Neotecha Model NXR PFA Lined Ball Valves IOM, Neotecha-EN Manuals & Guides

NEOTECHA NXR BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

2 SAFETY

Please also read through these notes carefully.

2.1 General potential danger due to:

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

2.2 Correct use

2.2.1 Area of application

Ball valves are bubble-tight shut-off industrial
valves that can be used for the isolation,
throttling and regulation of corrosive gases,
liquids, pastes and powder products in
pipelines, vessels, apparatus etc.
The surfaces of the body parts, together with
the ball that are in contact with the medium
are coated with PFA. Ball seats are available
in various material types and can be used to

1 GENERAL INFORMATION ON THE
INSTALLATION AND MAINTENANCE
INSTRUCTIONS

These instructions contain information on
how the valve should be safely installed and
operated in the prescribed manner. If any
problems are encountered during installation
or operation which cannot be resolved with
the aid of the installation and maintenance
instructions, please contact the supplier or
manufacturer for more information.
These installation and maintenance
instructions comply with the applicable
ENsafety standards.
When installing the fitting, the operator or
the person responsible for the design of
the installation must ensure that applicable
national regulations are complied with.
The manufacturer reserves all rights to
maketechnical changes and improvements
atany time.
The use of these installation and maintenance
instructions assumes that the user is qualified
to “Qualified Personnel” level. Operating staff
must be given appropriate training in the
operating and maintenance instructions.

suitthe medium.

2.2.2 Performance data

Nominal diameter range:
DIN-PN 16 and JIS10K
DN15, 20, 25, 40, 50, 80, 100, 150
ASME 150 lbs
NPS ½, ¾, 1, 1½, 2, 3, 4, 6
Pressure range:
16bar (0.1 mbar vacuum)
Test pressure = 1.5 x PN = 24bar
Temperature range:

-40°C to 200°C

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16

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NEOTECHA NXR BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

2.2.3 Pressure-temperature diagram for NXR ball valves

14

12

10

8

bar

6

4

2

Vacuum

0.1 mbar

0

-40 -20 0 50 100 150 180 200°C

2.2.4 Flow characteristic

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

10 20 30 40 50 60 70 80 90

Standard

3 SOURCES OF DANGER

3.1 External chemical effects

The valve body paint can be attacked externally
by strong solvents, leading to corrosion of
the body. If damage of this nature occurs,
the effects on the environment should
be investigated and the damage to the
painting made good in accordance with the
manufacturer’s data.

3.2 Mechanical

When using hand levers and handwheels,
it should be ensured that there is sufficient
clearance everywhere for the operator’s
hands,so that there is no risk of trapping.

3.3 Electrical

If static charges can lead to explosions,
the valve must be earthed by means of the
appropriate earthing accessory. In addition we
recommend the use of valves with electrically
conductive linings. For more information,
please contact the supplier or manufacturer.

3.4 Thermal

The operating temperature of the valve can
be up to a maximum of 200°C. Suitable
precautions should be taken to protect against
burns due to high or freezing temperatures.
In particular, insulated gloves should be worn
when using the hand lever, for example. In case
of fire, the mechanical strength of the PTFE
seals is no longer guaranteed above 200°C.

Degrees valve position

2.2.5 Usage restrictions

Before the valve is installed, a check should be
made on the extent to which the coating of the
surfaces is resistant to the intended medium.

2.2.7 Warning about foreseeable misuse

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

climbingaids.
Refer to appropriate literature or consult the
manufacturer or distributor for advice on this.

2.2.8 Duty to comply with the instructions

foroperation, maintenance and servicing

2.2.6 Modification prohibition

Mechanical modifications to the valves or the
use of other manufacturer’s parts for repair
purposes are not permissible, as otherwise

These instructions form part of the delivery

package and must be easily accessible to the

user. They should be protected from soiling

andkept in a suitable place.
safety is no longer guaranteed. Repair work
must only be carried out by the manufacturer’s
trained personnel. The manufacturer and
supplier will accept no liability in the event
ofmisuse.

2

NEOTECHA NXR BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Manufacturer’s code

Manufacturer

Ball valve type

Serial number

Ball valve type

Manufacturer

Serial number

Year of manufacture

Number of the notified body

Manufacturer’s code

Year of manufacture

Origin

Origin

3.5 Requirements for the operator

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

- Instruction in and duty to comply with all

installation-related, regional and internal
works regulations and requirements.

- Training or instruction in accordance with the

Safety Standards for personal care and use of
appropriate safety equipment and protective
workgear, like e.g. personal protection
equipment (insulated gloves or similar),

suitable for the operating conditions.
Furthermore, these people must have read
andunderstood these instructions.

3.6 Transport/storage

The valve is delivered with protective covers
which should protect against soiling and
mechanical effects. For this reason, the
protective covers should only be removed
immediately prior to installation.

3.7 Transport and storage conditions

- Transport and storage temperature

-20°C to +65°C.

- Protect against external force(impact,

shock,vibration).

- Do not damage the coating.

- In damp storage areas, a drying agent

or heating is required to protect against

condensation.

- Store the ball valve in open position.

3.8 Handling prior to installation

- On versions with protective covers,
only remove these immediately prior
toinstallation!

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

- Proper treatment prevents damage.

4 IDENTIFICATION

Each ball valve is fitted with a rating plate giving
information on valve type and origin. When
ordering spare parts this information should
becarefully noted down each time.
Ball valves in the size range DN 15 to DN 25
have a standard rating plate with no CE mark.
Ball valves in the size range DN 40 to DN 150
are provided with a rating plate with a CE mark.
Additional identification on the valve in
accordance with DIN19, such as: DN, PN,
NEOTECHA . The identification of the valve
body material is cast onto the valve.

5 DIMENSIONS AND WEIGHTS

Please refer to the product documentation
for any dimensions that are not contained in
the installation and maintenance instructions
andfor ball valve weights.

6 INSTALLATION

6.1 Installation in the pipeline

Fit the ball valve in the pipeline, ensuring that
the sealing surfaces on the faces of the flanges
are not damaged. The NXR ball valve can be
installed independently of the direction of flow.
Adequate clearance should be ensured around
the ball valve, so that it can be operated and
maintained easily.
The mounting flanges of the pipeline in which
the valve is to be installed must be aligned
axially and laterally, in order to prevent the
valve body being subjected to additional
stresses. Fit suitable flange packings, provided
that they are called for: then the fixing bolts
are inserted. Tightening the bolts in stages is
essential for an equal distribution of the of the
initial stress force of the clamping bolts.
The specified tightening torques must not
beexceeded.

The flanges must meet the following
requirements: cleaned and undamaged
matingsurface.

Flange packings are not required with flanges
with flat sealing surfaces. Additional packings
may possibly be required with rubberized
flanges.

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NEOTECHA NXR BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

6.2 Dimensions of the mounting flanges for NXR ball DIN-PN 16

DIMENSIONS (mm)

Size
(DN) (NPS) D Tk n x d

15 ½ 95 65 4 x 14
20 ¾ 105 75 4 x 14
25 1 115 85 4 x 14
40 1½ 150 110 4 x 18
50 2 165 125 4 x 18
80 3 200 160 8 x 18
100 4 220 180 8 x 18
150 6 285 240 8 x 22

6.3 Dimensions of the mounting flanges for NXR valves ASME B 16.10class150 (lbs)

DIMENSIONS (mm)

Size
(DN) (NPS) D Tk n x d

15 ½ 90 60.3 4 x 16
20 ¾ 100 69.9 4 x 16
25 1 110 79.4 4 x 16
40 1½ 125 98.4 4 x 16
50 2 150 120.7 4 x 19
80 3 190 152.4 4 x 19
100 4 229 190.5 8 x 19

- 6 280 241.3 8 x 22

6.5 Installation options

Ball valves can be equipped with various means
of operation e.g. with hand lever, handwheel,
electrical, pneumatic or hydraulic drive.
The hand levers are supplied complete with
a notched plate which allows the lever to be
latched in the end positions.
For installation in exposed places, shaft
extensions in various lengths are available
forall sizes.

6.6 Bolted joints in the pipeline

All flange bolts must be used, even on
low-pressure systems. The specified tightening
toques for the bolts must always be adhered to.

6.7 Body variants

NXR ball valves have the same body
dimensions. The face-to-face and mounting
flange dimensions of the ball valve bodies
varyaccording to the various standards.
When used as an end of the line valve, it must
be secured in such a way that access to the
isolating valve is restricted when in service.
It should also be noted that when a valve is
used as the end valve of a pressurized system,
a dummy flange must be assembled.

6.4 Dimensions of the mounting flanges for NXR ball and JIS-10K Multidrilled

DIMENSIONS (mm)

Size
(DN) (NPS) D Tk n x d

15 ½ 95 70 4 x 15
20 ¾ 100 75 4 x 15
25 1 115 90 4 x 19
40 1½ 140 105 4 x 19
50 2 155 120 4 x 19
80 3 185 150 8 x 19
100 4 210 175 8 x 19
150 6 280 240 8 x 23

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NEOTECHA NXR BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

6.7.1 Face-to-face body dimensions for NXR ball valves

FACE-TO-FACE BODY DIMENSIONS

Size DIN-PN 16 ASME-150lbs JIS-10K
(DN) (NPS) (mm) (mm) (mm)

15 ½ 130 130 130
20 ¾ 150 150 150
25 1 160 127 160
40 1½ 200 165 200
50 2 230 178 230
80 3 310 203 310
100 4 350 229 350
150 6 480 267 480

6.8 Step-by-step valve installation

1. Check that the distance between flanges matches the face-to-face dimension of the ball valve.
Before installing the valve, spread the mounting flanges apart sufficiently using a suitable tool.

2. Remove the protective caps and position the ball valve in the pipeline.

3. Insert the fixing bolts.

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

5. Tighten all flange bolts in opposite pair sequence. Refer to following table for tightening
torques.

6.9 Recommended tightening torques for mounting flange bolts

6.9.1 Recommended tightening torques for NXR ball valves DIN-PN 16 and JIS-10K

RECOMMENDED TORQUES

Size
(DN) (NPS) (Nm)

15 ½ 4 x M12 A2-70 10
20 ¾ 4 x M12 A2-70 15
25 1 4 x M12 A2-70 20
40 1½ 4 x M16 A2-70 27
50 2 4 x M16 A2-70 45
80 3 8 x M16 A2-70 60
100 4 8 x M16 A2-70 45
150 6 8 x M20 A2-70 85

Bolts

(metric) Class

Torque

6.9.2 Recommended tightening torques for NXR ball valves ASME B 16.10class150 (lbs)

RECOMMENDED TORQUES

Size
(DN) (NPS)

15 ½ ½” B7 9
20 ¾ ½” B7 13
25 1 ½” B7 18
40 1½ ½” B7 21
50 2 ⅝” B7 41
80 3 ⅝” B7 52
100 4 ⅝” B7 38
150 6 ¾” B7 68

Bolts

(UNC) (lbf·ft)

Class

Torque

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NEOTECHA NXR BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

6.10 Final checks

- Checking the ball position as far as the

fullyopen position.

- Cleaning and flushing the pipeline before

thefirst closure.

- Repeated opening and closing of the ball

valve, to ensure unrestricted movement
ofball and control shaft.

7 NOTES ON DANGERS DURING
INSTALLATION, OPERATION
ANDMAINTENANCE

Safe operation of the valve is only guaranteed
ifit has been correctly installed, commissioned
and maintained by qualified personnel
(see“Qualified Personnel”), taking into account
the warning information of these installation
and maintenance instructions.
In addition, compliance with the general
installation and safety regulations for the
pipeline or plant construction, together
with the correct use of tools and protective
equipment, must be ensured. The installation
and maintenance instructions must be
strictly followed when any work is carried
out on the valve or when handling the valve.
Non-observance can result in injuries or
damage to property. When the valve is used
as a final termination, a safety measure e.g.
a blank or dummy flange is recommended
when carrying out maintenance work. When
the valve is installed as an end of line valve,
theinformation given in DIN ENISO 13857 must
be observed.

8 COMMISSIONING

8.1 General commissioning

Before commissioning, the information relating
to material, pressure and temperature should
be compared with the installation diagram of
the pipeline system.
Tools for increasing the lever or handwheel
torque are not allowed.
Any debris left in the pipeline and valves
(dirt,welding beads, etc.) will inevitably
leadtoleakage.
Before each commissioning of a new system or
re-commissioning of a system after repair or
modification, it must be ensured that:

- All installation and assembly work has

been completed in accordance with the
regulations.

- Commissioning is only undertaken by

“Qualified Personnel”.

- The valve is in the correct operating position.

- New protective equipment is installed or

existing protective equipment repaired.

9 USE

9.1 Operation - general

NXR series ball valves should only be used
in the fully open or fully closed position, as
they are not designed for flow regulation.
Intermediate settings can result in turbulence,
leading to vibrations in the pipeline system
which then generates noise.
Operating:
Clockwise to close.
Counter clockwise to open.

9.2 Operation with hand lever

Neotecha ball valves are supplied with a hand
lever as standard, unless anything different
has been provided (except DN150/ NPS6 -too
high a torque). The hand lever should always be
fitted on the ball valve and only removed when
necessary for maintenance purposes. When
the hand lever points in the direction of the
pipeline, the ball valve is fully open; when the
hand lever is at right angles to the pipeline, the
valve is fully closed. The hand lever should be
turned clockwise to closethevalve.

Nominal diameters 15 to 100 (NPS ½ to 4)
Operating element: detent lever

The hand lever and detent lever must not be
modified. The locking function is otherwise
adversely affected. Damaged hand levers
shouldbe exchanged.

9.3 Operation with drive

Thanks to its modular design, the NXR ball
valve can be converted to anautomatic drive
at any time. In this case it may be necessary to
remove the ball valve fromthe pipeline.
When drives or gear units are used, the
instructions of the particular manufacturer
areapplicable.

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NEOTECHA NXR BALL VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

10 SERVICING AND MAINTENANCE

No routine maintenance or lubrication is
required. However, for systems with high
temperatures, an inspection for leakage at
the flanges should be carried out shortly after
installation. The large difference between
the temperature related expansions of PTFE
and some metals can result in cold flow.
Tightening the bolts once again will eliminate
this problem. This process may possibly have to
be repeated several times. We recommend that
the valve is operated at least once a month.

11 CAUSE AND REMEDY OF OPERATING
FAULTS

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

The safety regulations must always
beobservedwhen troubleshooting.
Repair work must only be carried out by
themanufacturer’s trained personnel.

ATTENTION

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

- Only allow assembly work to be carried out
byqualified personnel.

- Almost fully close the valve (note position
ofthe flat sections of the control shaft).

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

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

13 SPARE PARTS

Always provide the information in accordance
with the rating plate fitted on the mounting
flange when ordering seals and other
spareparts.

14 DISPOSAL

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

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

If the valve is passed on to a third party, the
manufacturer no longer guarantees the valve.

12 DECOMMISSIONING

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

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construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by
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