Orbinox EX Installation, Operation & Maintenance Manual

ORBINOX SPAIN

ORBINOX SPAIN ORBINOX SPAIN

ORBINOX SPAIN Pol.Ind. s/n-20270 ANOETA. Tel:[phone] Fax:[phone] e-mail:[e-mail]

ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL,ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE,

ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL,ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE, ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL,ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE,

ORBINOX CANADA, ORBINOX USA, ORBINOX BRAZIL,ORBINOX SPAIN, ORBINOX UK, ORBINOX FRANCE,
ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.

ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.

ORBINOX GERMANY, ORBINOX INDIA, ORBINOX CHINA, ORBINOX S.E.A.

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INSTALLATION, OPERATION &

MAINTENANCE MANUAL

MODEL

EX

EXEX

EX

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11-2011 EDITION

EX-2/13

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INDEX

INDEXINDEX

INDEX Page

0.- Description .........................………................................................................ .. 2

1.- Handling ..................................………....................................………………… 3

2.- Installation .................................……….....................................................….. 4

3.- Actuators .....................................………........................................................ 7

4.- Maintenance .....................................………................................................... 7

4.1.- Gland packing replacement …….………............................................ 8

4.2.- Seal replacement......………....…....……............................................ 9

4.3.- PTFE seal replacement ..…....…..........…............................................ 9

4.4.- Lubrication …………………….……………..…………………………..... 10

5.- Storage …………................................…..………............................................. 12

6.- Parts list & drawing ..................................………............................................. 13

0.- DESCRIPTION

The EX model knife gate is a uni-directional wafer valve designed for general industrial service
applications. The design of the body and seat assures non-clogging shut-off with suspended solids.

The EX valve complies with the following European directives:

- DIR 98/37/EC (machines)

DIR 98/37/EC (machines)DIR 98/37/EC (machines)

DIR 98/37/EC (machines)

- DIR 97/23/EC (PED)

DIR 97/23/EC (PED)DIR 97/23/EC (PED)

DIR 97/23/EC (PED) Fluid: Group 1 (b), 2 (Cat. I, mod.A)

It may also comply with the ATEX d

ATEX dATEX d

ATEX directive

irectiveirective

irective 94/9/EC (Explosive Atmospheres)

94/9/EC (Explosive Atmospheres) 94/9/EC (Explosive Atmospheres)

94/9/EC (Explosive Atmospheres) :

The EX valve may comply with the directive regarding equipment and protective systems for their
use in explosive atmospheres. In these cases, the logotype shall appear on the identification
label of the valve. This label shows the exact classification of the zone where the valve can be
used. The user will be liable for its use in any other zone.
This directive only applies in the following atmospheric conditions:

0,8 bar ≤ P ≤ 1,2 bar

-20ºC < T < 60ºC
Any increase in temperature due to frictional warmth is negligible, since the relative speed of
the moving parts is extremely low.
The risk analysis associated to this directive does not take into account the fluid that goes
through the valve, even when such fluid produces an explosive atmosphere. The user must take
into account the risks that the fluid generates, such as:

•

Heating of the valve surface.

•

Generation of electrostatic charges caused by displacement of the fluid.

•

Shock waves caused by the installation (water hammer), internal crashes generated by the
pellets or the risks due to foreign bodies susceptible of being present in the installation.

1.- HANDLING

The valves are packed according to the appropriate transport standards. If you receive the packing
damaged, please inform the transport company in writing and contact you Orbinox representative.

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When handling an Orbinox valve please pay attention to the following points:

•

Do NOT

Do NOT Do NOT

Do NOT attach lifting gear to the valve actuators or gate guards

attach lifting gear to the valve actuators or gate guardsattach lifting gear to the valve actuators or gate guards

attach lifting gear to the valve actuators or gate guards. They are not designed to

bear the weight, and could easily be damaged.

•

Do NOT lift the valve by the valve bore

Do NOT lift the valve by the valve boreDo NOT lift the valve by the valve bore

Do NOT lift the valve by the valve bore.
This can cause damage to the seating surfaces and seals.

•

Check that selected lifting gear is rated to carry the weight of the valve.

•

The valve can be handled using eyebolts, soft straps or slings.

•

Eyebolts: make sure the eyebolts have the same thread as the boltholes and they are all well
secured. Ideally when using lifting gear to move an Orbinox valve, it should be supported by
two or more eyebolts screwed into the tapped fixing holes in the valve body.

•

Soft straps: with the valve in the closed position, the straps should be placed between the
gland area and the bore such that the valve is balanced.

Fig. 1

Fig. 1 Fig. 1

Fig. 1 Handling

Handling Handling

Handling with eyebolts

with eyeboltswith eyebolts

with eyebolts

Fig. 2 Handling

Fig. 2 HandlingFig. 2 Handling

Fig. 2 Handling with

with with

with soft straps

soft strapssoft straps

soft straps

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2.- INSTALLATION

To avoid personal injury or damage to property from the release of process fluid:

•

Those in charge of handling and maintenance of the valve must be qualified and trained in
valve operations.

•

Use appropriate personal protection equipment (gloves, safety shoes, etc).

•

Shut off all operating lines to the valve and place a warning sign.

•

Isolate the valve completely from the process.

•

Release process pressure.

•

Drain the process fluid from the valve.

•

According to EN 13463

EN 13463 EN 13463

EN 13463----1 (15),

1 (15), 1 (15),

1 (15), during installation and maintenance operations, use hand

tools (non electric)

(non electric) (non electric)

(non electric) with Working Allowance.

Before installation, inspect the valve body and components for any damage that may have occurred
during shipping or storage. Make sure the internal cavities within the valve body are clean. Inspect the
pipeline and mating flanges, making sure the pipe is free of foreign material and that the flanges are
clean.

The valve is unidirectional. It should be installed with pressure exerted against the seat. The words
“SEAT SIDE” are marked on the valve body to indicate the position of the valve seat. Installation and
the correct orientation with respect to the direction of the flow is the responsibility of the user.

It should be noted that the direction of flow and differential pressure, do not always coincide.

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Special care should be taken to maintain the correct distance between the flanges and to ensure that
they are parallel to the valve body. Incorrect alignment of the valve can cause deformations, which can
lead to difficulties in operation.

The following table gives the maximum torque values for the valve fixing bolts. Also shown is the
maximum depth (T) allowed for the tapped blind boltholes drilled into the valve body.

DN

DNDN

DN 50

5050

50 65

6565

65 80

8080

80 100

100100

100 125

125125

125 150

150150

150 200

200200

200 250

250250

250 300

300300

300 350

350350

350 400

400400

400 450

450450

450 500

500500

500 600

600600

600 700

700700

700 800

800800

800 900

900900

900 1000

10001000

1000 1200

12001200

1200

T (mm)

T (mm)T (mm)

T (mm) 11 11 11 11 11 14 14 18 18 22 24 24 24 24 20 20 20 20 30

Kg.m

Kg.mKg.m

Kg.m 6 6 6 6 7 7 7 11 11 15 15 19 19 23 23 28 28 34 34

The valve can be mounted in any position with regard to the pipe. However, it is advisable to place it
vertically in horizontal pipeline (A) if the installation allows it. (Please consult the technical department
at Orbinox).

With larger diameters (> 300 mm), heavy actuators (pneumatic, electric, etc.), or with the valve
installed horizontally (B) or at an angle (C) on a horizontal pipeline, the installation will require the
construction of suitable supports. (See the following diagram and consult the technical department at
Orbinox).

B

B

A

CC

C*

A*

C*

* For these positions please consult Orbinox.

In vertical pipelines, the construction of suitable supports is always required (for further information
please consult the technical department at Orbinox).

Once the valve is installed, test that the flanges have been fastened correctly and that all electrical
and/or pneumatic connections have been properly made.

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These instructions must be observed when installing an Orbinox knife gate valve in an ATEX zone:

•

Make sure the valve is ATEX marked according to the requested zone and it includes all anti­static devices.

•

Check continuity between the body of the valve and the pipe (test in accordance with EN
12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).

•

This check must be done every time the valve has been removed from the line, serviced, and
put back to the line.

The operation of automated valves is limited only with fitted gate covers.

First, operate the valve with no flow in the pipeline. Then test operation and valve seal with flow. It
should be noted that the packing material might settle in shipping/storage, which can cause minor
leakage. This can be solved by tightening the gland follower (5) during installation. The nuts shall be
tightened gradually and crosswise until the leakage stops (see the next figure). Check that there is no
metal contact between the glandfollower (5) and the gate (2).

If the glandfollower nuts are overtorqued, the force needed to operate the valve will increase, the valve
function will be affected and the box packing lifetime will be shortened.

The table below shows the recomemended maximum torques for the glandfollower nuts.

DN

DNDN

DN Torque (N.m)

Torque (N.m)Torque (N.m)

Torque (N.m)

50 - 100 20

125 - 200 30

250 - 1200 35

Once performance has been tested, the valve can be put into operation.
Approximate weight of the handwheel-operated valve (rising stem):

DN

DNDN

DN 50

5050

50 65

6565

65 80

8080

80 100

100100

100 125

125125

125 150

150150

150 200

200200

200 250

250250

250 300

300300

300 350

350350

350 400

400400

400 450

450450

450 500

500500

500 600

600600

600 700

700700

700 800

800800

800 900

900900

900 1000

10001000

1000 1200

12001200

1200

Kg

KgKg

Kg 7 8 9 11 15 18 30 44 58 96 124 168 192 245 405 512 680 865 1055

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3.- ACTUATORS

3.1.- Handwheel
Turn the hand wheel (11) anticlockwise to open the valve. Turn the hand wheel clockwise to
close the valve.

3.2.- Lever
To operate the valve with this device, first loosen the locking clamp located on the top of the
yoke (8). Then either open or close the valve by moving the lever in the desired direction.
Finally, fix the position of the lever with the locking clamp.

3.3.- Pneumatic
Valves are usually supplied with a double acting pneumatic actuator although, upon request,
we can supply single-acting actuators. In either case the feed pressure can vary between 3,5
and 10 Kg/cm2.However, the size of the actuator for each valve has been designed for a feed
pressure of 6 Kg/cm2.
It is essential for a good maintenance of the cylinder that air should be well dried, filtered and
lubricated.
It is recommended to actuate the cylinder 3-4 times before the start up, once it is installed in the
pipeline.

3.4.- Electric actuator

Depending on the type or make of the electric actuator, specific instructions (i.e. a manufacturer’s
manual) will be supplied.

•

Allowed actuators for ATEX zones: Hand wheel, Chain Wheel, Bevel Gear, Lever, Pneumatic
Actuator (double acting ONLY

ONLYONLY

ONLY) and Electric Motor

•

Make sure these actuators are ATEX marked according to the requested zone.

•

Maximum travel speed of the gate must equal or below 0,05 m/s

4.- MAINTENANCE

The valve must not undergo any modifications without a previous agreement with ORBINOX.
ORBINOX shall not be liable for any damages that may arise due to the use of non original parts or
components

To avoid personal injury or damage to property from the release of process fluid:

•

Those in charge of handling and maintenance of the valve must be qualified and trained in
valve operations.

•

Use appropriate personal protection equipment (gloves, safety shoes, etc).

•

Shut off all operating lines to the valve and place a warning sign.

•

Isolate the valve completely from the process.

•

Release process pressure.

•

Drain the process fluid from the valve.

•

According to EN 13463

EN 13463 EN 13463

EN 13463----1 (15),

1 (15), 1 (15),

1 (15), during installation and maintenance operations, use hand

tools (non electric)

(non electric) (non electric)

(non electric) with Working Allowance.

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11-2011 EDITION

EX-8/13

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EX

The only maintenance required is to change the gland packing (4) or the seal (3) if the valve is a
resilient seated type.

The life of these components will depend on the working conditions of the valve such as: pressure,
temperature, abrasion, chemical action, number of operations, etc.

4.1.

4.1. 4.1.

4.1. ---- Replacement of the gland packing (4):

Replacement of the gland packing (4): Replacement of the gland packing (4):

Replacement of the gland packing (4):

1) Depressurise the circuit and place the valve in close position.

2) Remove the gate guards (for automatically actuated valves only).

3) - Rising stem valves. Photo 1: Release the spindle or stem (6) from the gate (2).

- Non rising stem. Photo 2: Release the stem nut from the gate (2).

Photo 1 Photo 2

4) Loosen the screws of the yoke (8) and remove it (without loosing the actuator).

5) Loosen the nuts of the gland follower (5) and remove it. (Photo 3)

6) Remove the old packing rings (4) and clean the stuffing box.

7) Insert the new packing rings (4), making sure that the ring joints alternate (the first on one

side of the gate, the next on the other and so on). (Photo 4)

8) Once the necessary packing rings (4) have been inserted, proceed with a steady initial

tightening of the gland follower (5).(Photo 3)

9) Place the yoke (8) (with the actuator) and screw it.

10) Fix the stem (6) to the gate (2)( Rising stem valves.Photo 1) or fix the stem nut to the

gate.(Non rising stem. Photo 2).

11) Remount the gate guards.

12) Carry out some operations with a loaded circuit and then re-tighten the gland follower (5)

to prevent leakage.

Photo 3 Photo 4

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4.2.

4.2.4.2.

4.2.---- Replacement of the seal (3) (only applicable to resilient seated valves):

Replacement of the seal (3) (only applicable to resilient seated valves): Replacement of the seal (3) (only applicable to resilient seated valves):

Replacement of the seal (3) (only applicable to resilient seated valves):

1) Remove the valve from the pipeline.

2) Remove the gate guards (for automatically actuated valves only).

3) Release the spindle or stem (6) from the gate (2).(Rising stem valves. Photo 1) or release

the stem nut from the gate.(Non rising stem. Photo 2).

4) Loosen the screws of the yoke (8) and remove it (without loosing the actuator).

5) Loosen the nuts of the gland follower (5) and remove it.(Photo 3)

6) Remove the old packing (4) and the gate (2) and clean the stuffing box.

7) Remove the seal retainer ring (10) which support the seals (3).

8) Remove the worn seal (3) and clean the seal housing.

9) Once the new seal (3) is cut according to size, insert it into the seat housing (making sure

that the union of the seal is at the top). (Photos 5 and 6)

If the valve has PTFE seal (3), follow the point 4.3.

Seal lengths

DN

DNDN

DN 50

5050

50 65

6565

65 80

8080

80 100

100100

100 125

125125

125 150

150150

150 200

200200

200 250

250250

250 300

300300

300 350

350350

350 400

400400

400 450

450450

450 500

500500

500 600

600600

600 700

700700

700 800

800800

800 900

900900

900 1000

10001000

1000 1200

12001200

1200

L

L L

L

(mm)

(mm)(mm)

(mm)

205 255 295 365 440 510 680 860 1020 1190 1350 1510 1630 2010 2350 2660 2945 3255 3915

Photo 5 Photo 6

10) Insert the seal retainer ring (10) by hammering gently around the edge. (Photos 7 and 8)

Photo 7 Photo 8

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11) Remount the gate (2).

12) Once the necessary packing rings (4) have been inserted, proceed with a steady initial

tightening of the gland follower (5).(Photo 3) following the steps of point 4.1.

4.3.

4.3. 4.3.

4.3. ---- Replacement of the PTFE seal (3):

Replacement of the PTFE seal (3): Replacement of the PTFE seal (3):

Replacement of the PTFE seal (3):

Follow the same procedure as point 4.2 but with following notes:

1. To obtain a tighter shut off in stainless steel valves (CF8M body), the machined housing of

the seat is sealed with plastic glue. This is not necessary in cast iron valves (GG25).
With the seal in this position:

2. Make a circle; joining the ends and making a heart-shaped form (see the following

diagram).

3. Insert both ends of the seal in the upper

side of the machined housing of the seat
(adjacent to the gland follower (5)), and
pushing the arched part with a finger,
insert the seal into the housing.
If the diameter of the valve is small
(DN≤150), a vice can be used.

4.4.

4.4.4.4.

4.4.----

Lubrication:

Lubrication:Lubrication:

Lubrication:
Twice a year, it is recommended to remove the protection cap (12) and fill up the stem
protector (13) halfway with a calcium-based grease with the following characteristics: highly
water resistant, low ash content, and excellent adherence.

Special requirements for ATEX valves

Special requirements for ATEX valvesSpecial requirements for ATEX valves

Special requirements for ATEX valves:

- The maintenance personnel must be made fully aware of the risks of explosion, and it is advisable

that they receive specific training regarding ATEX.

- Periodicity of check and evaluation of graphite packing status and valve electrical conductivity

must be determined by end user according to valve working conditions. In any case, once the
valve is put into operation, the packing area must be revised after the valve has been stroked 100

- times or after 3 months of operation, whatever happens first. After this preliminary check, new

checking periods must be determined by end user based on the results of this first check.

- Clean the valve periodically to prevent dust accumulation. Do not sweep or dump the dust. Always

use a vacuum cleaner system

- Dead en service is not allowed.

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- Do not apply any new coating to the valve. Should it require new coating, please contact our

closest representative.

- Allowed seals: EPDM, VITON, NITRILE, GRAPHITE and METAL (no seal)

- Allowed packing: ST and GRAPHITE packing

- Any other materials but those above are not allowed to be used in ATEX zones.

- In order to keep the ATEX approval, always use original spares from Orbinox.

•

Washer  DIN 6798A (This washer guarantees continuity among carbon steel parts, coated

in epoxy, yoke and body and stainless steel guards for coating thicknesses up to
200 microns)

•

ST and GR packing 

o ORBINOX ST: Synthetic packing impregnated with PTFE
o GR: Graphite packing  MONTERO Ecograflex 780R

- After any maintenance of ATEX valves, it is mandatory to check that the valve is earthed through

the pipe, and there is continuity among the different valve components, such as the body, the gate,
the supports, and guards (test in accordance with EN 12266-2 Standard, annex B, points B.2.2.2.
and B.2.3.1).

MAXIMUM FLUID TEMPERATURES

MAXIMUM FLUID TEMPERATURESMAXIMUM FLUID TEMPERATURES

MAXIMUM FLUID TEMPERATURES

Atmosphere

AtmosphereAtmosphere

Atmosphere

Gas/air, steam/air, an

Gas/air, steam/air, anGas/air, steam/air, an

Gas/air, steam/air, and mist/air

d mist/aird mist/air

d mist/air Dust/air

Dust/airDust/air

Dust/air

80% of minimum fluid ignition

temperature, minus 10ºK

2/3 of minimum dust cloud ignition

temperature minus 85ºK

Note: these maximum fluid temperatures apply to all categories. The differences between
categories are the consideration of foreseeable malfunction cases and rare malfunctions cases

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MAXIMUM

MAXIMUM MAXIMUM

MAXIMUM SEAL AND PACKING

SEAL AND PACKINGSEAL AND PACKING

SEAL AND PACKING TEMPERATURES

TEMPERATURES TEMPERATURES

TEMPERATURES

SEAL

SEALSEAL

SEAL

EPDM

EPDM EPDM

EPDM VITON

VITON VITON

VITON NITRILE

NITRILE NITRILE

NITRILE GRAPHITE

GRAPHITE GRAPHITE

GRAPHITE

Max Temperature

Max Temperature Max Temperature

Max Temperature

((((ºC)

C)C)

C)

120 200 120 600

PACKING

PACKINGPACKING

PACKING

ST

ST ST

ST GRAPHITE

GRAPHITE GRAPHITE

GRAPHITE

Max Temperature

Max Temperature Max Temperature

Max Temperature

((((ºC)

C)C)

C)

240 600

Note: Most of the times seals maximum temperature capacity is the key limitation factor when
evaluating valve maximum working temperatures. In ATEX zones these temperatures must be
compared to those above related to limitation of fluids temperatures.
Always consider the most restrictive as maximum valve working temperature.

5.- STORAGE

• For long storage periods keep the valves indoors in a safe and dry place and protect it from any

impact and or vibrations.

• Storing temperatures: -10ºC to +40ºC

• Valves must be stored in either full open or full closed position.

• For any component installed in the valves, electric motors, solenoid valves, etc, please refer to their

own instructions manuals

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6.- PARTS LIST & DRAWINGS

1.- BODY 8.- YOKE

2.- GATE 9.- COLLAR

3.- SEAL 10.- SEAL RETAINER RING

4.- PACKING RING 11.- HANDWHEEL

5.- GLAND FOLLOWER 12.- CAP

6.- STEM 13.- STEM PROTECTOR

7.- STEM NUT 14.- FRICTION WASHER