Flowserve 132000 User Manual

User Instructions LinedFlow - KMENIM3202-02 01/12

USER INSTRUCTIONS

Kämmer ® LinedFlow™ - 132000

Valves for Corrosive Applications

FCD KMENIM3202-02 01/12

Installation

Operation

Maintenance

Experience In Motion

User Instructions LinedFlow - KMENIM3202-02 01/12

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INDEX 1 Using FLOWSERVE valves and actuators

and accessories correctly 2 Transport and storage 3 Installation 4 Intended use 5 Installation 6 Pressure test pipe section 7 Normal operation and maintenance 8 Trouble-shooting 9 Product description 10 Bonnet 11 Plug and seat 12 Bellows seal 1 3 Stem 14 Packing 15 Test connection 16 Quick check 17 Maintenance 18 Remove actuator from valve 19 Install actuator on valve 20 Disassemble and assemble valve 21 Trouble-shooting chart

USING KÄMMER VALVES AND ACTUATORS CORRECTLY

1.1 Use

FLOWSERVE control valves and actuators are intended

exclusively for control of mediums in an approved pressure and temperature range after installation in a piping system and connection of the actuator to the control system.

The permissible pressure and temperature limits are deﬁned

in the operating instructions for the individual valve series.

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 pro-

perty damage can occur if proper precautions are not taken.

NOTE: indicates and provides additional technical infor-

mation, 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 Safety Notes for Operator

The manufacturer is not responsible for the following and it

is therefore necessary to ensure the following when using FLOWSERVE control valves:

1.3.1 ...use valve as intended (Section 1) DANGER: Never operate a control valve whose approved

pressure/temperature range according to the applicable documentation for the valve series is not sufﬁcient for the operating conditions. Moreover, it must be ensured that the valve is approved for the operating medium:

WARNING: Protection against incorrect use of control valve: In particular, it is necessary to ensure that the selected coating on the valve parts in contact with the medium are suitable for the mediums, pressures and temperatures encountered. The manufacturer is not responsible for damage to the valve resulting from corrosive mediums. Failure to observe these precautions can pose a danger for the use and cause damage to the piping system.

1.3.2 ...the piping system and control system must be installed properly and checked regularly. The wall thicknesses of the FLOWSERVE control valves correspond to the standards and regulations for the pressure stage requirements of the piping system in question.

1.3.3 ...the valves must be connected properly to this system.

1.3.4 ...the usual ﬂow rates in continuous operation are not exceeded in this piping system and abnormal operating conditions such as vibration, water hammer, cavitation and excessive quantities of solids in the medium – particularly abrasive solids – must be clariﬁed with the manufacturer.

WARNING: At temperatures > +50 °C and < -20 °C, it is

necessary to provide for protection against skin contact including the piping connections.

1.4 Particular dangers

DANGER: The valve stem is sealed with a packing gland.

Before loosening or unscrewing the packing nut , ensure that the pressure in the pipeline is completely relieved so that the medium cannot escape through the packing.

Observe the usual safety precautions for hazardous medium

– particularly the use of protective clothing – when working on the valves.

DANGER: On valves with a bellows seal also ensure that the

bellows does not leak by using a test connection, if present, before removing the packing gland nut.

DANGER: Before removing the valve from the pipeline, en-

sure that the pressure in the pipeline is completely relieved so that the medium does not escape uncontrolled from the line.

WARNING: If it is necessary to remove a valve from the

pipeline, medium can escape from the line or from the valves. In the case of mediums which pose a health danger or other danger, ensure that the pipeline is completely purged before removing the valve.

User Instructions LinedFlow - KMENIM3202-02 01/12

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Observe caution with residues ﬂowing out of the line or

remaining in the dead chambers of the valves. In the case of dangerous mediums, observe the usual safety precautions – particularly protective clothing.

WARNING: Disconnect or loosen the fastners – particularly

between bonnet and housing – only after the valve has been removed. When reinstalling, tighten the bolts as speciﬁed in these maintenance instructions using a torque wrench.

2 TRANSPORT AND STORAGE

Handle, transport and store FLOWSERVE control valves

carefully.

2.1 Store the valve in its protective packaging and/or with the protective caps on the connection ends. Valves heavier than approx. 10 kg should be stored and transported on a pallet (or similarly supported, where applicable also on the installation site).

WARNING: Do not place unpackaged valves on dirty

surfaces with the ﬂange sealing surfaces. Hard and/or sharp particles can damage the plastic lining.

2.2 During storage before installation, the valves should be stored in a closed room as a rule and protected against damaging inﬂuences such as dirt or moisture.

2.3 Large valves can be picked up using hoisting belts on the yoke stems / eyes or - if present – on the supporting shackles provided for this purpose. If hoisting belts are used for unpacking, connect them so that the outer piping and attached parts are not damaged.

WARNING: If hoisting belts are used, the center of gravity

of the valve can be higher than the connection point. In such cases, secure the valve against turning or support it to prevent injury or property damage.

In the event of transport damage, please contact your

FLOWSERVE representative immediately.

3 INSTALLATION

3.1 General

The same instructions apply for installing FLOWSER-

VE control valves in a pipeline as for connecting pipes and similar piping elements with plastic liner materials. For control valves, the following instructions apply in addition. Observe Section 3 for transport at the installation site.

WARNING: Handle valves with particular care and observe

instructions for ﬂange connections.

NOTE: As a rule, additional ﬂange seals are not required.

The counterﬂanges must have smooth sealing surfaces in

all cases, e.g. Form C, Form D or Form E according to Standard DIN 2526 or Form B1 or B2 according to EN 1092-1 or stock ﬁnish according to ANSI B16.5. Other ﬂange forms must be coordinated with the manufacturer.

In addition, observe the following for actuators:

WARNING: Never subject actuators to external loads; this

can damage the valve – actuators are not step ladders -

WARNING: Heavy actuators must be supported in a suita-

ble manner if it is possible that their installation situation would exert an impermissible bending force on the valve.

4 INTENDED USE

The series 132000 valves from Flowserve Essen GmbH

can be installed in all areas endangered by gas explosion, because they do not have any potential ignition sources. The valves can be used for shutting off the ﬂow of noncombustible gaseous mediums and combustible gaseous and ﬂuid mediums far below the maximum explosion limit. Inside the valve the atmospheric range is not reached under the conditions (see table below); here Directive 95/9/EC is not applicable. Please note that certain (non-conductive) mediums at certain ﬂow rates can result in a potential (static charge), which is subject to the operating conditions and therefore is the responsibility of the operator.

Version Packing Seat Ring

Standard PTFE Compound PTFE Compound

4.1 Description of Unit

The valve is a lined control valve. The housing consists

of cast iron and the lining and gaskets are of elastomer material.

The compatibility of the materials used with the surroun-

ding mediums must be observed in particular by the operator.

4.2 Evaluation

Conformance with EN 13463, Parts 1 through 8 (non-

electrical explosion protection)

The ﬁttings fulﬁll the following requirements.

4.2.1 All exposed parts were subjected to the impact and envi-

ronmental stress tests in conformance with

EN 13463-1 by the manufacturer and satisfy the require-

ments.

4.2.2 The valve body for the valves consists of cast iron. Formation of sparks resulting from the effect of exterior impact is excluded under normal conditions.

5 INSTALLATION WARNING: Plastic liners on the valves require particular

protection before/during installation; therefore:

CAUTION: Transport valve to installation site in protective

package if available. If ﬂange covers are present, remove them only immediately before installation.

5.1 Check valve for transport damage. Do not install damaged valves.

Ensure that only valves are installed whose pressure class,

type of connection and connection dimensions satisfy the installation conditions. See Markings and Valve speciﬁcations.

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DANGER: Do not install valves whose approved pressure

and temperature range is not sufﬁcient for the operating conditions. The limits for use are marked on the valves. Moreover, use only valves suitable for the operating medium in question.

Failure to observe these precautions can pose a danger for

the user and cause damage to the piping system.

5.2 The actuator must correspond to the intended connections and control data.

5.3 The connection ﬂanges must be inline with the valve connections and parallel. Connection ﬂanges which are not

parallel can damage the plastic liner during installation!

5.4 Before installing, thoroughly clean the valve and the pipeline to remove any contamination, particularly hard foreign particles.

5.5 In particular, it is necessary to ensure that the sealing surfaces on the ﬂange connection are free of all contamination when installing.

5.6 When inserting the valve into a pipeline already installed, the distance between the ends of the pipeline must be sufﬁcient to prevent damage to any of the sealing surfaces.

WARNING: Tighten all ﬂange connections to the torques

speciﬁed in Tables 1a or 1b. When using torque wrenches, ensure that these torques are reached, however not exceeded.

The values in the table apply for ﬂanges according to

EN1092, PN10/16 for a maximum operating pressure of 10 bar. Values for other ﬂanges can be obtained from the manufacturer.

5.7 Valves are to be installed in the appropriate ﬂow direction. The ﬂow direction is indicated by an arrow on the valve.

5.8 Observe the appropriate instructions for connecting the actuator to the valve. Control valves are equipped with a positioner. The connections for air supply and signals are marked clearly (see also applicable operating instructions for the positioner). The maximum air supply is speciﬁed on the name plate. If the air supply exceeds the pressure speciﬁed on the rating plate, a pressure reduction station is required. If no instrument air is available, install an air ﬁlter in the air supply line if required.

5.9 After completion of installation, perform a function test with the control signals: The valve should open and close properly corresponding to the control commands. Always eliminate

any recognizable malfunctions before startup. See also applicable sections in maintenance regulations for this valve series.

DANGER: Improperly executed control commands can pose

a danger for life and limb and damage to the piping system and/or the valve.

6 PRESSURE TESTING PIPING SECTION

The valve has already been pressure-tested by the manuf-

acturer. When pressure testing a section of the pipeline with valves installed, observe the following:

6.1 First thoroughly ﬂush newly installed piping systems to remove all foreign objects.

6.2 Valve opened: The test pressure should not exceed the value of 1.5 x PN (according to nameplate):

6.3 Valve closed: The test pressure should not exceed the value

1.1 x PN (according to nameplate).

If a leak occurs on the valve, observe Section 8 “Trouble-

shooting”.

CAUTION: If the ﬂange connection with plastic liner leaks:

First retighten ﬂange connection to torque speciﬁed in Table

1a or 1b in Section 5.6 (installation).

If the ﬂange connection is still leaks:

Loosen ﬂange connection. Check the ﬂange connection to

ensure that it is smooth and parallel.

Check the sealing surfaces on both ﬂanges: When the inner

lining is damaged, replace valve and/or counterﬂange.

Table 1a: Tightening Torques for Flange Connections, Flanges EN1092 (DIN)

DN [mm] 15 20 25 40 50 80 100 150

[Nm] 10 18 25 50 65 65 65 140

Table 1b: Tightening Torques for Flange Connections, Flanges EN1759 (ANSI)

NW [inch] ½" ¾" 1" 1½" 2" 3" 4" 6"

[Nm] 8 11 15 26 60 100 76 100

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