Operating instructions Installation / Operation PTFE
Contents
1. Do not insert the mounting plate without using spring dowel sleeves as the transverse forces cannot be absorbed by the screws e Insert the cylinder screws 31 and tighten them e Slide a square adapter 32 onto the stem if required Prevent the square adapter from sliding down the stem by using the attached washer 33 if required K PTFE Ausgekleidet Wartungsanleitung GB GR 10 12 2014 1 2 Operating instructions Maintenance Mounting PTFE seated butterfly valve series K Ggcer PROCESSTECHNIK GMBH 1a Upper part of the body 6 1b Lower part of the body 7 2 Seat 8 3 Disc 9 4 Elastomer 10 5 Thrust pad 29 Subject to modifications without notice K PTFE Ausgekleidet Wartungsanleitung GB GR 10 12 2014 Bearing with O ring Disc spring washer compression spring Body screw O ring O ring MULTITOP mounting plate Edition 2014 12 10 30 31 32 33 34 35 Spring dowel sleeve Cylinder screw Square adapter Retaining washer Washer Hexagonal nut 2 22. www gefa com butte rfly valve se ries K Maintenance e The valves do not require any special maintenance Disassembly e Valves with hand lever Loosen the lateral screw joint of the hand lever and pull the hand lever off the valve stem 3 If only the seat 2 or the disc 3 have to be replaced the throttle plate can be left mounted Remove the throttle plate by loosening the screws to replace the bearing 6 e Valves with actuator Loosen the fastening screws between the MULTITOP mounting plate 29 and the actuator or between the valve and the bracket and remove the actuator to replace the bearing 6 Remove the MULTITOP mounting plate 29 from the valve by loosening the fastening screws 31 and the clamping sleeves 30 If only the seat 2 or the disc 3 has to be replaced the actuator may remain on the valve e Turn the disc to OPEN position e Loosen and remove the two body screws 8 e Pull off the lower part of the body 1b The lower part or the body can easily be pulled off by pressing screw drivers into the body split e Pull the disc 3 with the seat 2 out of the upper part of the body 1a e lf the disc 3 is to be reused it should be heated together with the seat 2 to at least 100 C better 150 C This can be achieved in a water bath boiling 100 C or better in a heating furnace After warming the disc seat unit the seat ring becomes pliable Deform the seat into an oval and pull it first over
3. G LC F A Operating instructions PROCESSTECHNIK emgy _ NStallation Operation GermaniastraBe 28 Postfach 700110 PTFE se ated D 44379 Dortmund D 44371 Dortmund Telefon 49 0 231 61009 0 Fax 49 0 231 61009 80 E mail gefa gefa com Internet www gefa com butte rfly valve se ries K Introduction The following information and instructions are important for perfect installation and safe operation of the valve Prior to installation and initial use of the valve the qualified staff in charge of installing and operating the valve has to be instructed according to this information Proper use The PTFE seated butterfly valve series K may only be used to stop throttle and control media flows within the permissible pressure temperature limits 10 bar 9 Seat PTFE carbon 8 A Q 5 7 6 H Q io oo w 5 4 C 5 4 A PTFE Elastomer Seat PTFE silicone Elastorner EPDM 0 25 50 75 100 125 150 175 200 C 225 Temperature The suitability of the product related parts used and their chemical resistance properties have to be clarified before start up of the plant The usual flow rate must not be exceeded Vibrations water hammers and cavitation as well as abrasive components result in damage of the valve and affect its service life Valves must not be used to support the pipeline nor as a step up This includes the different kinds of operation like hand levers gea
4. aft Do not operate the valve in the cavitation area Do not exceed the pressure temperature range Avoid all foreign particles on the sealing surfaces Removing the valve Before removing the butterfly valve make sure that the pipe section is depressurised and evacuated In case of toxic caustic and other outgasing media the pipe section must also be ventilated Safety classification is the responsibility of the system operator The butterfly valve is removed by loosening the flange screws and sufficient spreading of the mating flanges The valve disc must be closed at an angle within the face to face dimension of the valve to prevent damage to the disc Actuators either have to be dismounted before the valve is removed or they have to be secured against unauthorized or unintentional operation Disposal repair of the valve After having removed the valve it has to be disassembled and cleaned to prevent injuries caused by residues of the medium If the valve is returned to the manufacturer a safety data sheet relating to the media must be included Subject to modifications without notice Edition 2010 07 13 K PTFE Ausgekleidet Einbauanleitung GB doc GR 13 07 2010 4 4 A Operating instructions PROCESSTECHNIK GyBH Maintenance Mounting GermaniastraRe 28 Postfach 700110 PT F E Se ate d D 44379 Dortmund D 44371 Dortmund Telefon 49 0 231 61009 0 Fax 49 0 231 61009 80 7 E mail gefa gefa com Internet
5. ngled position during installation Check for adequate clearance of the disc Remove valve before welding Valve has to be inserted easily the flanges if necessary spread the flanges Tightening torque for flange screws 2 2 yA 3 K PTFE Ausgekleidet Einbauanleitung GB doc GR 13 07 2010 3 4 Operating instructions Installation Operation CSE A PTFE seated butterfly valve series K ae re Mounting of actuators It must be ensured that the actuator is centred on the valve shaft The weight of a mounted actuator must not place a one sided load on the shaft of the valve if necessary actuators must be supported without fixing External loads must not be applied to actuators this can damage or destroy the valve Initial operation The butterfly valve has been tested for leakage using air or water Residues of the test medium may still be on the contact surfaces of the valve Possible reactions with the operating medium must be observed Prior to initial operation the pipeline must be flushed effectively with the valve fully opened to eliminate soiling and to avoid damage to the sealing surfaces The valve must not be switched during the flushing process During a system pressure test the following pressures must not be exceeded 1 5 x PN with disc in open position 1 1 x PN with disc in closed position Impermissible operation Never operate the butterfly valve without actuating devices and or locking of the sh
6. r operators actuators feedback and control systems When using a hand lever handwheel and manual emergency operation take care that there is enough space for a proper operation Earthing the valve If the butterfly valve is supplied with anti static device and used in potentially explosive zones the earthing strap supplied with the valve must be connected effectively at site with the potential compensation cable before the valve is put into operation K PTFE Ausgekleidet Einbauanleitung GB doc GR 13 07 2010 1 4 Operating instructions Installation Operation CSE FA PTFE seated butterfly valve series K i ia ballet Transport and storage The valve must be transported and stored dry and clean In humid rooms a drying material or heating must be used to avoid condensation During transport and intermediate storage the butterfly valve should not be outside a temperature range of 15 C and 30 C The transport packaging protects the valve against soiling and damage Impact and vibrations must be avoided The outer paintwork coating must remain undamaged otherwise the faulty spots must be repaired immediately The factory adjusted basic setting position of the disc at delivery must not be changed Conditions for mounting the valve The PTFE seated butterfly valve series K is installed between pipeline flanges acc to DIN2501 or ANSI B16 5 The pipeline must not have any axial or angular offset since otherwise the disc co
7. ring washers or compression spring 7 and the thrust pad 5 into the upper part of the body 1a Insert the complete disc 3 seat 2 unit into the upper part of the body 1a Place the disc spring washers or compression spring 7 and the thrust pad 5 into the lower part of the body 1b Assemble the upper and lower part of the body 1a 1b and fasten them with the body screws 8 Each body half has a small moulded cam at the body split that shows the correct position of the body halves in relation to each other Insert the bearing with the O rings 6 into the upper body part 1a if the bearing has to be replaced After the assembly the disc has to be switched for several times at least 4x by 180 Check the seat and the stem tightness Test pressure 1 1 times nominal pressure Valves with hand lever Loosely attach the throttle plate with the screws to the top flange Slide the hand lever onto the stem and position the throttle plate Tighten the fastening screws of the throttle plate and attach the lever with the lateral screw joint e Valves with actuator Attach the whole actuator unit align it and fasten it with screws Mounting of the MULTITOP mounting plate e Position the mounting plate 29 on the body e Insert the spring dowel sleeves 30 through the mounting plate into the body The slot in the spring dowel sleeve must point in the force direction See arrow in the assembly drawing to achieve a rigid connection
8. the lower stem part of the disc Thereafter pull the seat upwards e Allocate the thrust pads 5 disc spring washers or compression springs 7 and the adjusting washers if present to the upper and lower body part 1a 1b in the same way as they were found Comment Four disc spring washers are used per body half for DN 50 to DN 150 and DN 500 One compression spring is used per body half for DN 200 to DN 400 e Check all part for flawless condition and renew them if required Only use original GEFA spare parts Assembly e Thoroughly clean all parts and check them for wear Parts that show wear or corrosion must be replaced to ensure operational safety in future e Equip the thrust pads 5 with a new FPM O ring 10 if required e Allocate the disc spring washers or compression springs 7 to the body halves exchange them when they are corroded Insert the adjusting washers into the body parts in the original pattern e Check the disc 3 and slide a new FEP O ring 9 over both stem parts and into the groove of the disc e Heat the seat 2 in the form it is delivered as spare part with inlayed elastomer 4 in an heating furnace to 150 C maximum 15 minutes or in boiling water to 100 C e Pull the hot seat 2 over the long stem part of the prepared disc 3 Clamp the flat of the disc with a vice use aluminium jaws Pull the seat over the short stem part For this purpose the seat is distorted into an oval Place the disc sp
9. tion G CSA PTFE seated butterfly valve series K a ala SMR Installation The PTFE seated butterfly valve series K has to be switched to the fully closed position or a slightly angled position The position of the disc must be within the face to face dimension of the valve Spread the mating flanges and insert the valve carefully between the flanges If the pipeline is to be welded at site temporary fitting blocks should be installed instead of the butterfly valve since flying sparks and welding residues can damage the valve seat due to high temperatures Never leave the butterfly valve installed when welding of the pipeline flanges has to be completed Center the butterfly valve using the flange screws The outside diameter of the valve body is used for full centering Remove the flange spreaders and tighten the flange screws slightly and evenly crosswise with the disc fully closed During this procedure check that the valve is centered between the mating flanges Open and close the valve several times and cross tighten the flange screws once again with the disc in closed position Tightening torque please refer to below table Check that the disc has adequate clearance When installing the lug type butterfly valve as end in line valve the free port must be secured by a blind flange Complete welding of the flanges Crosswise tighten the flange screws the disc is fully closed Disc in fullly closed or in slightly a
10. uld be damaged and the PTFE seat can become deformed which is not permitted Due to the PTFE seat design the butterfly valve is self sealing to the flanges Do not use flange gaskets and does not require additional flange gaskets Pre condition The flange sealing surfaces have been checked to make sure that they have a smooth surface structure Residues welding beads must be removed No cross marks may be visible Use PTFE flange gaskets with metal back up ring only in exceptional case Make sure that the PTFE flange gaskets cover the whole sealing surface of the flange connection Seat serves as flange gasket The clearance of the mating flanges including inner coating has to be sufficient to allow the disc to be fully opened without touching ODi L 6 mm This must be checked before the valve is installed and compared with the space necessary for the valve according to the table Transport packaging Transport packaging protects the interior of the valve from soiling and damage Do not remove the packaging until the valve is going to be installed Installation position Basically the butterfly valve series K can be installed in any position The recommended position however is with the shaft being horizontal The lower disc edge should open in flow direction K PTFE Ausgekleidet Einbauanleitung GB doc GR 13 07 2010 2 14 Operating instructions Installation Opera
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