Control Valve
ZK 29
Original Installation Instructions
810685-05
Contents
Foreword ............................................................................................................................................ 3
Availability ............................................................................................................................................. 3
Formatting features in the document ...................................................................................................... 3
Shown and described types of equipment ............................................................................................... 3
Safety .................................................................................................................................................. 4
Use for the intended purpose ................................................................................................................. 4
Basic safety notes ................................................................................................................................. 4
Information on property damage or malfunctions ..................................................................................... 6
Qualification of personnel ....................................................................................................................... 6
Protective gear ...................................................................................................................................... 6
Typographic features of warning notes .................................................................................................... 6
Formatting features for warnings of property damage .............................................................................. 7
Description ......................................................................................................................................... 7
Scope of supply and equipment specification .......................................................................................... 7
Task and function ................................................................................................................................ 16
Storing and transporting the equipment ......................................................................................... 16
Storing the equipment ......................................................................................................................... 17
Transporting the equipment ................................................................................................................. 17
Mounting and connecting the equipment ....................................................................................... 18
Preparing installation ........................................................................................................................... 18
Connecting the equipment ................................................................................................................... 19
Checking the function .......................................................................................................................... 20
Starting up the equipment .................................................................................................................... 20
Operating the equipment ................................................................................................................. 23
After operation ................................................................................................................................. 23
Maintaining the equipment ................................................................................................................... 25
Rinse the equipment ............................................................................................................................ 26
Disassembling the equipment............................................................................................................... 28
Assembling the equipment ................................................................................................................... 37
Servicing the equipment and installing spare parts ................................................................................ 50
Troubleshooting ............................................................................................................................... 51
Putting the equipment out of operation .......................................................................................... 52
Removing harmful substances .............................................................................................................. 52
Removing the equipment ..................................................................................................................... 52
Disposing of the equipment .................................................................................................................. 54
Technical data .................................................................................................................................. 54
Dimensions and weights ...................................................................................................................... 54
Fluid flowrate and differential pressure .................................................................................................. 55
Pressure & temperature ratings ............................................................................................................ 57
Manufacturer's Declaration ............................................................................................................. 57
3
Foreword
This installation & operating manual (IOM) will help
you use the control valve ZK 29 and its variants
(referred to as "equipment" in this document) safely
and efficiently for its intended purpose.
This installation & operating manual is intended for
anyone commissioning, using, operating, servicing,
cleaning or disposing of this equipment and, in
particular, for professional after-sales service
technicians, qualified personnel and authorised and
trained staff.
All of these persons must read and understand the
content of this installation & operating manual.
Following the instructions given in this installation &
operating manual helps avoiding danger and
increases the reliability and service life of the
equipment. Please note that in addition to the
instructions given in this installation & operating
manual you must also observe all locally applicable
rules and regulations concerning the prevention of
accidents as well as approved safety guidelines for
good professional practice.
Availability
Keep this installation & operating manual together
with the plant documentation for future reference.
Make sure that this installation & operating manual
is available to the operator.
The installation & operating manual is part of the
equipment. Please hand over this installation &
operating manual when selling the equipment or
passing it on.
Keep the applicable documents specified on page 7
together with this installation & operating manual
for future reference.
Formatting features in the
document
Certain text elements of this installation & operating
manual feature a specific typographic design. You
can easily distinguish the following text elements:
Standard text
Cross-reference
Listing
Sub-items in listings
Steps for action.
Here you will find additional useful
informatio
n and tips serving to assist you
in using the equipment to its fullest
potential.
Shown and described types of
equipment
The drawings and descriptions in this installation &
operating manual refer to type
ZK 29/14
If any other variant is shown or described it will be
explicitly stated.
This installation & operating manual (IOM) describes
standard equipment. Contact the manufacturer for
more information on the variants and types not
described in this document.
4
Safety
Use for the intended purpose
The equipment is designed for controlling and
regulating the level, pressure and flowrate of fluids
in heat and process control systems.
Correct use includes compliance with the
instructions given in this installation & operating
manual, in particular obedience to all safety
instructions.
Indications and instructions stated in the applicable
documents are part of this installation & operating
manual.
Any other use of the equipment is considered to be
improper.
Note that the equipment is also used incorrectly if
the materials of the equipment are not suitable for
the fluid.
The equipment is also considered to be used
improperly if:
the equipment is not in proper working condition
when being used
the equipment is used in operating conditions
that exceed the pressure and temperature
ratings and limits stated in this IOM and the
applicable documents
the equipment is retrofitted or modified without
the written approval of the manufacturer
the equipment is fitted with spare parts that are
not approved by the manufacturer
the equipment is provided with an actuator that
is not approved by the manufacturer
the equipment is operated or serviced by
unqualified personnel.
The personnel must have the qualification and
experience specified in section "
Qualification of
personnel
" on page 6.
Basic safety notes
Explosion hazard
Explosion risk if equipment is used that is not
suitable for the environmental conditions. When
using the equipment in explosion risk areas
make sure that:
The permissible surface temperature of the
equipment for the place of installation must
not be exceeded.
If electrically insulated equipment is installed
appropriate measures must be taken to
discharge any static electricity between pipe
flanges.
The heat generated by friction caused by
moving parts that do not run smoothly can
cause explosions. Make sure that all moving
parts can operate smoothly.
When carrying out welding work in order to
install or remove the equipment flying sparks
may be generated that can cause fire or
explosion. Observe any on-site regulations for
fire and explosion prevention.
Only qualified personnel is allowed to mount or
remove the equipment or its components.
Risk of severe injuries
The equipment may become hot during
operation. Do not operate the equipment unless
thermal insulation or protection against
accidental contact prevents you from touching
hot surfaces.
The equipment is under pressure during
operation and may be hot. Before carrying out
any work on the equipment make sure that the
following requirements are met:
The pipes must be depressurized (0 bar).
The fluid must be completely removed from
the pipes and the equipment.
During work on the equipment the
installation must be switched off and
protected against unauthorised or
unintended activation.
The pipes and the equipment must have
cooled down to room temperature (approx.
20 °C).
5
If the equipment is used in contaminated areas
there is a risk of severe injuries or death caused
by harmful substances in or on the equipment.
Before working on the equipment make sure
that it is completely decontaminated. Always
wear the protective clothing prescribed for
contaminated areas when working on the
equipment.
The equipment must only be used with fluids
that do not attack the material and the gaskets
and sealings of the equipment. Otherwise leaks
may occur and hot or toxic fluid could escape.
The equipment and its component parts must
only be mounted or removed by qualified
personnel. A qualified person must be
acquainted with and experienced in the
following:
Making pipe connections.
Selecting suitable lifting gear and
understanding the rules for its safe use.
Working with dangerous (contaminated, hot
or pressurized) fluids.
If unsuitable lifting gear is used or the gear is
used improperly the equipment or parts of it
could fall down.
Make sure that only qualified personnel lifts
the equipment or parts of it.
Make sure that nobody is standing or
working below the hoisted equipment.
Make sure that the lifting gear is of sufficient
strength for the load to be hoisted and that
the load is properly secured and attached to
it. For more information on the nature and
weight of the components and safe lifting
points please contact the manufacturer.
Make sure that all locally applicable
regulations on safety and the prevention of
accidents are strictly adhered to.
If the admissible temperature and pressure
limits are exceeded the equipment may be
destroyed and hot or pressurized fluid may
escape. Make sure that the equipment is only
operated within the admissible service range
and limits.
For more information on limits and pressure &
temperature ratings see name plate and the
section "
Technical Data
".
The equipment may be damaged if the
connection of the equipment with the pipe is not
stable enough or the equipment is not
sufficiently supported. Hot or pressurized fluid
may escape. Only qualified personnel is allowed
to install and connect the equipment.
If the support of the equipment during
installation is insufficient the equipment might
fall down, thereby causing bruises or injuries.
Make sure the equipment is safely held in place
during installation and cannot fall down. Wear
the protective clothing specified for the place of
installation.
If the stuffing box is leaking there is a risk of
severe injuries caused by escaping hot fluid.
Use the equipment only if it is in proper working
condition. Replace any leaking stuffing box seal.
The equipment can be provided with different
types of actuator, e. g. with an electric or
pneumatic actuator. Depending on the type of
power supply for the actuator there is a risk of
severe injuries or death for various reasons.
Before working on the equipment cut off power
supply to the actuator. Observe all danger notes
and follow all instructions given in the
installation & operating manual of the actuator.
If you have a question please contact the
manufacturer of the actuator.
The moving parts of the equipment can cause
severe injuries or death. Make sure that nobody
is standing close to these moving parts or can
touch them while the equipment is operating.
Before working on the equipment make sure
that the power supply to the actuator is cut off
and cannot be switched on accidentally.
6
Risk of minor injuries
Sharp edges on component parts can cause
cuts. Always wear industrial gloves when
servicing the equipment.
The equipment can become hot during
operation. This presents the risk of burns
caused by heat radiation or when touching the
equipment. Do no touch the equipment during
operation. Always wear heat resistant protective
gear when working on the equipment.
Information on property damage
or malfunctions
Malfunctions will occur if the equipment is
installed in a wrong position or with the flow
arrow pointing in the opposite direction of the
fluid flow. This may result in damage to the
equipment or the installation. Make sure that
the flow arrow on the equipment body matches
the indicated direction of the fluid flow in the
pipe.
If the material is unsuitable for the fluid,
increased wear may occur and fluid may
escape. Make sure that the material is suitable
for the fluid used in your installation.
Qualification of personnel
A qualified person must be acquainted with and
experienced in the following:
the pertinent on-site rules and regulations for
preventing fire and explosions as well as
industrial safety regulations
working on pressure equipment
making pipe connections
working with dangerous (hot or pressurized)
fluids
lifting and transporting loads
observing all notes and instructions in this
installation & operating manual and the
applicable documents
connecting the power supply of the actuator
Protective gear
The required protective gear depends on the types
of fluid used and the regulations on site. For more
information on suitable protective clothing and
safety gear refer to the safety data sheet of the fluid
in question.
Protective gear comprises the following items:
Safety helmet to EN 397
Safety footwear to EN ISO 20345
Protective leather gloves to EN 388
Wear some form of ear protection to EN 352 when
standing close to the equipment (1 m or less)
during operation.
Typographic features of warning
notes
DANGER
Notes with the heading DANGER warn
against imminent dangerous situations that
can lead to death or serious injuries.
WARNING
Notes with the heading WARNING warn
against possibly dangerous situations that
could lead to death or serious injuries.
CAUTION
Notes with the heading CAUTION warn
against dangerous situations that could
lead to minor or moderate injuries.
7
Formatting features for warnings
of property damage
Attention!
This information warns of a situ
ation
leading to property damage.
Description
Scope of supply and equipment
specification
Scope of supply
The equipment is available with fitted actuator or
without actuator.
Our equipment is delivered packed and ready for
assembly.
Applicable documents
The following documents are part of the supply of
the equipment:
Declaration of incorporation
Documents provided by the manufacturer of
actuator
DImensional drawing with indications of centre
of mass
Data sheet
Parts list
These documents are part of the user
documentation and must be kept together with this
installation & operating manual for future reference.
Equipment specification
The equipment consists of the following main
components:
Body
Bonnet
Cover (only for ZK29/20)
Nozzle
If the equipment is fitted with a rotary actuator, the
bonnet and the upper part of the equipment form a
functional unit.
If the equipment is fitted with a pneumatic
diaphragm actuator, you can detach the bonnet
from the cover.
Different equipment variants are available. The type
designation has a code that indicates the respective
variant.
The equipment is available in sizes between
DN 25 and DN 150.
The body is available as straight-through or
angle-type. The code letter "D" in the type
designation indicates straight-through and "E"
indicates angle-type.
The equipment can be fitted with various types
of actuators. The actuator type is indicated by
the following code numbers in the type
designation:
01: Handwheel (retrofitting of an electric
rotary actuator NOT possible)
02: Handwheel (retrofitting of an electric
rotary actuator possible)
12: Electric rotary actuator
1
13: Electric linear actuator
1
14: Plug-in connection form B1,
EN ISO 5210 for an electric rotary actuator
20: Pneumatic diaphragm actuator
30: Lever actuator without part-turn actuator
attached
1
31: Lever actuator with part-turn actuator
attached
1
40: Hydraulic cylinder
1
The throttling system has four stages for
pressure reduction.
1 Special design (Note that special design
versions are not described in this installation
& operating manual)
8
Example of type designations
"ZK 29-D50/14"
Straight-through equipment DN50 with plug-in
connection form B1 to EN ISO 5210 for an electric
rotary actuator.
"ZK 29-E/20"
Angle-type equipment with pneumatic diaphragm
actuator.
In most cases the equipment described in
this IOM is of the straight-through type and
has
a spindle bearing for an electric rotary
actuator.
If any other variant is shown or described it
will be explicitly stated.
End connections
The equipment is available with the following end
connections:
Butt-weld ends
Socket-weld ends
Flanges
The end connection is not specified in the type
designation.
9
Component parts
No.
Designation
1
Mechanical connection for actuator, in
equipment with rotary actuator this is a
spindle bearing (shown here)
2
Pneumatic diaphragm actuator
3
Bonnet
No.
Designation
4
Cover
5
Name plate
6
Flow direction arrow (on both sides)
7
Body
10
The yoke is fitted with the following items:
No.
Designation
8
Spindle
9
Scale marking indicator
10
Scale
11
The design and mounting of the stuffing-box
packing is different in equipment with rotary
actuator and equipment with pneumatic diaphragm
actuator
Stuffing box in equipment with rotary actuator
No.
Designation
11
Stuffing box gland
12
Packing rings
13
Distance sleeve
No.
Designation
14
Base bushing
15
Hinged bolts
12
Stuffing box in equipment with pneumatic diaphragm actuator
No.
Designation
12
Packing rings
14
Base bushing
16
Union nut
No.
Designation
17
Packing gland
18
Grooved ring
13
The following items are fitted inside the equipment:
No.
Designation
19
Body gasket
20
Hexagon-head screws with lock wire
21
Thrust ring
22 Anti-wear element (sleeve or ring -
depending on equipment type)
No.
Designation
23
Gasket
24
Stem
25
Seat ring
26
Sleeve insert (pinned together with rivet)
14
Optional extras
The following items are available as optional extras:
Grease nipple (only on actuator with handwheel
or electric rotary actuator)
Connecting for sealing fluid
Sampling valve
Mechanical lift stop (not for equipment with
pneumatic diaphragm actuator)
The stem lift in equi
pment fitted with a
pneumatic diaphragm actuator can be
limited by means of a handwheel attached
to the actuator.
No.
Designation
27
Grease nipple
28
Sampling valve
29
Connecting for sealing fluid
30
Mechanical lift stop
15
Name plate
The following items are indicated on the name
plate:
Manufacturer
Type designation
Design
Nominal size
Pressure rating
Max. service temperature
Max. service pressure
Max. admissible differential pressure
Flow characteristic
CE marking
Serial number
The following items are indicated on the equipment
body:
Material
Identification marking of material testing
Batch code
Direction of flow
Manufacturing date (quarter/year)
Application of European Directives
Pressure Equipment Directive
The equipment conforms to this Directive (see
"Declaration of Incorporation" section) and can be
used for the following media:
Fluids of group 2
ATEX Directive
The equipment has classification: CE Ex II 2G/D c X.
For use in potentially explosive atmospheres in
zones (surrounding atmosphere to Directive
1999/92/EC) 1, 2, 21 and 22, please read and
observe the following information:
The sign "X" in the Ex label signifies that operation
at an excessive surface temperature caused by the
medium must be avoided. The equipment itself
does not generate additional surface temperatures.
Once installed, static electricity may arise between
the equipment and the connected system. During
use in potentially explosive atmospheres, the
discharge or prevention of possible electrostatic
charging is the responsibility of the manufacturer or
owner of the system. If there is a possibility that
medium might escape, e.g. via actuating devices
or leaks in screwed couplings, the manufacturer or
owner of the system must take this into
consideration when dividing the area into zones.
The equipment classification and Declaration of
Conformity do not apply to any electric, hydraulic or
pneumatic drive that may be installed.
If using the equipment with a drive, the category of
the drive may have an adverse effect on the
equipment category 2G/D.
Please read and observe the relevant
information in the drive manufacturer's
documentation.
16
Task and function
Purpose
The equipment is designed to reduce pressure in
pipes through which the following fluids flow:
water
steam
condensed water
In addition the equipment can control the flowrate
and the fluid level. The equipment can stop the fluid
flow completely, effecting a pipe seal to attain
bubble-tight shut off.
The control edge prevents high flow velocities at the
seat area during the opening and closing process,
thereby minimizing wear on the seating surfaces.
Function
The equipment features a system of flash chambers
where the differential pressure is reduced in stages
and the flow is split up into many partial flows.
This decreases the noise level during operation and
extends the service life of the equipment thanks to
reduced wear.
The equipment is fitted with an externally actuated
stem. During the opening process the stem controls
the fluid flow by successively opening a series of
flash chambers.
When the stem is in the closed position the fluid
flow is completely stopped and bubble-tight closure
is ensured.
When the equipment is closed the stem (24) is in
the lowest position.
In this position the fluid flow is stopped.
During opening the stem is lifted off the seat ring
(25). As a result the nozzle orifices (31) in the
sleeves are opened successively.
When the stem is completely lifted, the fluid can
flow through all nozzle sleeves and the max. fluid
flowrate is reached.
The optional mechanical lift stop allows you to set a
minimum flowrate that will constantly flow through
the equipment.
Storing and transporting the
equipment
Attention!
Equipment can be damaged if stored or
transported improperly.
Close all openings with the sealing
plugs or covers supplied with the
equipment or use similar sealing
covers.
Protect the equipment against
moisture and corrosive atmospheres.
Please contact the manufacturer if the
specified transport and/or storage
requirements cannot be met.
17
Storing the equipment
Please observe the following items when storing
the equipment:
Make sure that the equipment is completely
disconnected.
Before storage make sure that the equipment is
dry and free from any fluid residues.
The equipment must be protected by its
packaging. The packaging must protect the
equipment from moisture and mechanical
damage.
The equipment must be stored in a horizontal
position.
Make sure that the stem of the equipment is
moved at least every two months in order to
avoid that the packing rings get stuck.
CAUTION
There is a risk of getting crushed by the
spindle.
Wear sturdy leather gloves when
working on the spindle or stem.
Make sure that no persons are in the
area of the spindle or stem.
Move the spindle slowly.
Follow all instructions given in the installation &
operating manual of the actuator.
Make sure that all these requirements are
always met when storing the equipment.
Please contact the manufacturer if you cannot
comply with the recommended storage
conditions.
Transporting the equipment
DANGER
Risk of bruises if the equipment or
component parts fall down.
Always wear protective gear when
working on the equipment.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
To lift the equipment use only the
valve body or the bonnet.
Make sure that nobody is standing
below the lifted equipment.
The protective gear must comprise at least the
following:
Safety helmet to EN 397
Safety footwear to EN ISO 20345
Protective leather gloves to EN 388
For more information on suitable safety clothing and
safety gear refer to the safety data sheet of the fluid
in question.
The lifting gear must be of sufficient strength for
the equipment including the actuator.
For more information on the weight of the
equipment see the attached documents. For more
information on the weight of the actuator see the
documents provided by the actuator manufacturer.
For more information on lifting points and the
centres of mass see the attached documents.
Carefully clean the equipment before
transportation.
Meet the requirements for storage also when
transporting the equipment.
Prior to transport seal off connections with
sealing plugs.
18
If you do not have the sealing plugs
supplied with the equipment use
a
ppropriate seal caps to seal off the
connections.
For short distances (only a few metres) you can
transport the equipment unpacked.
When transporting the equipment over larger
distances use the original packaging.
If you do not have the original packaging use a
box that protects the equipment adequately
against corrosion and physical damage.
Mounting and connecting the
equipment
DANGER
Risk of bruises if the equipment or
component parts fall down.
Always wear protective gear when
working on the equipment.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
To lift the equipment use only the
valve body or the bonnet.
Make sure that nobody is standing
below the lifted equipment.
The protective gear must comprise at least the
following:
Safety helmet to EN 397
Safety footwear to EN ISO 20345
Protective leather gloves to EN 388
For more information on suitable safety clothing and
safety gear refer to the safety data sheet of the fluid
in question.
The lifting gear must be of sufficient strength for
the equipment including the actuator.
For more information on the weight of the
equipment see the attached documents. For more
information on the weight of the actuator see the
documents provided by the actuator manufacturer.
Preparing installation
Remove the transport packaging.
Check the equipment for transport damage.
If you detect any transport damage, please
contact the manufacturer.
When supplied by the factory, the connections may
be sealed off with sealing plugs.
Remove sealing plugs before mounting the
equipment.
Keep the sealing plugs and the packing for
further use.
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessa
ry,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
Drain pipes until they are empty.
19
Switch the installation off and protect it against
unauthorised or unintended re-activation.
Connecting the equipment
DANGER
Incorrectly connected equipment can result
in accidents with extremely severe injuries
or death.
Make sure that only specialist
personnel connect the equipment to
the pipe.
Make sure that the direction of flow in
the pipe matches the flow direction
arrow on the equipment.
Make sure that the connected pipe
does not subject the body to any
stress (forces or torques) during
installation and operation.
Specialist personnel must have knowledge and
experience of the type of pipe connection used.
An arrow indicating the flow direction is
provided on both sides of the inlet of the
valve body.
Attention!
Equipment will be damaged if the support
is undersized or in the wrong place.
Mount the support to the pipes next to
the equipment.
Make sure that the supports are
strong enough to hold the weight of
the equipment and to withstand the
forces that occur during operation.
Contact the manufacturer if you want
to mount the supports directly to the
equipment.
The equipment is designed for installation
with the stem in vertical position and the
actuator mounted on top.
Other installatio
n positions are possible.
Contact the manufacturer if you want to
mount the equipment in a different
position of installation.
Mount the equipment in the desired installation
position.
Make sure that the equipment is supported by
the pipes.
If the supports can only be attached
directly to the equipment ask the
manufacturer for more information on
po
ssible positions for the supports.
Connect the end connections of the equipment
properly to the pipes.
Some materials require a subsequent heat
treatment of the welds after the equipment has
been welded in place. If you want to perform a heat
treatment please observe the following notes:
You do not have to remove the internals of
the equipment in order to perform the heat
treatment.
Attention!
The equipment might get damaged.
Make sure that only qualified
personnel carries out the heat
treatment.
Before starting the heat treatment
make sure that the equipment is not
insulated.
Specialist personnel must be highly qualified and
fully experienced in making welded joints with the
type of material used. For information on the
materials of the equipment see the nameplate on
the equipment.
Make sure that the valve is at its middle
position, i. e. half stroke.
20
Make sure that only qualified personnel carries
out the heat treatment.
After the heat treatment you may insulate the
equipment if necessary.
DANGER
Incorrectly connected equipment
can
cause fatal accidents or severe injuries.
Make sure that only qualified skilled
personnel connect the actuator to the
power supply.
Follow all instructions given by the
actuator manufacturer.
Specialist personnel must be highly qualified and
fully experienced in connecting the power supply in
question.
Connect the actuator properly with the
mechanical connection of the equipment.
For more details on how to connect the
actuator with the stem and how to mount
the mechanical connection see page
37.
Connect the actuator properly to its power
supply.
Checking the function
Make sure that the equipment is safely mounted
and that all connections are made correctly.
CAUTION
There is a risk of getting crushed by the
spindle.
Wear sturdy leather gloves when
working on the spindle or stem.
Make sure that no persons are in the
area of the spindle or stem.
Move the spindle slowly.
Carry out a performance test to check the
functions of the equipment.
The stem must perform at least one full valve
stroke.
Change, if necessary, the actuator settings as
indicated in the operating manual of the
actuator.
Starting up the equipment
To finish the installation work please perform the
following jobs:
Adjust the stuffing box
Rinse the equipment
Adjust the mechanical lift stop (if provided)
Flush the installed equipment as described on
page 26.
Adjusting the gland seal
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
In equipment with pneumatic diaphragm actuator
the stuffing box can be adjusted via the union nut.
21
In equipment with other actuators the stuffing box
can be adjusted via the hinged bolts.
The following section describes how to adjust the
stuffing box in equipment with electric rotary
actuator.
The adjustment procedure is the same for other
types of equipment.
The torque required for tightening the stuffing box
screws depends on the type.
The torque required for tightening the screwed
union depends on the condition of the stuffing-box
packing. Tighten the screwed union until the
following requirements are met:
The stuffing box must not leak.
The movement of the stem must not be
impaired by the stuffing box.
If it is not possible to meet both requirements
you have to replace the stuffing-box packing.
Tighten the nuts on the two hinged bolts evenly.
Allow medium to flow through the equipment.
Move the spindle fully several times.
Tighten the hinged bolts evenly again so that no
medium escapes.
Check that the spindle can move easily.
If necessary, slacken the hinged bolts evenly.
The stuffing box is correctly adjusted if no medium
escapes and the spindle can move easily.
22
Adjusting the mechanical stroke limiter
You can adjust the lowest stem position using the
optional stroke limiter (8) on the spindle. This
ensures that an adjustable minimum quantity of
medium continually flows through the equipment.
The optional stroke limiter is only available for
equipment with a rotary actuator. For equipment
with a pneumatic diaphragm actuator, you can
adjust the stem stroke via a handwheel on the
actuator.
LIft the stem until the desired minimum stem lift
is reached.
Loosen the spring pin (32).
Turn the adjustment nut (33) downwards until it
hits the stop.
Re-insert the spring pin (7).
23
Turning the sleeve insert
The equipment can be adapted to the operating
conditions.
For this purpose shift the sleeves of the sleeve
insert relative to each other.
For more information on shifting the sleeve insert
see the drawing "Adjusting the nozzle" or contact
the manufacturer.
Remove the sleeve insert as described in the
section "
Disassembling the equipment
" on
page 28.
Knock the parallel grooved pin out of the sleeve
insert using a copper mandrel.
Turn the sleeves in accordance with the
manufacturer's instructions.
If necessary, you may have to drill new holes as
per the manufacturer's instructions.
Drive a new parallel grooved pin into the sleeve
insert using a copper mandrel.
Install the sleeve insert as described in the
section "
Assembling the equipment
" on
page 37.
Operating the equipment
Do not work on the equipment while it is operating.
DANGER
Risk of bruises when working on the
equipment during operation.
Switch off the equipment if you have
to work close to any moving
equipment parts.
Make sure that the equipment cannot
be switched on inadvertently.
The stem of the equipment is moved according to
the actuator setting.
If you want to change the settings please follow
the instructions given in the operating manual
for the actuator.
In equipment with a mechanical stroke limiter, you
can determine the minimum stroke.
To do so, proceed as described in the section
"
Adjusting the mechanical stroke limiter
" on
page 22.
Attention!
Damage to the equipment or malfunctions
may occur if the stem is not moved for a
longer period of time.
Make sure that the stem performs at
least one full stroke every two months.
After operation
DANGER
If the equ
ipment is used in contaminated
areas there is a risk of severe injuries or
death caused by harmful substances in or
on the equipment.
Only qualified personnel are allowed to
perform work on contaminated
equipment.
Always wear the protective clothing
prescribed for contaminated areas
when working on the equipment.
Make sure that the equipment is
completely decontaminated before
carrying out any service work.
Follow the pertinent instructions for
handling the hazardous substances in
question.
24
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even
loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised
or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
DANGER
Risk of br
uises when working on the
equipment during operation.
Switch off the equipment if you have
to work close to any moving
equipment parts.
Make sure that the equipment cannot
be switched on inadvertently.
Attention!
Damage to the equipment due to improper
maintenance work.
Make sure that only qualified
personnel performs maintenance
work.
A qualified person must be acquainted with and
experienced in the following:
Working on pressure equipment
Lifting loads
Assembling and disassembling the equipment
The qualified personnel must observe and follow
the instructions given in this operating manual
and in the applicable documents.
25
Maintaining the equipment
Maintenance schedule
Interval
Component
Activity
2 months
Spindle
Move spindle by at least one complete stroke.
3 months
Stuffing box seal
Visually inspect to ensure tightness.
Retighten a leaky stuffing box, replace if necessary.
Connections
Body gasket
Positioning of spindle in
gland seal
Spindle
Visually inspect the following points:
Tightness
Cleanliness
Wear
Replace leaky or worn components.
Remove dirt.
Stem
Seat ring
Check that the equipment closes correctly when the
stem is in closed position by measuring the
temperature.
Replace leaky or worn components.
Spindle bearing
Grease with the recommended grease (see next
section) and a lint-free cloth.
Lubricating nipples on spindle
bearing (equipment with
rotating motor)
Apply the recommended grease (see next section).
12 months
Secure actuator fastening
Check that screws and bolts are secure.
Tighten loose screws to the specified torque.
You can find information on the required torques in
the actuator installation instructions.
36 months Overall equipment Check condition of inner parts.
Check condition of spindle actuator.
Replace faulty or worn components.
Replace stuffing box.
Replace body gasket and sealing ring before
assembly.
26
Lubricating the equipment
Attention!
Equipment may be damaged if unsuitable
lubricant is
used.
Use only specified lubricants.
Use only lithium-saponified grease, penetration
grade 2, with MoS2additive.
The following lubricants are recommended for
lubricating the equipment:
WINIX 5000
Lubricate all moving parts of the equipment
every three months.
Lubricate the thread of the spindle and the
sliding surfaces of the position indicator while
operating the equipment at a speed of one
stroke movement an hour.
Keep lubricating until all old grease has exited
the spindle bearing.
Removing dirt deposits
To remove dirt deposits rinse the equipment
with fresh water and wipe it with a clean, lintfree cloth.
To remove any persistent residues use a
cleaning agent that is suitable for the material
and carefully wipe the equipment with a clean,
lint-free cloth.
For information on the materials of the equipment
see section
Disposing of the equipment
.
For more information on material options please
contact the manufacturer.
Replacing component parts
To replace a component part proceed as follows:
Disassemble the equipment as described from
page 28onwards.
Replace the component part with an original
spare part from the manufacturer.
For details on how to order spare parts refer to the
parts list.
The gaskets of the equipment must be replaced
in any case.
Re-assemble the equipment as described from
page 37 onwards.
Rinse the equipment
Rinse the equipment in order to remove any dirt
particles or fluid residues inside the equipment.
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the f
luid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
27
Preparing equipment for rinsing
Remove all parts from the body before rinsing the
equipment.
Disassemble the equipment as described from
page 28onwards.
Put a blind flange with gasket onto the body.
Contact the manufacturer to obtain information on
suitable blind flanges.
Fasten the blind flange and the gasket with the
stud bolts and hexagon nuts for the upper part.
Tighten the hexagon nuts with the same torque
that is specified for tightening the upper part.
Rinsing equipment and pipes
You can rinse the equipment with the same fluid
that is used during normal operation. You can also
use a special cleaning agent.
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstr
eam of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
Attention!
Equipment may be damaged by unsuitable
cleaning fluid.
Rinse the pipe with the same fluid that
is used during normal operation.
Make sur
e that the cleaning fluid does
not damage the equipment material if
you use a different fluid for cleaning
than the normal operating fluid.
Make sure that the cleaning fluid does
not come into contact with the fluid
used during normal operation.
For information on the materials of the equipment
see section
Disposing of the equipment
.
For more information on material options please
contact the manufacturer.
Switch on the installation and rinse the pipes.
Check connections for leaks.
After rinsing keep the installation switched on
until the pipes are completely empty.
Switch the installation off and protect it against
unauthorised or unintended re-activation.
Mounting parts after rinsing
After rinsing re-install the removed parts to render
the equipment operational.
Undo the hexagon nuts of the blind flange.
Remove the blind flange and the gasket.
Keep the blind flange for further use.
Re-assemble the equipment as described from
page 37 onwards.
28
Disassembling the equipment
You have to disassemble the equipment if you want
to
rinse the pipes and the equipment
service component parts
replace or exchange component parts.
If you exchange component parts you can
use the equipment for different application
conditions.
For this purpose you do not have to
remove the equipment from t
he
installation.
Ask the manufacturer for information on
possible retrofitting modifications for your
equipment.
CAUTION
Sharp edges on component parts can
cause cuts.
Wear industrial gloves when servicing
equipment parts.
To dismantle and re-assemble the equipment use
the following tools:
Torque spanner (US: wrench) 20–550 Nm
(depending on nominal size)
Open-end spanner
For equipment of size DN 25 the following
additional tool is required:
Hexagon socket spanner (US: Allen wrench) A.
F. 19 mm
The size of the tools depends on the
equipment type.
Use only tools of suitable size.
Preparing the equipment for disassembly
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
poisoning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment an
d the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
Shut off the pipes upstream and downstream of
the equipment.
29
DANGER
Risk o
f bruises if the equipment or
component parts fall down.
Always wear protective gear when
working on the equipment.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
To lift the equipment use only the
valve body or the bonnet.
Make sure that nobody is standing
below the lifted equipment.
The protective gear must comprise at least the
following:
Safety helmet to EN 397
Safety footwear to EN ISO 20345
Protective leather gloves to EN 388
For more information on suitable safety clothing and
safety gear refer to the safety data sheet of the fluid
in question.
The lifting gear must be of sufficient strength for
the equipment including the actuator.
For more information on the weight of the
equipment see the attached documents. For more
information on the weight of the actuator see the
documents provided by the actuator manufacturer.
Connect the lifting gear to the equipment or part
that you want to lift.
For this purpose use a noose strap of sufficiently
sturdy material.
Attach the noose strap to the lifting points or a
flange.
The space required for disassembling and
re
-assembling the equipment depends on
the optional extras and the type of
actuator.
For more information on the required
service space see the attached drawings.
Attention!
The equipment or component parts may be
damaged if it is disassembled or re
-
assembled in the wrong order.
Always follow the sequence of
activities described in the following
sections.
Attention!
Equipment may be da
maged if unsuitable
tools are used.
Use only tools that are suitable for the
size of the equipment components.
If a tools list is supplied with the
equipment, use only tools specified in
this list.
For more information on suitable tools
please contact the manufacturer.
30
Detaching actuator parts and removing the
cap
If the equipment is fitted with an actuator first
remove the actuator.
Disconnect the actuator as described in the
operating manual for the actuator.
Remove the actuator as described in the
operating manual for the actuator.
You can now remove the mechanical connection for
the actuator from the equipment.
There are different procedures for equipment with
rotary actuator and equipment with pneumatic
diaphragm actuator.
Removing the rotary actuator
Undo the nuts (37) on the stud bolts (34).
Remove the locking washers (36) from the stud
bolts.
Lift off the actuator from the actuator flange
(35).
Remove the stud bolts (34).
Equipment t
hat cannot be retrofitted with
an electric actuator is provided with a
handwheel which is firmly attached to the
threaded bush.
Removing the pneumatic diaphragm actuator
Unscrew the coupling (38) between the spindle
and the actuator.
Remove the groove nut (39).
Lift off the bonnet (3) together with the actuator
(3.).
31
The following steps are the same for both types of
actuator.
Remove the sealing fluid line (if mounted) from
the connection (29).
Unscrew the hexagon nuts (40) of the stud
bolts (41) on the cover.
You can now take the bonnet with stem off the
body.
Attention!
Equipment may not work properly or get
damaged if parts are canted or tilted
during removal work.
Use suitable lifting gear to lift the
components off the body.
Make sure that the components are
not canted or tilted.
Make sure that the component parts
are not damaged by physical shocks.
The required bearing capacity of the lifting gear
depends on the equipment type. Contact the
manufacturer for more information on the weights
of the individual parts.
Lift the cap (3) off the body together with the
spindle (8).
The following drawing shows the
equipment with actuator bearing for an
electric rotary actuator.
32
Removing inner parts
The procedure for removing the internals depends
on the size of the equipment.
Equipment of size DN 25
Loosen the nut (42).
Take the body gasket (19) out of the body.
Take the protective sleeve against wear (22) out
of the body.
Take the pinned sleeve insert (26) out of the
body.
Take the seat ring (25) out of the body.
Take the gasket (23) out of the body.
Equipment of size DN 50
Remove the locking wire (43) from the hexagon-
head cap screws (20).
Loosen the hexagon-head cap screws (1).
Push the thrust ring (21) downwards and hold it
down (2.)
33
Take the retaining ring (44) out of the body.
Take the thrust ring (21) out of the body.
Take the body gasket (19) out of the body.
Take the protective sleeve against wear (22) out
of the body.
Take the pinned sleeve insert (26) out of the
body.
Take the seat ring (25) out of the body.
Take the gasket (23) out of the body.
Equipment of size DN 80
Remove the locking wire (43) from the hexagon
head bolts (20).
Loosen the hexagon head bolts.
Take the smaller parts (45) out of the split ring.
Take the larger section (46) of the split ring out
of the body.
Take the thrust ring (21) out of the body.
34
Take the protective sleeve against wear (22) out
of the body.
Take the pinned sleeve insert (26) out of the
body.
Take the seat ring (25) out of the body.
Take the sealing ring (23) out of the body.
Equipment of size DN 100–150
Remove the locking wire (43) from the hexagon
head bolts (20).
Loosen the hexagon head bolts.
Take the smaller parts (45) out of the split ring.
Take the larger section (46) of the split ring out
of the body.
Take the thrust ring (21) out of the body.
35
Take the ring (58) out of the body.
Take the pinned sleeve insert (26) out of the
body.
Take the seat ring (25) out of the body.
Take the sealing ring (23) out of the body.
Removing the gland seal
You only have to dismount the stuffing box
if you want to exchange parts of the
s
tuffing-box packing.
There are different procedures for
equipment with rotary actuator and
equipm
ent with pneumatic diaphragm
actuator.
Removing the stuffing box in equipment with
rotary actuator
Knock the dowel pin (47) out of the position
indicator (9).
Loosen the hexagon nuts (48) on the hinged
bolts (15).
Fold the hinged bolts to the side.
Remove the washers (49).
Screw the spindle (8) out of the threaded bush
(50).
Pull the spindle out of the cap.
Remove the stuffing box gland (11).
36
The number of pure graphite rings
depends on the si
ze of the equipment.
Make a note of the type and order of the
individual packing rings for their later
re-installation.
Attention!
The packing rings may get damaged.
Make sure you do not damage the
packing rings during installation and
removal.
When installing and removing the
packing rings never use force.Make
sure that the packing rings are
correctly positioned and not skewed.
Position a punch made from aluminium or
copper onto the base bushing (14).
Force the rings out of the stuffing-box packing:
Packing rings (12)
Distance sleeve (13)
Grooved ring (if provided)
Check the stuffing-box chamber and all
dissembled parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
Removing the stuffing box in equipment with
pneumatic diaphragm actuator
The body cover must be detached in order to
remove the gland seal.
Removal of the cover is described on page 30.
Remove the union nut (16).
Remove the stuffing box bush (17).
Pull the spindle (8) out of the cover (4).
The number of pure graphite rings
depends on the size of the equipme
nt.
Make a note of the type and order of the
individual packing rings for their later
re-installation.
37
Attention!
The packing rings may get damaged.
Make sure you do not damage the
packing rings during installation and
removal.
When installing and removing the
packing rings never use force.Make
sure that the packing rings are
correctly positioned and not skewed.
Position a punch made from aluminium or
copper onto the base bushing (14).
Force the rings out of the stuffing-box packing:
Packing rings (12)
Grooved ring (18)
Check the stuffing-box chamber and all
dissembled parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
Detaching the stem from the spindle
The stem and spindle are connected by a
rivet pin. Only separate the stem and
spindle in orde
r to replace damaged parts.
Use a punch to knock out the rivet.
Check all parts for signs of damage.
Replace all worn or damaged parts.
Dismantling the sleeve insert
The sleeve insert is pinned together with a
slotted straight pin. You only have to
disassemble the sleeve insert if you want
to replace sleeves.
Use a punch to knock the slotted straight pin out
of the sleeve insert.
Assembling the equipment
Work prior to re-installation
CAUTION
Sharp edges on component parts can
cause cuts.
Wear industrial gloves when servicing
equipment parts.
Clean all component parts before re-installing
them.
Attention!
The equipment may leak if seals are
damaged.
Always insert new packing rings and a
new body gasket when assembling
the equipment.
Inspect all seals and packing rings
before installation to ensure they are
in perfect condition.
Replace damaged seals and packing
rings.
38
Make sure that the sealing surfaces of the stem
and seat are correctly surfaced in relation to one
another.
Check all component parts.
Replace all gaskets and all worn or damaged
parts.
Replace the two main gaskets and any
damaged components.
Attention!
Equ
ipment may not work properly or get
damaged if parts are tilted or skewed
when installed.
Use suitable lifting gear to mount the
component parts.
Do not tilt or skew the component
parts during installation.
During installation make sure that the
component parts are not damaged by
physical shocks.
The required bearing capacity of the lifting gear
depends on the equipment type. Contact the
manufacturer for more information on the weights
of the individual parts.
Fitting the sleeve insert
Assemble and align the sleeve insert.
Make sure that the holes in the sleeves for the
slotted straight pin are in alignment. For more
information on how to adjust the sleeve insert refer
to the manufacturer.
Use a punch to knock the slotted straight pin
into the sleeve insert.
Connecting the stem to the spindle
Align the stem and spindle so that the holes are
lined up.
Drive a new rivet pin into the hole.
Mounting the gland packing
Attention!
Malfunctions may occur if the packing
rings are damaged.
Before installation discard and replace
any damaged packing rings.
Make sure that the packing rings are
correctly positioned and not damaged
or skewed when fitted.
There are different procedures for
equipment wi
th rotary actuator and
equipment with pneumatic diaphragm
actuator.
Mounting the stuffing box in equipment with
rotary actuator
Attention!
The stem may be damaged if not installed
with due care.
Do not tilt the spindle during
installation.
Make sure the control notch and seat
of the stem are not damaged by
impact on hard surfaces.
The stem and spindle are pinned and installed
together.
Push the spindle halfway into the cap.
Insert the base bushing (14) in the cap.
Attention!
Malfunctions may occur if the packing
rings are fitted incorrectly.
Make sure that the packing rings of
the stuffing box are inserted in the
following order:
39
The number of pure graphite rings
depends on the size of the equipment.
The exact number is indicated in the parts
list.
For more detailed information please
contact the manufacturer.
Put the following parts of the stuffing-box
packing into the stuffing-box bore:
Distance sleeve (13)
Grooved ring (if provided)
Packing rings (12)
Position the stuffing box gland (11) on the
spindle.
Place the scale marking indicator (9) on the
spindle.
Align the scale marking indicator (9) so that the
hole for the dowel pin (47) is located above the
hole in the spindle (8).
Drive the dowel pin (47) into the holes using a
mandrel.
Fold up the hinged bolts (15) in the slots of the
stuffing box gland (11).
Place the shims (49) and hexagon nuts (48) on
the hinged bolts.
The torque required for tightening the screwed
union depends on the condition of the stuffing-box
packing. Tighten the screwed union until the
following requirements are met:
The stuffing box must not leak.
The movement of the stem must not be
impaired by the stuffing box.
If it is not possible to meet both requirements
you have to replace the stuffing-box packing.
40
Mounting the stuffing box in equipment with
pneumatic diaphragm actuator
Attention!
The stem may be damaged if not installed
with due care.
Do not tilt the spindle during
installation.
Make sure the control notch and seat
of the stem are not damaged by
impact on hard surfaces.
Insert the spindle (8) and stem (24) fully in the
cover (4) (1.).
Insert the base bushing (14) in the cap (2.).
Attention!
Malfunctions may occur if the packing
rings are fitted incorrectly.
Make sure that the packing rings of
the stuffing box are inserted in the
following order:
The number of pure graphite rings
depends on
the size of the equipment.
The exact number is indicated in the parts
list.
For more detailed information please
contact the manufacturer.
Put the following parts of the stuffing-box
packing into the stuffing-box bore:
Packing rings (12)
Grooved ring (18)
Put the packing gland (17) into the stuffing-box
bore.
Tighten the union nuts (16) hand tight.
41
Installing inner parts
DANGER
Risk of bruises if the equipment or
component parts fall do
wn.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
Make sure that nobody is standing
below the lifted equipment.
Attention!
Equipment may not work properly or get
damaged if parts are tilted or skewed
when installed.
Use suitable lifting gear to mount the
component parts.
Do not tilt or skew the component
parts during installation.
During installation make sure that the
component parts are not damaged by
physical shocks.
The required bearing capacity of the lifting gear
depends on the equipment type. Contact the
manufacturer for more information on the weights
of the individual parts.
Clean the sealing surface for the sealing ring in
the body.
Insert a new sealing ring (23) in the body.
Insert the seat ring (25) in the body.
Install the sleeve insert (26) in such a way that
the adjusting slots (55) face upward.
The next steps depend on the size of the
equipment.
42
Mounting internals of equipment size DN 25
Put the protective sleeve against wear (22) onto
the sleeve insert and make sure that the
marking notch (56) is centrally aligned and
points towards the outlet.
Apply lubricant to the socket-head cap screw
(42).
Screw the socket-head cap screw (42) into the
body.
Tighten the socket-head cap screw with a
torque of 160 Nm.
Insert a new body gasket (19).
43
Mounting internals of equipment size DN 50
Put the protective sleeve against wear (22) onto
the sleeve insert and make sure that the
marking notch (56) is centrally aligned and
points towards the outlet.
Put the thrust ring (21) into the body.
Insert the retaining ring (44) into the body.
Apply lubricant to the hexagon-head cap screws
(20).
Screw the hexagon-head cap screws into the
thrust ring.
Tighten the hexagon-head cap screws with a
torque of 40 Nm.
Secure the hexagon-head cap screws with the
locking wire (43).
44
Mounting internals of equipment size DN 80
Place the protective sleeve against wear (22) on
the sleeve insert.
Align the protective sleeve against wear so that
the hole (57) is positioned above the slot in the
outermost sleeve.
Put the thrust ring (21) into the body.
Insert the large parts of the segmented ring (46)
into the body.
To fix the large parts of the segmented ring
insert the small parts (45) into the body.
Screw the hexagon-head cap screws (20) into
the thrust ring.
Tighten the hexagon-head cap screws with a
torque of 100 Nm.
Secure the hexagon-head cap screws with the
locking wire (43).
45
Mounting internals of equipment sizes DN 100
and 150
Put the ring (58) onto the sleeve insert.
Put the thrust ring (21) into the body.
Insert the large parts of the segmented ring (46)
into the body.
To fix the large parts of the segmented ring
insert the small parts (45) into the body.
Screw the hexagon-head cap screws (20) into
the thrust ring.
Tighten the hexagon-head cap screws with a
torque of 100 Nm.
Secure the hexagon-head cap screws with the
locking wire (43).
46
Fitting the cap in equipment with a rotary
actuator
DANGER
Risk of bruises if the equipment or
component parts fall down.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
Make sure that nobody is standing
below the lifted equipment.
Inspect the sealing surfaces in the body and on
the cap for damage.
Replace damaged parts of the equipment.
Insert a new gasket (19).
Clean the sealing surfaces.
Coat the thread of the stud bolts (41) with high-
temperature paste.
Position the cap (3) and spindle (8) on the body.
Place the nuts (40) on the stud bolts.
Atten
tion!
Malfunctions due to incorrect tightening
torques.
Tighten the screws, nuts and bolts
listed in the following table only with
the indicated torques.
DN [mm (inch)]
Tightening torque
[Nm]
25 (1’’)
50
50 (2’’)
150
80 (3’’)
180
100 (4’’)
300
150 (6’’)
550
47
Tighten the nuts crosswise and evenly to the
specified torque.
With each round of tightening, check that the
spindle moves easily in the gland seal.
Screw the sealing fluid line (if provided) to the
connection for the sealing fluid.
If necessary, adjust the stuffing box as
described on page 20.
Fitting the cover on equipment with a
pneumatic diaphragm actuator
DANGER
Risk of bruises if the equipment or
component parts fall down.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
Make sure that nobody is standing
below the lifted equipment.
Inspect the sealing surfaces in the body and on
the cover for damage.
Replace damaged parts of the equipment.
Clean the sealing surfaces.
Coat the thread of the stud bolts (41) with high-
temperature paste.
Make sure that a new body gasket (19) is
inserted in the body (1.).
Position the cover (4) and spindle (8) on the
body (2.).
Place the nuts (40) on the stud bolts (3).
Attention!
Malfunctions due to incorrect tightening
torques.
Tighten the screws, nuts and bolts
listed in the following table only with
the indicated torques.
DN [mm (inch)]
Tightening torque
[Nm]
25 (1’’)
50
50 (2’’)
150
80 (3’’)
180
100 (4’’)
300
150 (6’’)
550
48
Tighten the nuts crosswise and evenly to the
specified torque.
With each round of tightening, check that the
spindle moves easily in the gland seal.
Screw the sealing fluid line (if provided) to the
connection for the sealing fluid.
If necessary, adjust the stuffing box as
described on page 20.
Installing the rotary actuator
DANGER
Risk of bruises if the equipment or
component parts fall down.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
Make sure that nobody is standing
below the lifted equipment.
Put the feather key (59) into the threaded bush
(50).
Screw the stud bolts (34) handtight into the
actuator.
Put the actuator onto the actuator flange (35).
Put the locking washers (36) onto the stud bolts.
Screw the nuts (37) onto the stud bolts.
Tighten the nuts with a torque of 40 Nm or
according to the specification of the actuator
manufacturer.
49
Installing the pneumatic diaphragm actuator
DANGER
Risk of bruises if the equipment or
component parts fall down.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
Make sure that nobody is standing
below the lifted equipment.
Place the actuator on the cover (4).
Hand-tighten the groove nut (39).
Install the coupling (38) between the spindle (8)
and the actuator spindle.
Attention!
The equipment may suffer damage or
malfunctions if actuator parts are not
correctly aligned.
Make sure that the spindle is
connected flush with the actuator
spindle.
Connecting the actuator
Connect the actuator properly to its power
supply.
Completing assembly
Bring the equipment back into operation as
described on page 20.
50
Servicing the equipment and
installing spare parts
You may exchange the following component parts
in case of wear or damage:
The material specification a
nd stock code
numbers of the component parts are
indicated in the supplied parts list.
Disassemble the equipment as described from
page 28onwards.
Remove the defective component part from the
equipment.
Attention!
Equipment may leak if the gaskets are
damaged.
Always inser
t new main gaskets when
assembling the equipment.
Check all gaskets, seals and packing
rings before installing them.
Replace any damaged gasket, seal or
packing ring.
Mount the new component part.
Check all component parts before re-installing
them.
Replace defective component parts.
Replace the joint ring and the body gasket.
Re-assemble the equipment as described from
page 37 onwards.
51
Troubleshooting
Problem
Cause
Remedy
The stem moves with difficulty
or jerky.
The actuator switches off
automatically.
Malfunction in actuator.
Follow the instructions in the operating
manual for the actuator.
Malfunction in controller.
Follow the instructions in the operating
manual for the controller.
The stuffing box packing
affects the stem lift.
Slightly loosen the stuffing-box screw.
Replace the stuffing box packing if it
keeps affecting the stem lift.
The flowrate is too small.
The stem lift is affected by
foreign matter.
The nozzl
es are dirty or clogged
by foreign particles.
Rinse the installation.
If necessary disassemble the equipment
and clean the component parts.
During operation loud noises
are audible.
The nozzles are dirty or clogged
by foreign particles.
The stuffing box is leaking.
The stuffing box has not been
tightened enough.
Adjust the stuffing-box packing.
Make sure that the stuffing box does not
impair the movement of the stem and
that it does not leak.
The stuffing-box packing is
damaged.
Replace the stuffing-box packing.
If faults occur that are not listed above or cannot
be corrected, please contact our Technical
Service or authorized agency in your country.
52
Putting the equipment out of
operation
Removing harmful substances
DANGER
If the equipment is used in contaminated
areas there is a risk of severe injuries or
death caused by harmful substances
in or
on the equipment.
Only qualified personnel are allowed to
perform work on contaminated
equipment.
Always wear the protective clothing
prescribed for contaminated areas
when working on the equipment.
Make sure that the equipment is
completely decontaminated before
carrying out any service work.
Follow the pertinent instructions for
handling the hazardous substances in
question.
Qualified personnel must have extensive experience
with and a working knowledge of:
pertinent rules and regulations concerning
handling hazardous substances
special regulations for handling the hazardous
substances encountered on site
using the required personal protective
equipment (PPE) and clothing
Caution
Environmental damage may be caused by
poisonous fluid residues.
Before disposing of the equipment
make sure that it is clean and free of
fluid residues.
For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
Remove all residues from the equipment.
For the disposal of all residues observe the
pertinent legal regulations concerning waste
disposal.
Removing the equipment
DANGER
Personnel working on pipes are exposed to
safety risks and may suffer severe injuries,
pois
oning or even loss of life.
Make sure that no hot or hazardous
fluid is in the equipment or the pipes.
Make sure that the pipes upstream
and downstream of the equipment are
depressurised.
Make sure that the installation is
switched off and protected against
unauthorised or unintended activation.
Make sure that the equipment and the
pipes have cooled down to room
temperatures.
Wear protective clothing that is
suitable for the fluid and, if necessary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
53
DAN
GER
Risk of bruises if the equipment or
component parts fall down.
Always wear protective gear when
working on the equipment.
Use suitable lifting gear when moving
or lifting the equipment and/or
component parts.
Make sure that the equipment cannot
topple over.
To lift the equipment use only the
valve body or the bonnet.
Make sure that nobody is standing
below the lifted equipment.
The protective gear must comprise at least the
following:
Safety helmet to EN 397
Safety footwear to EN ISO 20345
Protective leather gloves to EN 388
For more information on suitable safety clothing and
safety gear refer to the safety data sheet of the fluid
in question.
The lifting gear must be of sufficient strength for
the equipment including the actuator.
For more information on the weight of the
equipment see the attached documents. For more
information on the weight of the actuator see the
documents provided by the actuator manufacturer.
Switch the installation off and protect it against
unauthorised or unintended re-activation.
WARNING
Risk of severe injuries or death if the
actuator is not removed correctly.
Before working on the actuator cut off
power supply to the actuator.
Follow all instructions and observe all
notes given in the operating manual
for the actuator.
Make sure that only qualified and
trained personnel work on the actuator
and its connections.
A qualified person must be acquainted with and
experienced in the following:
safety issues when working on the installation
establishing connections with the respective
power source of the actuator
mechanical work on pipes.
Cut off the power supply to the actuator.
Detach the actuator from the mechanical
connection of the equipment.
Detach the end connections of the equipment
from the pipes.
Put the equipment onto a suitable base.
The base must be sufficiently strong to withstand
the weight of the equipment.
If necessary disassemble the equipment and put
down individual parts.
Store the equipment as described on page 17.
54
Disposing of the equipment
Caution
Environmental damage may be caused by
poisonous fluid residues.
Before disposing of the equipment
make sure that it is clean and free of
fluid residues.
For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
The equipment is made from the following
materials:
Component
EN
ASME
Body DN 25 (1’’) and
DN 50 (2’’)
1.7335
A182F12Cl.2
Body DN 80 (3’’),
100 (4’’), 150 (6’’)
1.7357 A217WC6
Bonnet
1.7357
A217WC6
Cover
1.7335
A182F12Cl.2
Threaded bolt
1.7709
A193B16
Nuts
1.7709
A194-7
Technical data
Dimensions and weights
For information on the exact dimensions of the
equipment see the dimensional drawing supplied
with the equipment.
For information on the exact weights of the
equipment see the dimensional drawing supplied
with the equipment.
For information on dimensions and weights of the
actuator please refer to the documents provided by
the manufacturer of the actuator.
For more information please contact the
manufacturer.
55
Fluid flowrate and differential pressure
Flowrates, cold water
A
Differential pressure
B
Flowrate
The chart shows the max. flowrates of cold water at the extreme regulation position with linear
characteristic curves and maximum Kvs value.
56
Flowrates, hot water, ts–5 K
A Differential pressure (assuming discharge to atmospheric pressure)
For higher back pressure take a correction factor into account. The ascertained flowrate is reduced by
the correction factor.
B
Flowrate
The chart shows the max. flowrates of hot water at the extreme regulation position with linear characteristic
curves and maximum Kvs value.
If p2/p1 > 0.5 multiply the flowrate read-out by the correction factor K taken from the backpressure chart.
57
Back pressure diagram
Y
Correction factor
X
Pressure ratio p2/p1 (absolute)
For more information see data sheet.
Pressure & temperature ratings
The following specifications refer to the
equipment and not to the end connection.
Please contact the manufacturer for
more information on the application
limits dictated by the type of end
connection used.
Admissible differential pressure Δ PMX:
[bar]
[psig]
Single stage
40
580
Multi stage
100
1,450
Maximum pressure
You can find precise information on the pressure
and temperature ratings of your equipment on the
name plate and in the data sheet.
Manufacturer's Declaration
You can find details on the conformity assessment
in accordance with European Directives in our
Declaration of Conformity or our Declaration of
Incorporation.
To request the valid Declaration of Conformity or
Declaration of Incorporation, please contact:
GESTRA AG
Münchener Straße 77
28215 Bremen
Germany
Telefon
+49 421 3503-0
Telefax
+49 421 3503-393
E-Mail
info@de.gestra.com
Web
www.gestra.de
This declaration is no longer valid if modifications
are made to the equipment without consultation
with us.
58
59
60
Agencies all over the world:
www.gestra.de
GESTRA AG
Münchener Straße 77
28215 Bremen
Germany
Telefon
+49 421 3503-0
Telefax
+49 421 3503-393
E-Mail
info@de.gestra.com
Web
www.gestra.de
810685-05/07-2017 kx_mm (808539-05) © GESTRA AG Bremen Printed in Germany
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