Operating Instructions - müller co
Contents
1. Page 9 10 Operating Instructions Quadax Series Butterfly Valves with Hand Drive Application Generation of ignition sources Corrosion 9 Further information 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 hazard analysis has to be performed 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 These operating instructions the so called CO AX brochures and further information also in other languages can be obtained here m ller 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 Februar 2014 Page 10 102. Butterfly valves of the 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 Information gt describes the permissible pressure and temperature range When using the valve please ensure that section 2 2 lt Safety instructions for the operator gt A If there is a pressure difference larger than 0 15 bar liquid agents at ca 20 C for valve Attention application limits with the manufacture Cavitations must be avoided 1 1 Fittings for oxygen With the goods inwards inspection it is to be checked whether the fittings supplied are furnished with appropriate certificates for the oxygen cleaning and whether the fittings have packaging suitable for oxygen see identification oxygen Clean for Oxygen Service The packaging is to be checked for damage If there is damage such fittings may not be employed for oxygen applications as there is a strong suspicion that the fittings are contaminated which could lead to an oxygen combustion When it is assured that the p
3. 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 I2GDcT6 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 transported and stored with care Version Februar 2014 Page 5 10 Operating Instructions Quadax Series Butterfly Valves with Hand Drive 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 sto red 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 must Especially the metallic seat in the valve and the flange connection faces weld ends 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 A Caution Valves delivered
4. to life and limb because oxygen combustion equates to an explosion Version Februar 2014 Page 3 10 used for uninterrupted operation for controlling please discuss the respective Operating Instructions Quadax Series Butterfly Valves WUA with Hand Drive 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 No valve may be operated whose permissible pressure temperature range IN 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 Danger materials pressures or temperatures that have not been specified in the above Life brochure permissible pressures above room temperature must be released by the threatening manufacture Non observance of these instructions can endanger life and limb and may cause damage to the pipe system It must be ensured that the selected materials of the parts of the valve that come into A contact with media must be suitable for the media us
5. 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 IN 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 Danger reduced so that no medium escapes from the stuffing box Version Februar 2014 Page 4 10 Operating Instructions Quadax Series Butterfly Valves with Hand Drive Life threatening A Danger Life threatening Before loosening the plug or the cover on the body or before 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 p
6. without a drive The valve must be transported carefully The unsecured valve disc may open from closing position due to external effects e g shaking 4 Installation in the pipeline 4 1 General The same in pipes and si structions apply to the installation of valves in a pipeline as for the connection of milar piping elements The following instructions additionally apply to valves For the transport to the installation site please also observe section 3 above Butterfly valves especially those with short face to face dimensions must be transported and installed with a closed valve disc Otherwise the disc could be damaged and the valve would leak Attention IN 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 Attention 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 Danger Life threatening 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
7. ackaging has suffered absolutely no damage during transport then the fittings are to be removed from the packaging in a room suitable for this purpose The room must be free of oxygen and grease and it must also be ensured that the room has no aliphatic atmosphere Staff who remove the fittings from the packaging and also install the fittings in the pipeline must have suitable protective clothing grease and oil free gloves grease and lubricant free clothing etc The fittings removed from the packaging are to be checked once again for damage An optical visual check under UV light is the minimum requirement The fittings which have been checked for possible contamination whose perfect condition has been established are to be taken without delay to the place of installation whereby it is to be ensured there that the fittings during this transportation route have not come into contact with oil and grease or been contaminated in any other way With the installation of the fittings the normal safety regulations and the instructions of this operation and maintenance manual are to be followed In this connection attention is additionally to be paid that in particular also the pipelines the adaptors face to face with the fitting and also in particular the seals are suitable for oxygen and that there is also absolutely no contamination in particular due to oil and grease apparent YN ee 9 Disregard of this instruction can represent a danger
8. 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 cause damage to the pipe system 4 2 Working steps gt T o gt ransport valve in the protective packaging to the installation site and unpack it nly there Inspect valve and drive for any damages that may have occurred during transport Damaged valves or drives may not be installed gt At the beginning of installation a function inspection must be performed The valve must open and close properly Discernible malfunctions must be remedied p rior to commissioning See also section 7 lt Troubleshooting gt The position indicator on the drive must correspond to the setting of the valve disc a Ensure that only valves are installed with the pressure class the connection type nd connection dimensions which meet the application requirements Observe the type plate on the valve Version Februar 2014 Page 6 10 Operating Instructions Quadax Series Butterfly Valves WUA with Hand Drive gt 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 p
9. anufacturer housing A lasting distortion of 1 10 mm in the seat area around the bearing IN A butterfly valve is normally not self locking The drive may not be removed as long as the butterfly valve is pressurized Caution 7 Troubleshooting When remedying faults section 2 lt Security notes gt must be observed Version Februar 2014 Page 8 10 Operating Instructions Quadax Series Butterfly Valves with Hand Drive Type of malfunction Measure Note Leakage on the flange connection or plug or housing cover Retighten flange screws If the leakage cannot be remedied in this manner repair required replace seal Observe section 2 3 lt Particular hazards gt and request spare parts and necessary manual from CO AX 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 Open close valve repeatedly under pressure If the valve continues to leak repair required Replace seat seal Observe section 2 3 lt Particular hazards gt and request spare parts and necessary manual from CO AX Leakage on the stuffing box Retighten both nuts on the stuffing box gland alternately and in small steps of quarter turns each clockwise If the leakage cannot be remedied in this manner repair required Request spare parts and necessary instructions from CO AX If the nuts on t
10. ding load occurs between the valve and the drive 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 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 AX Attention Butterfly valves with a short face to face dimension partly require screws of a varying length for the connection to the counterf
11. ed The manufacturer assumes no liability for damages that have been caused by corrosion or aggressive media Caution Non observance of these instructions can endanger life and limb and may cause damage to the pipe system 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 professionally routed pipelines an additional load Fz of the standard range Fz 17 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 gt 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
12. he stuffing box gland have to be loosened or 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 Check function of drive If drive and control are ok Remove and inspect valve in observance of the notes from section 2 3 lt Particular hazards gt Note 1 Spare parts must be ordered incl all specifications made on the type plate Only original CO AX spare parts can be installed Note 2 If after the removal it is discovered that the body and or the inner parts are not sufficiently resistant to the medium parts made of a suitable material are to be selected Maliuneuan 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 Measure atmosphere may otherwise develop a non flammable atmosphere Operating instructions Please watch out for leakages as a flammable Operating instructions Assembly disassembly service only allowed for Please make sure that the QUADAX valve is earthed Any existing instructions attachment parts should be dealt with in line with manufacturer Version Februar 2014
13. ing 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 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 m
14. langes For the measurements for the flange screws please refer to CO AX planning documentation Version Februar 2014 Page 7 10 7 ta Operating Instructions Quadax Series Butterfly Valves re AS with Hand Drive 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 gt Butterfly valves gt DN 400 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 IN example the weld end should be crossed in order to prevent tension to the valve housing Attention Non compliance with these constructions may lead to a distortion of the valve sockets can render the valve useless 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 follow
15. osition 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 Caution Gamage Caution when closing such as valve Danger of crushing gt Caution 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 harmful to health or hazardous the pipeline has to be completely empty before the 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 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
16. ressures 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 butterfly 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 AX 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 ben
17. sr 7 102 DIS YURA leading valve technology Operating Instructions Quadax Series Butterfly Valves with hand drive Version Februar 2014 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 1 1 Fittings for oxygen 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 00 0 O Q 09 Oo TV RA A A A OO OO Version Februar 2014 Page 2 10 eae Operating Instructions Quadax Series Butterfly Valves wr AS with Hand Drive 0 Introduction These operating instructions are designed to offer the user of butterfly valves from the QUADAX series support in terms of installation operation and maintenance IN hazards which in turn may cause the warranty to become invalid Attention section 9 Non adherence to the following caution and warning notices may lead to Please contact the manufacturer for any questions For addresses please refer to 1 Intended use
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