BA 4.9_EN - Ebro Armaturen
Contents
1. and order spare parts from EBRO ARMATUREN Disassemble the motor unit loosen the bolting 11 of the shaft cartouches 2 and 3 Disassemble the cartouches Attention Check and note the number of centring washers at each side 2 and 3 for correct re assembling If not the lead of the wing wheel will not remain exactly centred Leakage at the shaft seal Then replace the shaft seals 2c 3c and the O ring set 2a 3a and re assemble the centring washers10 in the position as documented be fore Check that the impeller wheel rotates without visible friction if not reassemble the centring washers10 accordingly Note To protect the shaft seal function it is recommended to replace these spare parts or to let it replace by EBRO ARMATUREN as a preven tive maintenance in an adequate period Observe clause B5 lt Disassembling gt If the motor unit control circuit is without fail Disassemble the valve observe clause B5 Disassembling Fail of function and inspect the valve functional parts At any valve defect Send back the valve to EBRO ARMATUREN for repair Ug EBRO ARMATUREN Seite 9 WS INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M D Technical annex planning documents Note This annex is no integral part of the Instruction BA 4 9 but is an extract from the EBRO catalogue sheets Impeller valve More details may be found in this document D1 Technical specification of2. INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M Installation in the pipe system Functional check This instruction gives safety warnings for installation of valves in the pipe system The user shall complete this instruction with all necessary information that are necessary for the in site pipe system More safety information may be included in the relevant manual of the actuator e Installation shall be performed by qualified personal Qualified are those persons who due to experience can judge the risk and execute the work correctly and who are able to detect and to eliminate possible risks e After installation the function of the valve shall be in accordance with the Valve and the actuator destination as defined in clause A2 e An impeller valve supplied without motor unit shall not be fed with bulk goods e A valve with an actuator unit shall be actuated only if is installed with a feed hopper at inlet and a protecting section of the pipe system at outlet any action before is a danger to squeeze one s hand or fingers and is the risk of the user only e An impeller valve that has an open end in the pipe or vessel section shall be pro vided with a protecting device to eliminate any danger for the personnel Preconditions for installation Ensure to install those impeller valves only that fit with layout body and wheel material to the plant destination see the relevant data in the valve mar
3. Series FS M e with unit electric motor e or with other actuating device is a not completed machine within the meaning of the European Directive 2006 42 EC but conforms to this directive The Table page 2 of this declaration lists clauses with conformance to 2006 42 EC the EBRO installation operation instruction no lt BA 4 9 gt for the valve shall be observed the valve installed into the pipe system shall not be put into operation before the confor mance of this pipe system to the requirements of the Directive 2000 42 EC has been declared that in case of a reasoned request EBRO ARMATUREN obligates himself to transmit relevant documentation on the partly completed machinery to national authorities This shall be without prejudice to the intellectual properly rights of the manufac turer The responsible person for this documentation is Mr G nter Kipp in the company EBRO ARMATUREN GmbH 58135 Hagen Germany declares that for the valve Technical Standards used EN 12100 Safety of machinery General design requirements Any modification of the valve and or the valve actuator unit which changes the design and or the valve application other than specified in clause 1 valve destinations invalidates this declaration Hagen Datum 30 09 2013 m Peter Br er General manager N Seite 12 EBRO ARMATUREN INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M Requirement of Machiner
4. from pressure and if necessary empty e Disconnect all electric and or pneumatic hydraulic connections e f necessary observe clause A4 to fix the lifting devices at the valve e Disassemble the flange bolting spread the counter flanges as much as necessary to take out the valve without damage at the protuberant impeller wheel e Take out the impeller valve and store it as described in clause A4 If a valve is disassembled from a pipe with contaminative pulp good All inside surfaces shall be decontaminated properly before any other handling Warning At disassembling of the valve D O rings and shaft seal shall not come in contact with oil or grease specifically not with oil or grease of mineral substance EEUU T nmm Seite 7 EBRO ARMATUREN INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M C Normal service and inspection The user of the system shall make a risk analysis as per Machinery and the Pressure Directive 2006 42 EC and the Pressure Directive 97 23 EC For that analyse EBRO ARMATUREN supplies the following documents e his Original installation and service instruction for the impeller valve e he manufacturer s declaration to EC Directives added in the end of that instruction This instruction includes safety warning notes for industrial application for foreseeable risk at use of the valve only It is the responsibility of the user plant designer to complete these warnings for specif
5. wheel in the intermediate open position to flush the pipe section e Finally make a functional test with pipe empty respecting the electric data at the motor mark ing The motor unit assembled to the impeller shall smoothly without friction execute all func tions initiated by the control circuit and shall stop at all criteria defined in the end of clause B2 EBRO ARMATUREN Seite 6 ar J INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M e Defaults of signals and signalisation could mean danger for the health of the user and or cause damage in the piping system Any functional default of the valve actuator unit should be repaired before start up observing clause C3 Troubleshooting B4 Pressure test before start up The impeller valve has been pressure tested by the manufacturer as per EN12266 1 If a pipe system pressure test is necessary observe e he test pressure shall be limited to 1 5x PS or the relevant fluid level see valve nameplate The impeller wheel shall not be in closed position at the valve waterway e Do not test the valve with the impeller wheel in CLOSED position at more than 3 bars or more than 1 bar at DN gt 300 Otherwise the wheel could be damaged B5 Additional information Disassembling For the valve the same safety instructions apply as at installation see clause B1 Disassemble the valve in the following sequence e Check the pipe section vessel to be released free
6. EBROARMATUREN BA 4 9 DGRL MRL bu 4 Impeller valve Series FS M for pulp powdery granular and paste goods DN150 DN400 Original installation instruction With service instruction and technical annex as per EC Pressure Direction 97 23 EG as per EC Machinery Direction 2006 42 EG English version Revision 00 09 13 INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M Contents Page A GENERAL 3 A1 SYMBOLS 3 A2 VALVE DESTINATION 3 A3 VALVE MARKING 4 A4 TRANSPORT AND STORAGE 4 B INSTALLATION IN THE PIPE SYSTEM FUNCTIONAL CHECK 5 B1 SAFETY WARNINGS AT INSTALLATION 5 B2 PRECONDITIONS FOR INSTALLATION 5 B3 STEPS AT INSTALLATION 6 B4 PRESSURE TEST BEFORE START UP 7 B5 ADDITIONAL INFORMATION DISASSEMBLING 7 C NORMAL SERVICE AND INSPECTION 8 C1 IMPORTANT SAFETY WARNINGS AT SERVICE AND MAINTENANCE 8 C2 AUTOMATIC SERVICE 8 C3 TROUBLESHOOTING 9 D TECHNICAL ANNEX PLANNING DOCUMENTS 10 D1 TECHNICAL SPECIFICATION OF THE VALVE 10 D2 ADMISSIBLE PRESSURE 10 D3 ADMISSIBLE SERVICE TEMPERATURE 10 D4 DRAWING PART LIST 10 D5 SPARE PARTS 11 D6 FLANGE BOLTING 11 MANUFACTURER S DECLARATIONS 12 This manual EBRO catalogue sheets and other information even in other language may be asked from www ebro armaturen com or from EBRO ARMATUREN GmbH KarlstraBe 8 D 58135 Hagen 43 02331 904 0 Fax 02331 904 111 post ebro armaturen com ne er eee Seite 2 EBRO ARMATUREN INS TALLATION AND OPERAT
7. ING INSTRUCTION IMPELLER VALVE SERIES FS M A General A1 Symbols Warning notices and tips are marked by symbols A Danger Warning Points out a dangerous situation which may cause personal injuries or death If these notes and warnings are not respected by the user dangerous situations may occur and may invalidate the warranty of the manufacturer A2 Valve destination An Impeller Valve FS M installed in the bottom of a silo in the bulk industry is destined to control or dose pulp powdery or granular material or to charge discharge pulp material to mixing or weighing assemblies in the admissible range of pressure and temperature At installation in a vertical pipe section the flow may be powered by gravity only Powdery or granular pulp material should be dry The impeller Valve FS M may be as well e installed in a horizontal or inclined pipe section then powdery or granular pulp shall be con veyed pneumatically or equivalent e Used for liquid or paste product streams or for a suspension of liquids with small solid particu lates Then a pump or worm conveyor is necessary for conveyance The impeller wheel of the impeller valve shall be driven continuous or intermittent by a unit mo tor worm gear the electric control circuit generally is planned and supplied by the customer As a rule the impeller valve shall be installed between flanges EN1092 1 or EN1759 1 with mating faces form A or form B installed p
8. arallel and in line Any other kind of installation shall be agreed by EBRO ARMATUREN The maximum admissible temperature is marked with TS in the valve nameplate the maximum ad missible differential pressure at the impeller wheel is 3 bars up to DN300 and 1 bar for DN gt 300 Note 1 A load from filling level of 3 kp cm 230 t m corresponds to 3 bars Note 2 The body of the impeller FS M may be loaded up to 6 bar and up to 160 C even higher if agreed by EBRO ARMATUREN up to 250 C The first start up of the valve shall not be activated before the following documents have been ob served e Declaration of conformance to EC Directives gt see last pages of this instruction e This Installation and operation instruction added to the valve supply The use of the valve in an 9 hazardous area is allowed only if the customer has specified this risk in his order and only if EBRO ARMATUREN has marked this valve with the 9 label In this case the user shall strictly observe additionally the EBRO instruction BA 4 9 ATEX If this Valve destination specified above is not respected by the user dangerous situations may oc cur and may invalidate the warranty of the manufacturer EBRO ARMATUREN Seite 3 WS INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M A3 Valve marking Each valve is marked at the body nameplate as follows EBRO ARMATUREN Address see page 2 valve type FS M J as described
9. ellendichtring NBR 820 x B30 x 7 ENNS O Ring 830 x Example DN250 shaft cartouche item 2 and 3 with sealing elements NBR D6 Flange bolting As a rule the impeller valve flange standard is specified by the customer the flange bolting and the gaskets as well For all other valve dimensions see section 4 9 of the catalogue of EBRO ARMATUREN Ug Seite 11 EBRO ARMATUREN INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M Manufacturer s Declarations Page 1 of 2 Pages Conformance to EC Pressure Directive 97 23 EG The manufacturer EBRO ARMATUREN Gebr Broer GmbH D 58135 Hagen declares that for EBRO impeller valve Series FS M the valves 1 is a pressure equipment within the meaning of the European Directive 97 23 EC PED and conforms to this directive 2 the EBRO installation operation instruction no lt BA 4 9 gt for the valve shall be observed Technical Standards used EN12516 1 2 4 Industrial valves Design of pressure loaded parts EN 12266 1 2 Industrial valves Pressure tests of assembled valves before supply Name of the Independent Expert Register no of the Independent Expert TUV S ddeutschland Conformance Procedure used as per Annex Ill of the PED 97 23 EC for Categories to Ill Module H Installation Declaration as per EC Machinery Directive 2006 42 EG The manufacturer EBRO ARMATUREN Gebr Broer GmbH D 58135 Hagen EBRO impeller valve
10. essary maintenance is e the check of the impeller valve output in appropriate periods e a periodical check if an impeller wheel empty turns smoothly without visible friction remain without damage e and a periodical check if the outside ends of the impeller wheel precisely adjusted to the body inside diameter remain undamaged At any fail see clause C3 Troubleshooting After a long standstill it is recommended to activate the valve shortly without pulp load to check the valve functions EEUU T nmm Seite 8 EBRO ARMATUREN INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M C3 Troubleshooting Table 2 List of possible troubles Kind of trouble Leakage at the pipe flange connection Tighten the gasket by the flange bolting If the leakage persists Check the mating faces of the pipe flanges It shall be exactly parallel and plain if necessary replace the gaskets Observe clauses B1 and C1 Safety warnings gt Check that the wheel stops in the position exactly parallel to the E valve body Not admissible leakage at i the impeller wheel at stand If yes but at exact closed position the leakage is too high still To repair and adjust the impeller wheel send the valve back to EBRO ARMATUREN Observe clauses B5 lt Disassembling gt and C1 Safety warnings gt Repair of the shaft seal is necessary Repair is necessary Observe clauses B1 und C1 Safety warnings
11. ic risks from the plant At service the function of the impeller valve shall be in compliance with the valve destination see chapter A2 The use of the valve shall be in compliance with the valve markings in clause A4 Service and maintenance shall be performed by qualified personal Qualified are those persons who due to experience can judge the risk and execute the work correctly and who are able to detect and to eliminate possible risks Disassembling of a shaft cartouche item 2 3 or other maintenance shall be done only when the pipe section is free from pressure and if necessary discharged to prevent any leakage to outside e Any kind of foreign particles shall be filtered out from the fluid if not the inside di ameter of the body seat and the exactly adjusted outside diameter of the impeller wheel would be damaged If necessary a fitting filter should be installed Danger of jamming one s hand or fingers at the impeller wheel Do not operate a valve not properly installed in a pipe section or without both valve ends being capped by the pipe system or a protecting device Any actuating without this caution is the full responsibility of the user C2 Automatic service The impeller valve is operated continuously or intermittent by the action of the motor unit The motor unit will rotate by the signals of the local control circuit the layout of this control circuit is the responsibility of the user The nec
12. in 4 9 of the EBRO catalogue i e 123456 012 001 Digits 1 6 EBRO serial no digits 7 9 position in confirmation of order digits 10 12 current piece of the order confirmation DN and number Body marking i e DN80 Nominal Pressure ie PN6 This is the necessary nominal pressure of the flanges Note 1 the year of manufacture is coded in the serial no Note 2 The electric motor has an additional nameplate Note 3 An impeller valve for x application has an additional nameplate All markings shall remain legible to identify the valve at any time later A4 Transport and storage For shipment and storage observe e Handle the valve with the protective packaging just until the installation into the pipe sys tem e Store it at room temperature and protect the valve from harsh environmental conditions such as dirt debris and humidity e fa hoist shall be used for better handling fix the lifting devices at the valve body only not at the actuator unit See Fig 1 to Fig 3 e Do not fix belts or straps at the wings of impeller valves Protect specifically the protruding impeller wheel at storage Put down the valve on the body surface only and support it by a wooden truss ISO 2230 describes the storage conditions and limited lifetime for elastomeric spare parts O ring and shaft seal Store it in a cool and dark place without UV light How to fix lifting belts EBRO ARMATUREN Seite 4 WS B
13. ite 5 ar INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M When contamination such as pipe scale welding slag and any other hard foreign ma terial will not be removed the impeller wheel body sealing surfaces may be dam aged and the valve function may be endangered e As a rule the impeller valve is supplied with an electronic sensor to have the option to stop a wing pair by the electric or pneumatic actuator unit in the position with minimum leakage at standstill The data sheets of motor and sensor are supplied together with this instruction and are added to each EBRO supply At supply of a valve with x marking only see valve nameplate Make sure that gt the groundling contact at the valve body will be installed correctly and endurable Warning 9 at both flanges only gaskets with an electric conductivity are installed that is certified by the gasket manufacturer e The control circuit of the motor 21b actuation shall at least assure the following criteria gt One of the pairs of the impeller wheel 4 shall remain at the signal Tight stop of the impeller in the position parallel to the valve body but alternatively an intermediate position just between shall be possible to drain the pipe section gt at indication of the sensor 33 standstill the motor 21b shall stop as soon as possible gt when the thermo sensor in the encapsulated winding if any of the electric mo
14. king plate clause A3 as well As a rule the impeller is supplied with a motor unit the electrical control circuit normally shall be planned and connected to the plant control circuit by the user s experts Only if specified the impeller valve is supplied without a motor unit An impeller supplied without transport damage should be handled and stored in its original packaging and shall be unpacked just at the place of installation All outer edges surfaces of the impeller wheel are precisely machined to ensure the maximum pulp tightness Be careful at any installation handling to protect these surfaces The impeller shall be installed between two flanges with mating 2gasket contact surfaces be ing in line parallel and clean Make sure the correct choice of the flanges The type of the gaskets shall be chosen by the pipe system manufacturer The flange bolting shall conform to the gasket characteristics The clearance of the pipe flanges shall be sufficient to the impeller wheel rotation See dimensions D in Table 1 Table 1 Minimum inside diameter D of the connecting flange DN 150 200 250 300 350 400 ep s 12 240 292 342 392 Inspect and be sure that the valve waterway and the adjacent pipe entry are free from contami nation specifically free from hard and sharp particles To flush the pipe sections before start up observe notice in the end of clause B3 EBRO ARMATUREN Se
15. sk analysis for the valve actuator unit installed into the pipe section under the service conditions such analysis is not possible for EBRO ARMATUREN The valve has been designed at the principles of lt inherent safe design gt The user shall observe the clause A2 lt Valve destination gt of EBRO instruction BA 4 9 The knowledge of documented malfunctions and misuse as per ISO 9001 at the manu facturer EBRO ARMATUREN are the basis of this analysis The limits of the valve actuator unit are defined in clause A2 lt Valve destination gt of the EBRO instruction Not the responsibility of the manufacturer EBRO ARMATUREN The valve shell and motor housing enclose all moving parts No risk at use But the user shall observe the warnings in clause C1 of this Original instruction BA 4 9 Necessary for specific accessories only if applicable See confirmation of order Valves with actuator operate automatically after connection to the plant control circuit Necessary information for valve typical application is included in this Original installation and service instruction and shall be made available to the user of the pipe system The risk analysis as per Machinery Directive Annex VII B has been made and docu mented by EBRO ARMATUREN me Seite 13 EBRO ARMATUREN
16. the valve The impeller valve Series lt FS M gt complies with the EBRO manufacturer standard See EBRO catalogue chapter 4 9 Impeller valve D2 Admissible pressure Maximum admissible pressure PS valves up to DN300 3 bars valves DN300 1 bar D3 Admissible service temperature Depends on the material of the O ring set 2a 3a and shaft seal 2c 3c See valve marking D4 Drawing Part list ITEM DESIGNATION body with liner 18 8CrNi bronze bush per manently lubricated worm gear electric motor mounting plat set position indicatorr electric connector EBRO ARMATUREN N Co 3B augruppe geh rt zu Pos 3 2 Baugruppe gehart zu Pos 2 Schlagschutz gehBrt zu Fas 33 20 sEW Antrleb s E 9 s EZ T E 5 L 3 T uL geh rt zu Pos 33 Maontageplatte gehort zu Fos 33 Schrauben Erdungslasche Pos 13 14 und 15 zelchnerisch nicht dargestellt Hinwels Seite 10 INS TALLATION AND OPERATING INSTRUCTION IMPELLER VALVE SERIES FS M D5 Spare parts The O rings 2a 8a the bushes life time lubricated 2 3 b and the shafts seals 2 3c are spare parts that shall be replaced at any disassembling of the shaft cartouches unit 2 and 3 For supply ask EBRO ARMATUREN address see page 2 KXXF 250 0027 3x O Ring 32 x 1 5 wur we Sinterbroenzelager olimpragniert ZAq Form nach DIN 1850 Teil 3 920 x 8 30 x 30 W
17. to the PED 97 23 EC For functional parts Ensured at contractual use of the valve Requirements are fulfilled at contractual use of the valve No maintenance or service is allowed when the valve is pressurized and or it is connect ed to the control circuit Warning note See Original installation and service instruction clause lt Valve destina tion and Important safety warnings if protection is necessary this shall be confirmed by EBRO ARMATUREN in the order acknowledgement Use the valve as marked in the nameplate only Not applicable at use with not dangerous fluids to stock elastomeric wear parts see installation service instruction clause A4 Valve see clause A3 of the Original installation service instruction Actuator see actuator instruction Necessary additional warnings for the customer s lt Complete machine gt are specified in this Original installation and service instruction clauses B and C The valve is not a lt complete machine gt but a lt not complete machine gt only No CE marking for conformance with the Directive 2006 42 EC Not applicable for Impeller valves Series FS M applies This analysis has been made under the condition of the valve as a lt not complete ma chine gt The EBRO product standard lt Impeller Valve gt equipped with motor has been the basis of this hazard analysis Note For the requirements as per clauses 4 to 6 of EN 12100 it is assumed that the user makes a ri
18. tor 21b acts the impeller valve shall stop as soon as possible e If this control circuit of the motor 21b is not planned or supplied by the customer himself a sup ply from EBRO ARMATUREN may be agreed B3 Steps at installation e Check and be sure that the valve and the actuator are free from damage Valves or actuator units with visible damage shall not be installed e The impeller valve shall be centred exactly with the counter flanges For the flange bolting observe the notes in clauses B2 und D6 e fin a special case the valve is supplied without motor it shall not operated before the retrofit ting The necessary instruction shall be supplied by the actuator manufacturer The nominal torque shall fit to the impeller valve characteristics cy Ensure not to feed an impeller valve installed without a motor unit with any pulp fluid e The actuator and the sensor shall be connected to the plant control circuit by the responsible expert follow the documentation of the electric units e At installation of the valve with an open end of pipe section If an impeller valve with motor is installed in the end of a pipe section this open end shall be protected by a protective device to prevent the danger to squeeze one s fin gers by the protruding wheel Warning At such an installation the user shall analyse the risk acc to the machinery Directive 2006 42 EC and or may install the necessary safety devices e hen bring the impeller
19. y Directive 2006 42 EC Annex 1 1 1 g Valve destination foreseeable misuse 1 1 3 material in contact with the fluid 1 1 5 handling 1 2 and 6 2 11 control circuit 1 3 2 withstand to stresses 1 3 4 sharp edges or angles 1 3 7 8 risks related to moving parts 1 5 1 1 5 3 enero 1 5 5 service temperature suppl 1 5 7 explosion 1 5 13 emission of dangerous substances 1 6 1 maintenance 1 7 3 marking 1 7 4 service instruction Requirements from Annex lll Requirements from Annexes IV Vill amp XI equirements as per EN 1210 3 20 6 1 inherent design Analyse as per clause 4 5 and 6 5 3 Limits of the machine 5 4 Decommissioning waste management 6 2 2 Geometric factors 6 3 Technical protective devices 6 4 5 Instruction 7 Risk analysis Manufacturer s Declarations Page 2 of 2 Pages for Impeller valves Series FS M applies See Original installation and service instruction See Original installation and service instruction 1 1 2 c protecting clothing same as for the pipe system into which the valve is installed The material of wetted parts in contact with the fluid has been agreed between the cus tomer and the manufacturer and is specified the relevant EBRO ARMATUREN docu ments and in the EBRO ARMATUREN order acknowledgement The relevant risk analysis of the material consistency is the responsibility of the user For parts under pressure See declaration of conformity
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