Contents 1 Preface 3 2 Introduction 3 3 Safety
Contents
1. a Shipham Valves ESTABLISHED 1798 Revision 01 Shipham Valves Hawthorn Avenue Hull HU3 5JX United Kingdom Tel 44 0 1482 323163 Fax 44 0 1482 224057 web http Avww shipham valves com email sales shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 This revision supersedes all previous revisions Date 8 July 2008 Contents 1 Preface 2 Introduction 3 Safety Precautions 4 Valve Description 4 1 General 4 2 Butterfly Valve 4 3 Valve Characteristics 5 Handling and Storage 5 1 Handling 5 2 Storage 6 Installation 6 1 Inspection Prior to Installation 6 2 Installation 6 3 Testing 7 Operation 8 Maintenance 8 1 Routine Scheduled Maintenance 8 2 Breakdown Maintenance 8 2 1 General Leak via the Flange 8 2 2 Butterfly Valve Not Sealing Correctly When Closed 8 2 3 Butterfly Valve Shaft Leak 9 Spare Parts 9 1 For 2 Piece Taper Shaft Butterfly Valves 9 2 For 1 Piece Parallel Shaft Butterfly Valves 10 PPE RHR WO WD Q aon Oo Ol ou 10 10 If in doubt please contact Shipham Valves Page 1 of 9 ie Revision 01 Shipham Valves isese web http www shipham valves com ESTABLISHED 1798 email sales shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 Date 8 July 2008 This revisio2. Shipham Valves Page 4 of 9 ie Shipham Valves isese web http www shipham valves com ESTABLISHED 1798 email sales shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 Revision 01 Date 8 July 2008 This revision supersedes all previous revisions OPERATION Check for smooth operation In high volume liquid flow when closing the valve do not close the valve too quickly as this may induce a pressure surge water hammer MAINTENANCE 8 1 Routine Scheduled Maintenance It is recommended to schedule a periodic partial or full cycle of exercising of valves which remain in either the open or closed position for long periods of time e Check for smooth operation e Check for leaks from the flanges and valve stem e On ball valves leaks from the valve stem can be stopped by tightening the chevron packing on to the stem using the gland packing plate adjustment each nut should be tightened equally until the gland stops leaking 8 2 Breakdown Maintenance 8 2 1 General Leak via the Flange Cause Valve not being centred in the pipe centreline Solution Remove the valve actuating mechanism Remove valve from pipeline check flanges for damage repair if necessary Inspect gaskets for damage replace if necessary Install valve in accordance to the installation instructions supplied with t
3. actuating mechanism Remove valve from pipeline It is recommended to replace entire valve Install valve in accordance to the installation instructions supplied with the valve Reconnect the valve actuator Cause Actuator incorrectly adjusted Solution Check that the disc is stopping at 90 Adjust actuator see actuator manufactures installation information Cause Incorrectly adjusted closure limit stop Solution Remove the valve actuating mechanism Remove valve from pipeline Close the valve Insert and tighten a short socket head screw into the end of the eccentric cam pin Loosen the cam locking grub screw accessed via the treaded hole in the end of the shaft Rotate the cam pin away from the stop face Close the valve fully to the point that the flat of the disc is parallel with the face of the valve body Rotate the cam pin until it comes into contact with the stop face Tighten the locking grub screw Remove the short socket head screw from the end of the eccentric pin Open and close the valve and retest for parallelism If required make further adjustments following the previous steps Install valve in accordance to the installation instructions supplied with the valve Reconnect the valve actuator If in doubt please contact Shipham Valves Page 6 of 9 1 Revision 01 OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 A Shipham Valves tsi web ht
4. using isocyanate glue If a new disc assembly has been used it will be necessary to adjust the closure limit stop as detailed above Install valve in accordance to the installation instructions supplied with the valve Reconnect the valve actuator If in doubt please contact Shipham Valves Page 8 of 9 ie Revision 01 Shipham Valves isese ESTABLISHED 1798 email sales shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 This revision Ss Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 web http Avww shipham valves com SPARE PARTS DISCLAIMER For general operating conditions no spare parts are required For heavy duty erosion high frequency cycling the following spare parts are recommended for spares holding 9 1 For 2 Piece Taper Shaft Butterfly Valves Shaft seal 2 per valve Small o ring 2 per valve Large o ring 5 per valve Thrust washer 2 per valve 9 2 For 1 Piece Parallel Shaft Butterfly Valves Small shaft seal 1 per valve Large shaft seal 1 per valve Small o ring 2 per valve Large o ring 3 per valve Thrust washer 2 per valve Locking pin 2 per valve Devcon Titanium loaded epoxy resin Araldite 2014 While Shipham Valves has taken all reasonable care to ensure the information contained herein is accurate this document is provided as is and Shipham Valves makes no warranty no warranty
5. ently tap the shaft whilst hand tightening this will be sufficient force to correctly assemble the valve Insert a new resin plug into the bottom of the valve and secure using isocyanate glue If a new disc assembly has been used it will be necessary to adjust the closure limit stop as detailed above Install valve in accordance to the installation instructions supplied with the valve Reconnect the valve actuator Solution for 1 piece parallel shaft Note For specialist applications acids caustics solvents etc it is important that the valve be replaced or returned to AVT for refurbishment Remove the valve actuating mechanism Remove valve from pipeline Remove the resin plug from the bottom of the valve this is lightly glued in place and is sacrificial Remove screw and corresponding washer if applicable PTFE washer from bottom of the shaft If disc locking pins have been used it will be necessary to use a 12mm masonry drill to remove the Epoxy material sealing the pins and drive out the securing pins from the flat face of the disc If in doubt please contact Shipham Valves Page 7 of 9 ie Revision 01 Shipham Valves isese E S TABLI S HED 1798 web http Avww shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 email sales shipham valves com Date 8 July 2008 This
6. he valve Reconnect the valve actuator Cause Valve and pipeline flange dimensions incompatible Solution Remove the valve actuating mechanism Remove valve from pipeline Mount flanges with the correct sealing area Inspect gaskets for damage replace if necessary Install valve in accordance to the installation instructions supplied with the valve Reconnect the valve actuator 8 2 2 Butterfly Valve Not Sealing Correctly When Closed Cause Damage of the sealing area by foreign parts Solution Remove the valve actuating mechanism Remove valve from pipeline inspect sealing area for damage Repair minor damage by dressing valve seat and disc seal using fine abrasive paper or an abrasive block no coarser than 120 grit finish with 400 grit more extensive damage will require valve replacement If in doubt please contact Shipham Valves Page 5 of 9 ie Revision 01 Shipham Valves isese web http www shipham valves com ESTABLISHED 1798 email sales shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 Date 8 July 2008 This revision supersedes all previous revisions Install valve in accordance to the installation instructions supplied with the valve Reconnect the valve actuator Cause Wear of sealing surface Solution Remove the valve
7. maintain the valves and components supplied under this contract Inappropriate installation use and maintenance will invalidate the warranty On actuated valves there is the potential of stored energy in the form of springs electric pneumatic or hydraulic therefore care must be taken that the energy is release or removed in a controlled manor Always avoid contact with the ball or disc when it may cycle Take the necessary precautions when handling large valves and valve components VALVE DECSRIPTION 4 1 General The valve body is manufactured from a composite material that is light weight strong and corrosion resistant The body of the valve has been designed as a pressure containing part it has been tested to a pressure above the normal working rated pressure The body has end connections for mounting between pipe flanges 4 2 Butterfly Valve The body has two apertures for securing the single shaft the shaft extends out from the body and is used to operate the disc by the actuation device The disc is circular device that can rotate on the axis of the shaft by approximately 90 the sealing of the valve is performed when the valve disc is perpendicular to the pipeline this is ultimately achieved by an elastomer material on the outer edge of the disc mating with the fixed valve seat on the body of the valve When the valve disc is parallel to the pipeline the valve is fully open The end of the valve shaft indicated the disc orientati
8. n supersedes all previous revisions DESCRIPTION PREFACE INTRODUCTION SAFETY PRECAUTIONS THIS COVERS AVT BUTTERFLY VALVE RANGE This document is a manual for ball and butterfly valves it is intended for system engineers and users For instructions regarding the actuation devices see the actuator user manual When mounted in a pipeline system in Europe the valve actuator unit may become a component on which the European directives are applicable The end user and system engineer shall complete the certification procedure for the CE marking if applicable This manual gives instructions for the system engineer and end user regarding the installation and use of the butterfly and ball valves in flanged pressurised piping systems This manual shall be reviewed in detail prior to handling and installation and kept in the documentation file for future reference It is therefore recommended that these maintenance instructions are incorporated into the total system maintenance instructions The valves are intended as isolation valves they may under certain circumstances be used as a control valve depending on the process and having an appropriate actuator fitted The ball valves are suitable for bi directional flow however the butterfly valves have a preferred direction and must be installed in the correct orientation the body of the butterfly valve indicates the preferred direction The valve materials used in the body shaft and
9. of any kind with respect to accuracy of the information Shipham Valves cannot be held responsible for normal wear and tear any improper installation use maintenance or storage negligence of the owner or user unauthorised repair or modification after delivery failure to follow instructions or recommendations or anything else beyond our control Shipham Valves reserve the right to amend the information without notice If in doubt please contact Shipham Valves Page 9 of 9
10. on 4 3 Valve Characteristics The valve test certificate supplied with the valve details the specific valve characteristics The valve is designed and tested for a maximum working pressure The valve components are selected to withstand the minimum and maximum service temperature component selection takes account of the process fluid that the valve will be exposed to If in doubt please contact Shipham Valves Page 3 of 9 ie Revision 01 Shipham Valves isese web http www shipham valves com ESTABLISHED 1798 email sales shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 Date 8 July 2008 This revision supersedes all previous revisions INSTALLATION The valve shall be properly inspected and installed 6 1 Inspection Prior to Installation e Carefully unpack the valve e Inspect the valve visually for damage during transport handling and storage e Check the identification plate attached to the side of the valve correctly fulfils the intended application requirements Check the valve interior is clean free of foreign matter and damage e f practical actuate the valve through open and closed cycles check that the valve functions smoothly and correctly avoid contact with the ball disc when cycling the valve Immediately prior to installation check that the flanges
11. revision supersedes all previous revisions Set the disc to the open position Carefully hammer out the shaft or using a hydraulic press and suitable mandrel screwed into the lower end of the shaft push out the shaft from the valve Remove the disc Remove the disc and spacers that are located are either side of the disc Clean any resin reside from the shaft Remove remaining pin sections Replace the failed components if appropriate the use of silicone grease will ease assembly of the elastomer o rings and shaft seals Using a small amount of Devcon titanium loaded epoxy resin in a ratio of 4 3 parts of resin to 1 part of hardener by weight lightly coat the short tapered section of the shaft Assemble the valve disc with spacers either side on to the valve body Slide shaft into valve body spacer disc and spacer tap home gently Insert and corresponding washer from bottom of the shaft and hand tighten Allow the epoxy to cure for a minimum of 1 hour Press lightly tap in replacement pins so that they are sub flush with the disc by a minimum of 5 mm Create a header tank around one of the disk hole using blue tack or similar and fill with Araldite 2014 epoxy resin until the resin floods from the second hole Note it is important to coat the shaft with mould release to enable disassembly at a later date Allow the epoxy to cure for a minimum of 16 hours Remove excess epoxy Insert a new resin plug into the bottom of the valve and secure
12. seat components are selected based on anticipated system conditions they must be chemically and physically compatible with the line fluids rinsing fluids and other connecting pipe components Follow carefully all instructions in this manual with respect to handling installation operation and maintenance Not observing the recommendations and cautions in this manual will decrease the assurance of safe and satisfactory valve performance When the valves are used in a hazardous location all electric components e g solenoids actuators shall comply with the relevant or application standard relating to the hazard Do not operate the valve with system pressures higher than allowable for the valve Do not operate the valve with system temperatures lower or higher than allowable for the valve Do not operate the valve with system fluids other than those specified for use with the valve If in doubt please contact Shipham Valves Page 2 of 9 ie Shipham Valves isese web http www shipham valves com ESTABLISHED 1798 email sales shipham valves com OPERATING AND MAINTENANCE INSTUCTIONS OMI 12 2 Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 Revision 01 Date 8 July 2008 This revision supersedes all previous revisions Only appropriately qualified and competent personnel are to place into operation operate withdraw from operation and
13. to which the valve is to be fastened are parallel are set apart the correct distance and will not cause the valve to be placed under stress are without burrs free from oil or other contaminants 6 2 Installation e The valve is designed to be installed with gaskets the selection of these should take account of the pipeline size and process fluid pressure and temperature Take account of the flow direction if the valve is mono directional The orientation of the valve within the pipe line is not important Make sure that the valve is located were it can be operated maintained and inspected e Check that the valve fixings to be used are the correct length size and are suitable for the environmental conditions It is important to use washers of the correct size Offer the valve into position and secure Tighten the bolts studding in the correct tightening sequence and to the correct torque as indicated in the data supplied with the valve 6 3 Testing e f possible flush the line with a compatible rinsing liquid e Open and close the valve to ensure that there is no interference e Connect the actuator if applicable according to the actuators installation information Warning A system test at a pressure higher that the working pressure shall only be performed with the valve in the open position It is recommended that pressure testing only be undertaken with water and taking into account all safety precautions If in doubt please contact
14. tp www shipham valves com ESTABLISHED 1798 email sales shipham valves com Shipham Valves Hawthorn Avenue Hull HU3 5JX Tel 44 0 1482 323163 Fax 44 0 1482 224057 Date 8 July 2008 This revision supersedes all previous revisions 8 2 3 Butterfly Valve Shaft Leak Cause Shaft seal is worn aged or damage Solution for 2 piece taper shaft Remove the valve actuating mechanism Remove valve from pipeline Remove the resin plug from the bottom of the valve this is lightly glued in place and is sacrificial Remove bolt and corresponding washer from bottom of the shaft Set the disc to the open position Insert a drift through the screw hole taking care not to damage the tread lightly tap out the shaft Insert a drift in the main shaft aperture and lightly tap out the lower shaft sleeve Remove the disc and spacers that are located either side of the disc Replace the failed components if appropriate the use of silicone grease will ease assembly of the elastomer o rings and shaft seals Insert the lower shaft sleeve Assemble the valve disc with spacers either side on to the valve body note the taper hole in the disc is correctly oriented to accept shaft assembly Slide shaft into valve body spacer disc spacer and then into lower shaft sleeve note the flat on the shaft will be facing the curved face of the disc Insert the bolt and corresponding washer from bottom of the shaft and hand tighten finally g
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