Spirax Sarco RJ216Z, GXM16Z, RJ205N, GXMZ, RJ Series Installation And Maintenance Instructions Manual
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3.531.5275.200 Issue 3 - 2015
EXPER
AINABILITY
RJ check valves
Installation and Maintenance Instructions
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
1. General safety information
TISE SOLUTIONS SUST
2. General product information
3. Quality control and storage
4. Installation
5. Commissioning
6. Maintenance
7. Spare parts
© Copyright 2015
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1. General safety information
A products’ safe operation is assured when they are properly installed, commissioned, used and
maintained by qualied personnel (see section 11 of the present instruction paper) according to the
operation instructions.
Compliance with installation and safety general instructions must also be observed during piping
and plant assembly together with an appropriate use of safety equipment and facilities.
1.1 Intended use
Referring to Installation and Maintenance Instructions, Name Plate and Technical Information Sheet,
check that the product is suitable for the intended use/application. The products listed below comply
with the requirements of the European Pressure Equipment Directive 97/23/EC and carry the mark,
when so required. The products fall within the following Pressure Equipment Directive categories:
Valve type PN
Group 1 Group 2 Group 1 Group 2
GXMZ 16 ½" - 2" - SEP - SEP
GXM16Z
65 - 100 - 1 - SEP
RJ216Z
65 - 100 - 1 - SEP
RJ205N 16 ½" - 2" - SEP - SEP
RJ205Z 16 ½" - 2" - SEP - SEP
SEP = not subjected to marking as per Para 3.3 of Directive 97/23/EC.
I) The products have been specically designed for use on steam, compressed air, water /
II) Check material suitability, pressure and temperature and their maximum and minimum values.
III) Determine the correct installation situation and direction of uid ow.
IV) Spirax Sarco products are not intended to withstand external stresses that may be induced
V) Remove protection covers from all connections and protective lm from all name-plates, where
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condensate, dyatermic oil or other uids that are in Group 2 of the above mentioned Pressure
Equipment Directive. The products’ use on other uids within Group 2 may be possible but, if
this is contemplated, Spirax Sarco should be contacted to conrm the suitability of the product
for the application being considered.
If the maximum operating limits of the product are lower than those of the system in which
it is being tted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.
by any system to which they are tted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
appropriate, before installation on steam or other high temperature applications.
DN
15 - 50 - SEP - SEP
15 - 50 - SEP - SEP
Gas Gas Liquid Liquid
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: ammable materials, substances hazardous to health, extremes of temperature.
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1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, re hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the eect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel at
risk? Dangers might include isolation of vents or protective devices or the rendering ineective
of controls or alarms. Ensure isolation valves are turned on and o in a gradual way to avoid
system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects and
dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the product according
to the Installation and Maintenance Instructions. Where a formal ‘permit to work’ system is in force
it must be complied with.
Where there is no such system, it is recommended that a responsible person should know what
work is going on and, where necessary, arrange to have an assistant whose primary responsibility
is safety. Post ‘warning notices’ if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.
1.13 Residual hazards
During ordinary use, the external surface of the product may be extremely hot. If any product
is employed at limit working conditions, their surface layer warmth may reach the temperature
of 200°C. Many products are not self-draining: consider it when disassembling or removing the
product from the plant (refer to "Maintenance" paragraph).
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.
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1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law,
when returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present
a health, safety or environmental risk.
This information must be provided in writing including Health and Safety data sheets relating to
any substances identied as hazardous or potentially hazardous.
1.17 Working safely with cast iron products on steam
Cast iron products are commonly found on steam and condensate systems. If installed correctly
using good steam engineering practices, it is perfectly safe.
However, because of its mechanical properties, it is less forgiving compared to other materials
such as SG iron or carbon steel.
The following are the good engineering practices required to prevent waterhammer and ensure
safe working conditions on a steam system.
Safe Handling
Cast Iron is a brittle material. If the
product is dropped during installation
and there is any risk of damage the
product should not be used unless it
is fully inspected and pressure tested
by the manufacturer.
Please remove label before
commissioning.
Prevention of water hammer
Steam trapping on steam mains:
Steam
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30÷50 m. intervals
Gradient 1:100
Trap set
Condasate
Gradient 1:100
Trap set
Condasate
Steam
Trap set
Condasate
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Steam Mains - Do’s and Dont’s:
Prevention of tensile stressing
Pipe misalignment:
Installing products or re-assembling after maintenance:
Do not over tighten.
Use correct torque gures.
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Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
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Thermal expansion:
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guides
Axial movement
Short distance
Guides
Medium
distance
Fixing point
Limit rods
Fixing point
Limit rods
Guides
Guides
movement
Small
lateral
Small
lateral
movement
Large
lateral
movement
Axial movement
Large
lateral
movement
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2. General product information
2.1 Utilization
Stop valves GXM series are designed to interrupt the passage of uids in the plant. They are manually
controlled by the provided handwheel that can be opened by rotating the handwheel counterclockwise
and closed by rotating the handwheel in clockwise direction. These valves aren’t provided and can’t
be used for ow control pourpose.
Check valves RJ series are designed to open when subjected to a dierential pressure enough to
exceed the strength exercised from the weight of the valve spring loaded plug (0,1 bar).
Check valves RJ205Z and RJ205N are designed to open when subjected to a dierential pressure
enough to exceed the strength exercised from the weight of the valve plug.
2.2 General description
Stop valves GXM series are provided both with threaded or with anged connection. The bonnet
is enbloc type for threaded valves and bridge type for anged connections. The spindle seal is
graphite ring type.
Valves RJ216Z are lift check valves with in line connections. The construction is with anged
connections.
Valves RJ205Z and RJ205N are lift check valves with in line connections. The construction is with
threaded gas female connections.
Type Material Size Connections PN
GXMZ DIN GG25 ½" - 2" UNI-ISO 7/1 gas 16
GXM16Z DIN GG26 15 - 100 UNI 2237 - 2229 16
RJ216Z DIN GG27 15 - 100 UNI 2237 - 2229 16
RJ205Z DIN GG28 ½" - 2" UNI-ISO 7/1 gas 16
RJ205N RG5 7 OT58 ½" - 2" UNI-ISO 7/1 gas 16
2.3 Limiting conditions
Body design conditions PN 16
PMA - Maximum allowable pressure 16 bar g
TMA - Maximum allowable temperature
GXMZ, GXM16Z, RJ205Z, RJ216Z 200°C
PMO - Maximum operating pressure 16 bar g (rating PN 16)
TMO - Maximum operating temperature
GXMZ, GXM16Z, RJ205Z, RJ216Z 200°C
Designed for a maximum cold hydraulic test pressure of 24 bar g
RJ205N 180°C
RJ205N 180°C
2.4 Operating ranges
GXMZ
GXM16Z
RJ216Z
RJ205Z
The product must not be used in this region
A-B-C Restriction imposed by PTFE gasket for RJ205N
8
180
A
Temperature °C
Steam
saturation
curve
B
C
Pressure bar g
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Fig. 1
GXMZ Stop valve
Fig. 2
GXM16Z Stop valve
Fig. 3
RJ216Z Check valve
Fig. 4
RJ205Z Check valve
Fig. 5
RJ205N Check valve
3. Quality control and storage
3.1 Control upon receipt
All the valves upon receipt must be examined to check they have not suered injuries during the
transport. Detection of possible problems must be promptly communicated to Spirax Sarco.
Likewise it is necessary to verify the compatibility between the plant features in which will be installed the valves and the specications of the supplied product. Check the correctness of maximum
temperature, pressure and uid limits (see the valve label and refer to this handbook).
In case of doubt, contact Spirax Sarco.
3.2 Storage
All the valves must be stored in dry and covered place, properly protected from both atmospheric
agents, dirt and any other foreign body that may result harmful.
Valves must be protected until installed on the plant. Protective covers for connections and anges
must not be removed until the installation of the valves on the plant.
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4. Installation
Note: before actioning any installing operation observe the ‘General safety information’ in
Section 1.
4.1 General rules
Unpack the valve and remove protective covers from the joints, taking care that any dust or dirt can
not enter into the valve. Subsequently, visually verify that the appliance is intact and haven’t suered
damages due to transport and storage; otherwise do not proceed to installation.
Check again that the label’s data are compatible with plant’s requirements.
Check that no pressure exists in the plant and that the piping is clean, carefully blown and free from
foreign bodies that may cause irreversible damages to the seal between seat and plug. Damages
caused by particles of dust or dirt are not under warranty.
4.2 Installation
Valves may be installed on the piping in any position, in any case preferential arrangement may be
with handwheel or cap upwards; only the check valves model RJ205 must be installed on horizontal
pipe with the cup oriented upward.
It is always necessary to respect the ow direction, indicated by the arrow marked on the body of
the valve. Inlet and outlet piping must be appropriately supported and aligned, and pipe expansions
must not generate stress to the valves as they are not designed to withstand it. While positioning and
welding the piping, valve must be properly xed and supported. Threaded valve clam ping must not
involve further stresses to the equipment and the material employed for joints must be appropriate
and compatible with plant requirements and specications.
Flanged connections must be accurately cleaned to assure perfect positioning and tightness of the
gasket. Gasket must be perfectly centred to avoid obstruction inside the passages. Allow a safe
access and free space all around the handwheel to carry out work. Flange bolts must be tightened
following crossed sequence, adequate to obtain co planarity and uniform clamping.
Do not proceed to tighten the bolts in lack of co planarity or when anges are excessively spaced.
During painting works, protect the valve stem. Before commissioning the plant and in any case after
maintenance works, piping must be accurately washed and blown, keeping the valve completely
opened to remove every possible foreign body.
4.3 Hydraulic test
When an hydraulic test of the plant is required, the declared test pressure must never been
exceeded.
5. Commissioning
After installation or any maintenance work, check the whole operativeness of the system and test
all the alarms and protection devices.
To commission the plant, slowly increase the pressure, avoiding sudden pressure and temperature
variations; simultaneously check presence of leakages at piping connections and on the body of
the valve, till achievement of working full pressure. This process is hazardous, and must be worked
out with the utmost care.
In leakage case, immediately relive the pressure proceed with appropriate action to restore the
tightness.
Sizes of handwheels are proportioned to the driving force required for the operation of the valve.
For no reason supplementary levers should be employed. to operate the valve.
Regular operativeness has to be controlled carrying out some opening and closing cycles.
For GXM threaded valves, in case of leakage of shaft seal, the graphite packing rings must be
compressed by tightening the provided threaded nut of the stufng box, while with anged valves
the compression must be done by clamping the two stufng box nuts.
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6. Maintenance
Note: Before actioning any maintenance operation observe the ‘General safety information’
in Section 1.
Maintenance operations must be carried out by qualied sta, properly equipped and provided with
original spare parts.
Before disassembling the valve from the plant, disconnect and adequately support the concerned
pipe parts.
6.1 When carry out maintenance
It is advisable to check the valve after some time, to solve simple problems that may become
dangerous in the future. Such period of time depends on features and eective use of the plant (type
of uid, temperature, pressure, etc.) and must be xed from the person in charge of plant maintenance.
6.2 Basic controls
To guarantee safe and enduring use of the tted valves, the following inspections should be
performed:
- Visual inspection of the body: visually check searching for appeared roughness, possible
aroused damages, corrosion or erosion.
- Lubrication of the stem: it is recommended to apply to the stem thread a small quantity of
graphite-based or copper-based grease to avoid irregular friction or jamming.
- Checking of the body-cover and of ange-bolts clamping: after the use of the valve in a
continuous cycle of the plant, it is recommended to verify the tightening of components.
6.3 Operation for leakages
- Leakage of connections: it is necessary to depressurize the system and replace the gaskets,
referring to section 4, “Installation”.
- Leakage between valve seat and plug: this fault is generally caused by foreign bodies entrapped
between the inner valve surfaces; the use of the valve in such a situation over an extended period
of time could cause irreparable damages. The prompt intervention, grinding the seat and plug can
restore the functionality.
- Stem packing leakage: this is the most frequently worn out point of the valve; it is therefore
required to carry out periodic compression of graphite rings referring to work conditions.
- Procedure for compression of stem packing ring: depressurize the system.
For threaded valves GXMZ series, tighten the compression nut of the rings; for valves GXM16Z
series tighten alternatively the ange compression nuts, paying attention to maintain it perpendicular to the stem axis. It should be noted that the compression of the gasket rings increases the
operating torque of the valve. Should this operation fail to restore tightness, it is required to replace
the rings.
- Leak between body and cap: depressurize the system.
• For GXM valves always operate with open plug; unscrew the threaded cap or loosen the
screws which x the cap to the valve body, acting alternatively and with crossing procedure.
Verify integrity and good conditions inside the valve body. Remove the old body gasket and
accurately clean the contact surfaces. Using a new gasket, ret the parts and, in case of bridge
cap, tighten the bolts alternatively and with a crossing procedure.
• For RJ216Z check valves, loosen the xing screws between body and cap alternatively and
with a crossing procedure. Pay attention to the thrust of the plug internal spring. Verify integrity
and good conditions of the inside valve body. Remove the old body gasket and accurately clean
the contact surfaces. Using a new gasket, ret the parts and tighten the bolts alternatively and
with a crossing procedure.
• For RJ205Z and RJ205N check valves, unscrew the cap and verify clearness and good
conditions inside the valve body. Remove the old gasket and accurately clean the contact
surfaces. Using a new gasket, carry out the assemblage and clamp the cap.
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7. Spare parts
Place orders for spare parts always indicating the spare designation and valve model and diameter.
Model Spare designation
Stem seal (n° 10 rings)
GXMZ
Body seal (n° 5 o)
GXM16Z
Body seal (n° 5 o)
RJ216Z Body seal (n° 5 o)
Stem seal (n° 10 rings)
SERVICE
For technical support, please contact our local Sales Engineer or our Head Ofce directly:
Spirax Sarco S.r.l. - Technical Assistance
Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Italy
Tel.: (+39) 0362 4917 257 - (+39) 0362 4917 211 - Fax: (+39) 0362 4917 315
E-mail: support@it.spiraxsarco.com
LOSS OF GUARANTEE
Total or partial disregard of above instructions involves loss of any rights to guarantee.
Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307
3.531.5275.200 Issue 3 - 2015.12
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