation
position is with the spindle horizontal,
with thelower sealing strip opening in
thedirectionof flow.

A butterfly valve is not a crowbar! Please do
not use it to force the flanges apart, as this
would lead to damage to the ring bellows and
seat. To avoid damage to the disc and bellows,
the protective covers should only be removed
immediately prior to installation.
The valve can be installed either with the drive
mounted above or without a drive, assuming
that the drive allows the valve to be installed
in such a way that the sealing strip of the valve
disc is positioned a minimum of 5 to 10mm
within the body.

It is not advisable to use the valve for positioning
pipelines in new systems. Sparks which occur
during spot welding can damage the seat.
Use adjusting pieces instead. Final welding of
the flange with the valve in position will lead
to severe damage to the valve seat dueto the
hightemperature.

Always use all flange bolts, even on low
pressure systems. The valve should never
be pressurized if one of the four flange
bolts that align the shaft axis is missing. If
a pipe lined with an unattached material
(e.g.PTFE) is used, it must be ensured that the
temperature-related expansion of the lining
does not restrict the movement of the valve
discor damage the area of the seat.

6.3 Body variants

Wafer body NeoSeal
DN40-300 (1½”-12”)
Lugged flange body NeoSeal
DN40-300 (1½”-12”)
Double flanged body NeoSeal
DN350-900 (14”-36”)
Refer to the product documentation for
boltsizes to be used for the installation.

6.4 Step-by-step valve installation

1. Check that the distance between flanges
matches the installation length of the
butterfly valve. Before installing the valve,
spread the flanges apart sufficiently using
asuitable tool.

2. Close the valve until the sealing strip of the
valve disc is 5 to 10mm within the body.

3. Slide the butterfly valve between the opened
flanges and insert the flange bolts through
the adjusting holes.

4. Fully open the valve. The valve is open when
the flat sections on the shaft are parallel to
the pipeline. With nominal diameters above
DN 125, the marking on the face of the
control shaft should be observed. If these
are parallel to the pipeline, the valve is open.

5. Tighten the flange bolts hand-tight as the
tool holding the flanges apart is gradually
removed. Make sure that the flanges
remaincorrectly aligned.

6. Slowly close the valve disc and check that
the Y measurement is less than the internal
diameter of the pipe and also has adequate
clearance.

7. When the disc is in the ‘open position’,
tighten the flange bolts in opposite pair
sequence. Refer to following table for
tightening torques.

When used as an end of line valve, it must be
secured in such a way that access to the valve
isrestricted when in service.
It should also be noted that when a valve is used
as the end valve of a pressurized system, the
valvemust be installed with a blind flange.

WAFER BODY

LUGGED FLANGE BODY

DOUBLE FLANGED BODY

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NEOTECHA NEOSEAL BUTTERFLY VALVE

INSTALLATION AND MAINTENANCE INSTRUCTIONS

RECOMMENDED TIGHTENING
TORQUES(Nm)OF BOLTED
CONNECTIONSFOR INSTALLING
BUTTERRFLY VALVES

DN Torque
mm inches Nm

40 1.5 35
50 2 50
65 2.5 70
80 3 50
100 4 60
125 5 65
150 6 70
200 8 95
250 10 100
300 12 115
350 14 140
400 16 170
450 18 190
500 20 220
600 24 280
700 28 275
750 30 ­800 32 386
900 36 453

6.5 Final checks

Inspection of the valve position as far as
thefully open position.
Cleaning and flushing the pipeline before
thefirst closure.
Repeated opening and closing of the valve
to ensure unrestricted movement of the
valvedisc.

7 NOTES ON DANGERS DURING
INSTALLATION, OPERATION AND
MAINTENANCE

Safe operation of the valve is only guaranteed
ifit has been correctly installed, commissioned
and maintained by qualified personnel
(see‘Qualified Personnel’), taking into account
the warning information of these installation
and maintenance instructions. In addition,
compliance with the general installation and
safety regulations for the pipeline or plant
construction, together with the correct use
of tools and protective equipment, must
beensured.

8 COMMISSIONING

Detent lever

8.1 General commissioning

Before commissioning, the information relating
to material, pressure and temperature should
be checked against the installation diagram of
the pipeline system.
Tools for increasing the lever or handwheel
torque are not allowed.
Any debris left in the pipeline and valves
(dirt,welding beads, etc.) will inevitably
leadtoleakage.

Before each commissioning of a new system or
re-commissioning of a system after repair or
modification, it must be ensured that:

- All installation and assembly work has been

completed in accordance with the regulations!

- Commissioning is only undertaken by ‘Qualified

Personnel’.

- The valve is in the correct operating position.

- New protective equipment is installed or

existing protective equipment repaired.

8.2 Mounting additional modules

Where valves are fitted with additional options
(limit switches etc.), these should be connected
according to their operating mode in line with
the installation diagram.

9 OPERATION (HAND LEVER)

Model variants

Nominal diameter 40-150 (1½”-6”)
Hand lever with notched plate with
10°divisions, range 90°
Operating element: detent lever

The hand lever and graduated lever must
notbemodified.
The locking function will otherwise be
adverselyaffected.
Damaged hand levers should be exchanged.
The butterfly valve should be mounted so
that operating staff can operate the valve
withoutdanger.

When drives or gear units are used, the
instructions of the particular manufacturer
areapplicable.

The installation and maintenance instructions
must be strictly followed when any work is
carried out on the valve or when handling the
valve. Non-observance can result in injuries or
damage to property. When the valve is used as a
final termination, a safety measure e.g. a blank
or dummy flange is recommended when carrying
out maintenance work. If the valve is operated
as an end of line valve, the information given in
DINEN294 point 5 must be observed.

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NEOTECHA NEOSEAL BUTTERFLY VALVE

INSTALLATION AND MAINTENANCE INSTRUCTIONS

10 SERVICING AND MAINTENANCE

No routine maintenance or lubrication is
required. However, for systems with high
temperatures, an inspection for leakage at
the flanges should be carried out shortly
after installation. The different coefficients of
expansion and temperature expansions can
cause settlement of the PTFE. Tightening the
bolts once again will remedy this. This process
may possibly have to be repeated several times.
We recommend that the valve be operated at
least once a month.

11 CAUSE AND REMEDY OF OPERATING
FAULTS

If the valve function or operating action is
faulty, a check should be made to ensure that
the assembly and installation work has been
carried out and completed in accordance with
the installation and maintenance instructions.
The information relating to material, pressure,
temperature and direction of flow should be
compared with the installation diagram of the
pipeline system. Furthermore, a check should
be made on whether the installation conditions
correspond to the technical data given in the
data sheet or on the rating plate.

ATTENTION!

Check that the pipe is depressurized and drained.
With corrosive, inflammable, aggressive or toxic
media, ventilate the pipeline system.

1. Only allow assembly work to be carried out
by qualified personnel (see Section 2.2).

2. Almost completely close the butterfly valve
(the disc is in line with the flat faces of the
operating shaft).

3. Loosen all flange bolts and withdraw
themuntil the valve can be removed.

4. Spread the flanges apart using a
suitabletool and withdraw the valve.

13 DISPOSAL

Hand in the correctly cleaned valve to the
scrapmaterial recycling plant.

Badly cleaned valves can cause severe burning
ofthe hands and other parts of the body.

If the valve is passed on to a third party, the
manufacturer does not guarantee the safety
ofthevalve.

The safety regulations must always be
observedwhen troubleshooting.

12 DECOMMISSIONING

Removal of the valve for repair or servicing
is often carried out carelessly, as the valve
has to be repaired or replaced. However, it is
recommended that the valve is removed with
care, without damaging the PTFE, so that the
possible cause of damage can be determined
after removal.

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

Neotecha is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions, Emerson
and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by
our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without
notice.

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