Operating Instructions - müller co
Contents
1. Leakage in the seat seal Check whether the valve is 100 sealed If the valve is closed Check whether the drive closes with full torque If this is the case specifications made on the type plate Only original CO AX spare parts can be installed Version November 2012 Page 8 10 Operating Instructions Quadax Series Butterfly Valves with Hand Drive If the valve continues to leak repair required Replace seat seal Observe section body and or the inner 2 3 lt Particular hazards gt and request spare parts parts are not and necessary manual from CO AX sufficiently resistant to Open close valve repeatedly under pressure Note 2 If after the removal it is discovered that the clockwise Retighten both nuts on the stuffing box gland alternately and in small steps of quarter turns each material are to be If the leakage cannot be remedied in this manner repair required Request spare parts and necessary instructions from CO AX Leakage on the If the nuts on the stuffing box gland have to be loosened or stuffing box unscrewed counter clockwise Danger Life threatening In order to protect the operating personnel against any danger please ensure that the line has been depressurized on both sides of the valve Please observe section 2 3 lt Particular hazards gt the medium parts made of a suitable selected Check function of drive If drive and control are ok2. A Danger Life threatening No valve may be operated whose permissible pressure temperature range rating is insufficient for operating conditions This permitted range is described in the CO AX brochure lt QUADAX butterfly valves gt see section 8 lt Information gt For materials pressures or temperatures that have not been specified in the above brochure permissible pressures above room temperature must be released by the manufacture Non observance of these instructions can endanger life and limb and may cause damage to the pipe system A Caution It must be ensured that the selected materials of the parts of the valve that come into contact with media must be suitable for the media used The manufacturer assumes no liability for damages that have been caused by corrosion or aggressive media Non observance of these instructions can endanger life and limb and may cause damage to the pipe system Version November 2012 Page 3 10 Operating Instructions Quadax Series Butterfly Valves with Hand Drive A drive which was subsequently mounted on the valve which was adjusted to the valve and in both end positions correctly adjusted In the closed position the end stop must be in the seat of the valve A stroke limitation in the drive should either be reset or made ineffective The pipe system was installed professionally The wall thickness of the valve body is dimensioned so that in such pr
3. Remove and inspect valve in observance of the notes from section 2 3 lt Particular hazards gt Malinen If the valve is damaged Repair required Request spare parts and necessary instructions from CO AX 8 Warnings Source of danger Generation of a flammable atmosphere Sparks during commissioning assembly Loading single components Application Generation of ignition sources Measure Operating instructions Please watch out for leakages as a flammable atmosphere may otherwise develop Operating instructions Assembly disassembly service only allowed for a non flammable atmosphere Please make sure that the QUADAX valve is earthed Any existing attachment parts should be dealt with in line with manufacturer instructions Any heat build up of valve parts as a result of hot media must be below ignition temperature Sound energy can be caused by attachment parts or flow noise Closing times below the rule of thumb are not allowed Closing time in s nominal width in mm 100 not allowed The specific manufacturer operating instructions must be referred to for any existing attachment parts When installing additional parts which have not been installed by the manufacturer or have been explicitly approved for installation such as aluminium plates or other fittings e g electric position feedback a NEW Version November 2012 Page 9 10 eae Operating Instructions Quadax Series Butterfly Valves
4. gt Butterfly valves gt DN 400 A Attention When welding the valve into the pipeline the welding process has to be controlled so that the supplied heat is limited and a distortion of the valve body is avoided For example the weld end should be crossed in order to prevent tension to the valve housing Non compliance with these constructions may lead to a distortion of the valve housing A lasting distortion of 1 10 mm in the seat area around the bearing sockets can render the valve useless Version November 2012 Page 7 10 Operating Instructions Quadax Series Butterfly Valves with Hand Drive 5 Pressure test and commissioning The pressure test of the valves has already been performed by the manufacturer For the pressure test of the pipe section with installed valves the following should be taken into consideration First thoroughly flush newly installed line systems in order to flood out all foreign substances Valve opened The testing pressure may not exceed the value 1 5 x PS according to type plate PS maximum permissible rated pressure at 20 C Valve closed The testing pressure may not exceed the value 1 1 x PS according to type plate If any leakage occurs from a valve please refer to section 7 lt Troubleshooting gt 6 Normal operation and maintenance Valves which were delivered ex works with the drive are adjusted for correct operation and should not be re adjusted as long as the
5. 1 or ANSI B16 21 are to be implemented Counterflanges must have smooth sealing strips e g shape C D or E in line with EN 1092 or stock finish as per EN 1759 Other flange shapes are to be agreed with the manufacturer CO AX Attention Butterfly valves with a short face to face dimension must be inserted in the gap between the pipeline ends with a closed valve disc Otherwise the disc could be damaged and the valve would leak gt Flanged butterfly valves are to be centered on the counterflange during installation by means of the flange screws before the screws are tightened IN Butterfly valves with a short face to face dimension partly require screws of a varying length for the connection to the counterflanges For the measurements for the flange Attention screws please refer to CO AX planning documentation Only butterfly valve with weld ends The weld ends of the valve have to be flush level and parallel and of the same material as the pipes see type plate of the valve Opposite weld ends have to fit to one another in terms of diameter and shape Welding cables must not be connected to the valve but to the pipeline By professional welding it has to be ensured that neither considerable tensions are generated in the pipe section or transferred to the valve nor that the butterfly valve is damaged by heat effect Only temperatures of lt 300 C measured on the body wall are permissible
6. Pe dN with Hand Drive hazard analysis has to be performed Corrosion Corrosion exceeding 1 5mm may lead to a weakening of pressure parts and impair the functionality of the valve or may even lead to breakdown 9 Further information These operating instructions the so called CO AX brochures and further information also in other languages can be obtained here miller co ax ag Gottfried M ller Str 1 74670 Forchtenberg Germany Tel 49 7947 828 0 Fax 49 7947 828 11 Www co ax com Version November 2012 Page 10 10
7. transported and stored with care gt The valve is to be kept in its original packaging and or with the protection caps on the flange connections weld ends The valve should be stored and transported also to the installation site on a pallet or supported in a similar way If stored prior to installation the valve is to be stored in a closed room and to be protected against harmful influences such as dirt or moisture Especially the metallic seat in the valve and the flange connection faces weld ends must not be damaged by mechanical or any other influences Valves must be stored in the same way they were delivered The drive may not be activated Valves delivered without a drive IN The valve must be transported carefully The unsecured valve disc may open from closing position due to external effects e g shaking Caution 4 Installation in the pipeline 4 1 General The same instructions apply to the installation of valves in a pipeline as for the connection of pipes and similar piping elements The following instructions additionally apply to valves For the transport to the installation site please also observe section 3 above Version November 2012 Page 5 10 Operating Instructions Quadax Series Butterfly Valves VA with Hand Drive Butterfly valves especially those with short face to face dimensions must be transported and installed with a closed valve disc Otherwise the disc
8. QUADAX series with hand drives are only to be used following the installation of a pipeline system between flanges or by welding and following the connection to the controls to close off or pass on media or to regulate flow within the permitted pressure and temperature limits These butterfly valves are not recommended for media with solid particulates they are especially not recommended for wear causing solid media In the planning documentation of the CO AX brochure lt QUADAX butterfly valve gt cf section 9 lt l When using nformation gt describes the permissible pressure and temperature range the valve please ensure that section 2 2 lt Safety instructions for the operator gt A Attention If there is a pressure difference larger than 0 15 bar liquid agents at ca 20 C for valve used for uninterrupted operation for controlling please discuss the respective application limits with the manufacture Cavitations must be avoided 2 Safety instructions 2 1 General safety instructions The same safety instructions apply to valves as to the piping system in which they are installed These instructions only offer safety instructions that should be observed additionally for valves 2 2 Safety instructions for the operator It is not the responsibility of the manufacturer CO AX and it must be ensured prior to use of the valve that gt the valve is only used as intended as described in section 1
9. also section 7 lt Troubleshooting gt The position indicator on the drive must correspond to the setting of the valve disc Ensure that only valves are installed with the pressure class the connection type and connection dimensions which meet the application requirements Observe the type plate on the valve A Danger Life threatening No valve may be installed whose permissible pressure temperature range rating is insufficient for operating conditions This permitted range is described in the CO AX brochure lt QUADAX butterfly valves gt see section 9 lt Information gt For materials pressures or temperatures that have not been specified in the above brochure permissible pressures above room temperature must be released by the manufacture Non observance of these instructions can endanger life and limb and may cause damage to the pipe system If in doubt please contact the manufacturer Butterfly valve with short face to face dimension Counterflanges and or pipe ends have to have a clear span allowing for sufficient space for the opened valve disc so that the latter is not damaged when being swivelled out Prior to installation the valve and the downstream pipeline have to be thoroughly cleaned of any contamination especially of hard foreign substances Butterfly valves of the series QUADAX can generally be installed irrespective of the flow direction To benefit from the optimum function of the butte
10. c L ae DIS YURA leading valve technology Operating Instructions Quadax Series Butterfly Valves with hand drive Version November 2012 miller co ax ag Gottfried M ller Str 1 74670 Forchtenberg Germany Tel 49 7947 828 0 Fax 49 7947 828 11 E Mail info co ax com Internet Wwww co ax com Operating Instructions Quadax Series Butterfly Valves with Hand Drive Table of Contents 0 Introduction 1 Intended use 2 Safety instructions 2 1 General safety instructions 2 2 Safety instructions for the operator 2 3 Particular hazards 2 4 Labeling of the butterfly valve 3 Transport and storage 4 Installation in the pipeline 4 1 General 4 2 Working steps 5 Pressure test and commissioning 6 Normal operation and maintenance 7 Troubleshooting 8 Warnings 9 Further information O O O O0 1 0 TT gt WA WwW W W _ Version November 2012 Page 2 10 Operating Instructions Quadax Series Butterfly Valves UA with Hand Drive 0 Introduction These operating instructions are designed to offer the user of butterfly valves from the QUADAX se ries support in terms of installation operation and maintenance A Attention Non adherence to the following caution and warning notices may lead to hazards which in turn may cause the warranty to become invalid Please contact the manufacturer for any questions For addresses please refer to section 9 1 Intended use Butterfly valves of the
11. could be damaged and the valve would leak If the valve is intended to be used as an end flap either the closing lid has to be mounted at the outlet or the drive must be securely shielded against unauthorized operation in order to prevent any risk of crushing The butterfly valve must be adjusted by the manufacturer for a sealed closed position In the closed position the end stop of the manual gear box must be made ineffective and the disc must be able to reach the seat of the butterfly valve The CLOSED position of the end stop may not be changed If in an exceptional case a valve has to be mounted without the drive It must be ensured that such a valve is not pressurized If a drive is retrofitted torque direction of rotation and the setting of the end stops OPEN and CLOSED of the valve have to be adjusted to the operating conditions Non observance of these instructions can endanger life and limb and may threatening cause damage to the pipe system 4 2 Working steps Transport valve in the protective packaging to the installation site and unpack it gt gt only there Inspect valve and drive for any damages that may have occurred during transport Damaged valves or drives may not be installed At the beginning of installation a function inspection must be performed The valve must open and close properly Discernible malfunctions must be remedied prior to commissioning See
12. efore removing the valve from the pipeline the pressure in the pipeline has to be completely reduced so that no medium can escape from the line uncontrollably It must be ensured that the valve is opened 5 10 so that any pressure can escape from both sides of the valve The gear box may if required be disassembled only once the valve has been opened for this purpose and that it remains in this opened position A For valves used at end of line With normal operation especially with gaseous hot and or hazardous media a blind flange or a sealing cover has to be mounted on the free connecting socket or Caution only for short term use the valve has to be securely locked in CLOSED position Caution when closing such as valve Danger of crushing If a valve has to be opened in a pressurized line as a terminal valve this must be IN performed with utmost caution so that spurting medium does not cause any damage Sanno Caution when closing such as valve Danger of crushing If a valve has to be removed from a pipeline Medium may escape from the line or the valve In the case of media which are A harmful to health or hazardous the pipeline has to be completely empty before the Caution valve is removed Please be careful with residues which continue to flow from dead spaces of the valve or line or which remain in the valve under pressure Version November 2012 Page 4 10 Operating Instructions Q
13. ofessionally routed pipelines an additional load Fz of the standard range Fz 1 4 DN PS is considered With butterfly valves for clamping even higher values for Fz can be permitted Any shear forces applied to the valve may not exceed 10 of the aforementioned forces PS maximum permissible rated pressure at room temperature The butterfly valve is professionally connected to the pipeline system especially such valves which are connected to the pipeline by welding In this pipe system the usual flow rates e g 4 m s for liquids in continuous operation are not exceeded and abnormal operating conditions such as vibrations water hammers temperature shocks cavitations wet steam with a high water content and more than insignificant portions of solids in the medium particularly abrasive ones are cleared with the manufacturer valves which are operated at operating temperatures of gt 50 C or lt 20 C are protected against contact together with the pipe connections the valves are only operated and maintained by specialized and trained personnel 2 3 Particular hazards A Danger Life threatening The valve shaft is sealed by a stuffing box Before the nuts on the stuffing box gland are loosened or unscrewed the pressure in the pipeline has to be completely reduced so that no medium escapes from the stuffing box A Danger Life threatening Before loosening the plug or the cover on the body or b
14. rfly valves it is recommended to install the valve so that an arrow direction marked on the housing corresponds to the direction that the pressure exerts on the closed disc This direction may well be opposite to the flow direction with opened butterfly valve The preferred installation position is the one with horizontal valve shaft If possible the drive should not be mounted directly below the valve Stuffing box leakage could damage the drive Version November 2012 Page 6 10 Operating Instructions Quadax Series Butterfly Valves WA with Hand Drive gt Caution A subsequently mounted drive must be supported if as a result of its weight and or the mounting position on the mounting kit a non scheduled bending load occurs between the valve and the drive gt When inserting the valve and the flange seals in an already mounted pipeline the distance between the pipeline ends has to be dimensioned in such a way that all connecting surfaces and seals remain undamaged The gap however must not be larger than necessary so that no additional stress is generated in the pipeline during installation Only butterfly valve with flanges gt The counter flanges of the pipeline have to be flush level and parallel Attention Butterfly valves with flange ends The sealing surfaces on bodies with flange ends of the butterfly valve are designed in such a way that flange seals according to EN1514
15. uadax Series Butterfly Valves WUA with Hand Drive 2 4 Labeling of the butterfly valve Each butterfly valve is labeled with the following data type plate Marking Comment Manufacturer www co ax com Address see section 9 lt Information gt Type code e g EQK102004XXXXXXXXxX Code no valve identification XXX XXC XXXXX Serial number e g 251896 1 AA Corresponds to Order no and production no KNA Nr e g 800005 Kundenneutrale Artikelnummer Type PN QUADAX DNXXX X Numerical value in mm e g DN200 or in inches e g 8 PN class Numerical value for PN PN class Dimension standard for flanged butterfly class valve CWP PS Numerical value in bar or Pressure upper limit of usage at 20 C PSI max T TS Numerical value in C or F Temperature upper limit of usage Year of e g 43 09 Delivery week year of manufacture manufacture cE 0036 number of the specified body in accordance with RL 97 23 EG CE amp 112 GDcT6 Ex marking none electrical part directional Marking of the preferred flow direction arrow The materials used in the valve as well as parts that come into contact with the media as well as pressure parts are uniquely coded in the type code The manufacturing date can be uniquely traced via the serial number In order to be able to identify the valve the type plate may not be removed nor damaged 3 Transport and storage Valves have to be handled
16. valve is in perfect working order To operate the hand wheel on the drive regular hand force is sufficient the use of extensions to increase the actuation torque is not permitted Regular maintenance work on the valves is not required however when the line section is inspected no leakage may escape to the outside on any valve In such cases please refer to section 7 lt Troubleshooting gt It is recommended to actuate valves remaining in one position once or twice a year Furthermore the nuts on the gland should be retightened every 6 months or after 1000 switching cycles whichever occurs first The prospective switching cycles of the valve are being calculated with the following formula 4 000 000 DN mm If the actual amount of switching cycles exceeds the calculated number please review with the manufacturer A butterfly valve is normally not self locking The drive may not be removed as long as the butterfly valve is pressurized A Caution 7 Troubleshooting When remedying faults section 2 lt Security notes gt must be observed Type of Measure Note malfunction Retighten flange screws Note 1 If the leakage cannot be remedied in this manner repair required replace seal Observe section 2 3 Leakage on the flange connection or ordered incl all Spare parts must be plug or housing cover lt Particular hazards gt and request spare parts and necessary manual from CO AX
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