Flowserve 051 000 User Manual
1
Flow Control
Kämmer Control Valves
®
Installation, Operation, Maintenance Instructions
Tank Flush Valve
Series 051 000, without bellows seal
KMEIM5100-00 02.05
1
USING KÄMMER VALVES AND ACTUATORS CORRECTLY
1.1 General
The following instructions are designed to assist in
unpacking, installing and performing maintenance as
required on Kämmer products. Product users and
maintenance personnel should thoroughly review this
bulletin prior to installing, operating or performing any
maintenance.
DANGER: In most cases Kämmer valves and actuators
are designed for specific applications (e.g. with regard
to medium, pressure, temperature). For this reason
they should not be used in other applications without
first contacting the manufacturer.
1.2 Terms concerning safety
The safety terms DANGER, WARNING, CAUTION
and NOTE are used in these instructions to highlight
particular dangers and/or to provide additional
information on aspects that may not be readily
apparent.
DANGER: indicates that death, severe personal injury
and/or substantial property damage will occur if proper
precautions are not taken.
WARNING: indicates that death, severe personal injury
and/or substantial property damage can occur if proper
precautions are not taken.
CAUTION: indicates that minor personal injury and/or
property damage can occur if proper precautions are
not taken.
NOTE: indicates and provides additional technical
information, which may not be very obvious even
to qualified personnel. Compliance with other,
not particularly emphasised notes, with regard to
transport, assembly, operation and maintenance and
with regard to technical documentation (e.g. in the
operating instruction, product documentation or on
the product itself) is essential, in order to avoid faults,
which in themselves might directly or indirectly cause
severe personal injury or property damage.
1.3 Protective clothing
Kämmer products are often used in problematic
applications (e.g. extremely high pressures, dangerous, toxic or corrosive mediums). In particular
valves with bellows seals point to such applications.
When performing service, inspection or repair
operations always ensure, that the valve and actuator
are depressurised and that the valve has been cleaned
and is free from harmful substances. In such cases pay
particular attention to personal protection (protective
clothing, gloves, glasses etc.).
1.4 Qualified personnel
Qualified personnel are people who, on account of
their training, experience and instruction and their
knowledge of relevant standards, specifications,
accident prevention regulations and operating
conditions, have been authorised by those responsible
for the safety of the plant to perform the necessary
work and who can recognise and avoid possible
dangers.
1.5 Installation
DANGER: Before installation check the order-no,
serial-no. and/or the tag-no. to ensure that the valve/
actuator is correct for the intended application.
Do not insulate extensions that are provided for hot
or cold services.
Pipelines must be correctly aligned to ensure that the
valve is not fitted under tension.
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Index
1 Using Kämmer valves and actuators correctly.
2 Unpacking
3 Installation
4 Quick check
5 Maintenance
6 Remove and install actuator
7 Disassemble and assemble valve
8 Trouble-shooting chart
2
Flow Control
Kämmer Control Valves
®
2 UNPACKING
2.1 Each delivery includes a packing slip. When unpacking,
check all delivered valves and accessories using this
packing slip.
2.2 Larger valves can be lifted using slings on the yoke
rods or, if present, on the lugs provided for this purpose. If slings are used, attach them so that the outer
tubing or attaching parts are not damaged.
WARNING: If slings are used, be aware that the centre
of gravity of the valve may be above the lifting point. In
this case, secure or support the valve against rotating,
to prevent damage or personnel injury.
2.3 Report transport damage to the carrier immediately.
2.4 In case of discrepancies, contact your nearest
FLOWSERVE sales office.
3 INSTALLATION
3.1 Clean tubing prior to installing.
3.2 If possible, install the valve in an upright position
(actuator on top), to ease maintenance. An upright
installation position is important with low-temperature
applications, in order to keep the distance between
the packing material and the medium as large as possible. The packing material then retains the ambient
temperature as much as possible.
NOTE: Do not insulate extension bonnets that are
provided for hot or cold services
3.3 Make sure that sufficient overhead clearance above
the actuator is maintained, to allow for disassembly
of plug from the valve body (see following table).
3.4 If the valve is to be welded into the line, make sure
that the valve is shielded from excessive heat.
3.5 Connect supply pressure and signal lines. Control
valves are supplied with a positioner. The end connections for supply pressure and signal are clearly
marked. Actuator and positioner are suitable for max.
4.2 bar (60 psi) supply pressure. If the supply pressure exceeds the pressure specified on the nameplate,
a pressure reducing station is required. If instrument
air is not available, install an oil separator/air filter in
the air inlet line. All connections must be leak free.
1.6 Spare parts
Use only Kämmer original spare parts. Kämmer cannot
accept responsibility for any damages that occur from
using spare parts or fastening materials from other
manufactures. If Kämmer products (especially sealing
materials) have been on store for longer periods check
these for corrosion or deterior-ation before using these
products. Fire protection for Kämmer products must
be provided by the end user.
1.7 Service / repair
To avoid possible injury to personnel or damage to
products, safety terms must be strictly adhered to.
Modifying this product, substituting nonfactory parts,
or using maintenance procedures other than outlined
in this instruction could drastically affect performance
and be hazardous to personnel and equipment, and
may void existing warranties. Between actuator and
valve there are moving parts. To avoid injury Flowserve
provides pinch-point-protection in the form of cover
plates, especially where side-mounted positioners
are fitted. If these plates are removed for inspection,
service or repair special attention is required. After
completing work the cover plates must be refitted.
Apart from the operating instructions and the
obligatory accident prevention directives valid in the
country of use, all recognised regulations for safety
and good engineering practices must be followed.
WARNING: Before products are returned to Kämmer
for repair or service Kämmer must be provided with
a certificate which confirms that the product has been
decontaminated and is clean. Kämmer will not accept
deliveries if a certificate has not been provided (a form
can be obtained from Kämmer).
1.8 Storage
In most cases Kämmer Products are manufactured
from stainless steel. Products not manufactured
from stainless steel are provided with an epoxy resin
coating. This means that Kämmer products are well
protected from corrosion. Nevertheless Kämmer
products must be stored adequately in a clean, dry
environment. Plastic caps are fitted to protect the
flange faces to prevent the ingress of foreign materials.
These caps should not be removed until the valve is
actually mounted into the system.
1.9 Valve and actuator variations
These instructions cannot claim to cover all details of
all possible product variations, nor in particular can
they provide information for every possible example of
installation, operation or maintenance. This means that
the instructions normally include only the directions to
be followed by qualified personal where the product
is being used for is defined purpose. If there are any
uncertainties in this respect particularly in the event
of missing product-related information, clarification
must be obtained via the appropriate FLOWSERVE
sales office.
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Actuator Clearance Actuator Clearance
size (mm) size (mm)
37/47 95 P2 140
38/48 140 P3 140
39/49 140 P4 140
39D/49D 140 P5 140
3
Flow Control
Kämmer Control Valves
®
4 QUICK CHECK:
Before operating, check the valve as follows:
4.1 Open and close the valve, and observe the movement
of the actuator stem. The movement must be smooth
and linear.
4.2 Check for maximum stroke through change of signal
(for pneumatic positioners, 0.2 - 1.0 bar or corresponding split-range values; for IP positioners, 4-20
or 0-20 mA).
4.3 Check all air connections for leaks.
4.4 Tighten packing nut (see table 1).
NOTE: An excessively tightened gland nut can cause
excessive packing wear and can hinder the free movement of the plug stem.
4.5 Check fail-safe position. To do this, close supply pressure and observe whether the valve opens or closes
as defined.
4.6 After use at fluctuating temperatures, re-tighten all bolt
connections and check for leaks.
5 MAINTENANCE
Check valves for correct function at regular intervals
(at least once every 6 months) as follows. This check
can be made when installed and in many cases
without interrupting production. If internal defects are
suspected, see section „Disassembly and Assembly of
Valve“.
5.1 Examine gaskets for leaks and if necessary re-tighten
bolts.
5.2 Check bellows gasket and test connection - if present
- for external leaks.
5.3 Check valve for damage caused by corrosive residues
or corrosive vapours.
5.4 Clean valves and repaint as necessary.
Warning: To prevent a buildup of electrostatic charge
clean the actuator/valve with a damp cloth only.
5.5 Check gland nut for correct torque (see table 1).
NOTE: An excessively tightened gland nut can cause
excessive packing wear and can hinder the free movement of the plug stem.
5.6 If possible, open and close valve and check for maximum stroke and smooth movement of the plug stem.
Irregular movement of the plug stem may indicate
internal defects.
NOTE: With graphite packing, irregular movement of
the plug stem is normal.
WARNING: Keep hands, hair, clothing, etc. away from
all moving parts. Failure to do so can lead to serious
injury.
5.7 Check all accessories for firm seating.
5.8 If possible, close supply pressure and check the failsafe position.
5.10 Check stem boot (when fitted) for wear.
5.11 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and check for any bubble formation.
5.12 Clean plug stem.
5.13 Check air filter, if present, and if necessary replace
insert.
NOTE: For further information regarding service and
maintenance please contact your nearest FLOWSERVE
office.
DANGER: On actuators with aluminium cases the
actuator springs must be renewed with original spare
parts every 10 years or after 50.000 operating hours
which ever occurs first.
Table 1: Standard torque values for gland nut
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Thread
Stem Ø
(mm)
Torque in Nm
PTFE Graphit
M20 x 1,5 6 2,5 6,0
M30 x 1,5 10 7,0 15,5
M38 x 1,5 16 17,0 38,0
M45 x 1,5 16 19,0 48,0
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