Operating instructions
Contents
1. KLAUS UNION Operating instructions Swing check valves BA 1731 1733 EN Rev 2 Page 1 7 Table of contents Generalities Safety Corrosion protection transport and storage Description corresponding documents Installation Operation putting into and out of operation Maintenance Commissioning Malfunctions and their elimination 1 Generalities ONOAAPRWON The following operating instructions are valid for KLAUS UNION swing check valves of the series 1731 and 1733 which are in stalled in pipelines and serve to let through the flow of liquids gases and steams in only one direction KLAUS UNION valves are subjected to the rules according to the PED 97 23 EC and their harmonised standards regula tions in their development construction and testing By acorrect assembling maintenance or repair we guarantee a trouble free valve operation The manufacturer carries no responsibility for efficiency and safety of the valves whenever these operating instructions are not observed and followed accurately The valves are marked in accordance with DIN EN 19 ISO 5209 as follows nominal diameter DN nominal pressure PN body material heat no or specimen no manufacturer brand factory number flow direction arrow and if necessary admissible working temperature and admissible operating pres sure bar By attaching a CE marking to the valves we concur rently declare compliance with PED 972. 23 EC ATTENTION The valves must not be activated beyond the lim its and rules indicated in the different documents such as op erating instructions purchase documents type sheets Opera tions beyond the indicated limits lead to overstrain which cannot be sustained by the valves A non observance of this warning can cause injuries to persons and defects of the machines such as Injuries caused by escaped medium cold hot toxic under pressure Affect in activity or damage of the valves The descriptions and rules included in these operating instruc tions refer to standard types but are also valid for alternatives These operating instructions do not take into consideration Any accident and incident which can arise by assembling op eration or maintenance of the valves Any safety rule in relation with the place where the valve is in stalled The operating company is responsible for the observa tion of the safety rules also by the assembling staff ATTENTION It is essential that the valves are handled by skilled staff that must be aware of the interactions between the valves and the plants in which they are installed BA 1731 1733 Swing check valves_Rev 2_EN doc An incorrect use of the valves may cause strong consequences to the complete plant such as gt escape of medium lt standstill of a plant machine affects decreases or increases of operation or work of a plant ma
3. 00 043 1731 63 160 1 4308 1731 500 700 202 1731 63 160 1 4408 1731 500 700 205 1731 63 160 1 4552 1731 500 700 203 1731 63 160 1 4581 1731 500 700 206 a SN LE 5 22 23 13 ANS ZZLIT gt za 77 gh HH Tp ie f BA 1731 1733 Swing check valves_Rev 2_EN doc Issue 09 2011 KLAUS UNION GmbH amp Co KG 4 2 Parts index Pos Denomination 1 Body 2 Cover 3 Lever 4 Disc Flap 5 Shaft 7 Lever 8 Weight 10 Stuffing box with bolt and nut 11 Packing 12 Seal 13 Locking ring 18 Bolt 19 Nut 22 Screw plug 23 Seal ring 4 3 Function mode Swing check valves consist of the pressurised parts body 1 and cover 2 as well as the functional unit Body 1 and cover 2 are connected by the stud bolts 18 and nuts 19 and are sealed up outside by the gasket 12 The block device consists essentially of the disc flap 4 the lever 3 and the shaft 5 The shaft 5 is sealed up outside using seal rings 23 and screw plugs 22 on both sides In the case of the design with lever 7 and weight 8 the shaft 5 passes through one sided Here the shaft is sealed up us ing packing rings 11 and the stuffing box 10 The tight surfaces of the body seat 1 and the valves 4 are made of stainless steel 4 4 Appl
4. 1 10 16 1 7357 1731 100 200 042 1733 10 40 1 7219 1733 100 400 044 1731 10 16 1 7363 1731 100 200 043 1733 10 40 1 7357 1733 100 400 042 1733 10 40 1 7363 1733 100 400 043 1731 10 16 1 43808 1731 100 200 202 1731 10 16 1 4408 1731 100 200 205 1733 10 40 1 4308 1733 100 400 202 1731 10 16 1 4552 1731 100 200 203 1733 10 40 1 4408 1733 100 400 205 1731 10 16 1 4581 1731 100 200 206 1733 10 40 1 4552 1733 100 400 203 1733 10 40 1 4581 1733 100 400 206 Constructional length EN 558 1 series 1 DIN 3202 F1 1731 10 40 1 0619 1731 100 400 040 Constructional length EN 558 1 series 2 DIN 3202 F2 1731 10 40 1 5419 1731 100 400 041 1733 63 160 1 0619 1733 500 700 040 1731 10 40 1 7219 1731 100 400 044 1733 63 160 1 5419 1733 500 400 041 1731 10 40 1 7357 1731 100 400 042 1733 63 160 1 7219 1733 500 400 044 1731 10 40 1 7363 1731 100 400 043 1733 63 160 1 7357 1733 500 400 042 1733 63 160 1 7363 1733 500 400 043 1731 10 40 1 43808 1731 100 400 202 1731 10 40 1 4408 1731 100 400 205 1733 63 160 1 4308 1733 500 700 202 1731 10 40 1 4552 1731 100 400 203 1733 63 160 1 4408 1733 500 700 205 1731 10 40 1 4581 1731 100 400 206 1733 63 160 1 4552 1733 500 700 203 1733 63 160 1 4581 1733 500 700 206 Constructional length EN 558 1 series 2 DIN 3202 F2 1731 63 160 1 0619 1731 500 700 040 14 32 12 18 19 1731 63 160 1 5419 1731 500 400 041 1731 63 160 1 7219 1731 500 400 044 1731 63 160 1 7357 1731 500 400 042 1731 63 160 1 7363 1731 500 4
5. 2 Swing check valve with pass through 4 Description corresponding docu shaft lever and weight ments Connecting flange in accordance with EN 1092 1 DIN 2501 Sealing edge in accordance with EN 1092 1 DIN2526 The following pictures represent some examples for the princi Constructional length in accordance with EN 558 DIN 3202 ple valve construction Pictures and information referring to par ticular construction series can be found in the corresponding type sheets Type PN Material Type sheet no Constructional length EN 558 1 series 48 DIN 3202 F6 1733 10 16 1 0619 1733 100 200 040 4 1 Overview corresponding documents 1733 10 16 15419 1733 100 200 041 1733 10 146 1 7219 1733 100 200 044 4 1 1 Swing check valves with interior shaft 1733 10 16 1 7357 1733 100 200 042 1733 10 16 1 7363 1733 100 200 043 Connecting flange in accordance with EN 1092 1 DIN 2501 Sealing edge in accordance with EN 1092 1 DIN 2526 1733 10 16 1 4308 1733 100 200 202 Constructional length in accordance with EN 558 DIN 3202 1733 10 16 1 4408 1733 100 200 205 1733 10 16 1 4552 1733 100 200 203 Type PN Material Type sheet no 1733 10 16 1 4581 1733 100 200 206 Constructional length EN 558 1 series 48 DIN 3202 F6 1731 10 16 1 0619 1731 100 200 040 Constructional length EN 558 1 series 1 DIN 3202 F1 1731 10 16 1 5419 1731 100 200 041 1733 10 40 1 0619 1733 100 400 040 1731 10 16 1 7219 1731 100 200 044 1733 10 40 1 5419 1733 100 400 041 173
6. ation position the residual liquid possibly re mained in the valve and has to be drained off and correctly dis posed Before a possible transport the valves have to be carefully flushed and emptied For any further information please contact KLAUS UNION GmbH amp Co KG 7 2 Maintenance The valves are constructed in almost all of their parts mainte nance free Materials for sliding parts are chosen which cause a very minimal wear In order to improve operation safety and to minimise repair costs all valves specially those ones which are seldom put into operation or are hard to get to should be regu larly tested that means put into operation OPEN CLOSED at least once or twice a year The operator is responsible to determine the convenient test and maintenance intervals depending on the application of the valve The life cycle of maintenance free and not maintenance free valves can be extended if x the shaft and stuffing chamber surfaces are kept clean and undamaged the mobile parts such as stuffing box bolts are greased except oxygen valves by using standard lubricants acc to DIN 51825 the stuffing box packing is punctually additionally packed or the packing is renewed the gasket is punctually renewed The safety instructions in par 2 7 1 and in par 8 must be ob served 7 3 Valve mounting After reassembling and before putting into operation the valves have to be subjected to a resistance a
7. chine For any further inquiries or in case of damage please contact KLAUS UNION GmbH amp Co KG Bochum In case of local inquiries or orders especially for spare parts please indicate the production or factory serial number the type the model version and possibly also the year of construc tion The technical data service data referring to the valves can be found in their technical documentation paragraph 4 In case of a return transport it has to be proceeded as ex plained in paragraph 3 lt Transport gt 2 Safety These operating instructions contain essential information that has to be observed by assembling operation and maintenance of the valves For this reason they have to be read by the as sembling staff by the skilled staff and by the operator before the valves are assembled and put into operation and they should always be kept in the proximity of the valves Not only the general safety instructions indicated in this main paragraph have to be observed but also the other ones indi cated in other paragraphs 2 1 Indication of notes in the operating in structions The safety instructions contained in these operating instruc tions which have to be observed in order to avoid injuries to persons are indicated by the following general and particular picot graphs Security signal acc to DIN 4844 W 9 Beware of the electrical voltage Security signal acc to DIN 4844 W 8 In order to avoid defects o
8. f valve efficiency and of its accesso ries the following warning mark has to be observed in safety instructions ATTENTION The signs marked directly on the valves such as nominal pres sure have absolutely to be considered and kept in a readable condition Issue 01 2010 KLAUS UNION GmbH amp Co KG 2 2 Dangers that can result if safety instruc tions are not observed The non observance of the safety instructions may cause risks to persons the environment and the valves or plants The non observance of the safety instructions may lead to the loss of any indemnity rights In particular the non observance of the safety notes can cause dangers such as z break down of important functions of the valves plants z failure of prescribed methods of maintenance and com missioning danger to persons caused by electrical mechanical and chemical impacts environmental injuries caused by a leakage of dangerous materials 2 3 Working with safety consciousness The safety instructions included in these operating instructions the national regulations for prevention of accidents as well as the internal regulations referring to work operation and safety have to be observed by the operator 2 4 Safety instructions for the operator user Whenever some hot or cold valve parts e g casing parts lever or handwheel may cause any danger the operator must construct these parts in a way that they are protected
9. from contacts The contact protection for moving parts such as lever or weight must not be taken away while the machine is work ing Leakages f ex in shaft sealing of dangerous conveyed materials explosive toxic hot have to be removed in a way that no danger to persons or environment can arise Legal determinations must be respected Injuries by electrical energy have to be excluded please find details to this point in the VDE and local power supply enterprise regulations 2 5 Safety instructions for maintenance in spection and assembly works It must be provided that all maintenance inspection and as sembly works are executed by skilled staff who must have pre viously studied these operating instructions Basically when any kind of work on valves is executed they have to be cooled down and free of pressure And the vaporisa tion temperature of the medium must be lower than the tem perature of all parts it gets in contact with Valves which get in contact with health injuring media have to be decontaminated Immediately after the work is done all safety and protection devices have to be put into position or operation again Before putting the valve into operation again the points referring to paragraph 6 lt Putting into operation gt have to be observed 2 6 independent conversion and spare parts manufacture Reconstructions or modifications of the valves are only accept able under agreement with t
10. he manufacturer The use of origi nal spare parts and by the manufacturer authorised accessories promotes safety Any violations cause the liability for the con sequences arising to be cancelled 2 7 Inadmissible operation modes A safe operation is only guaranteed if the valves are used ac cording to the determinations included in paragraph 1 lt Gener BA 1731 1733 Swing check valves_Rev 2_EN doc Page 2 7 alities gt of these operating instructions The limits included in the technical documentation must not be exceeded 3 Corrosion protection transport and storage 3 1 Corrosion protection 3 1 1 Carbon steel valves Valves made out of unalloyed or low alloyed cast steel are painted with a hard sticking primer made of a 2 components colour based on epoxy resin paint The minimum film thickness is 70 um The inner surfaces are free of paint and only coated with a temporary corrosion protection e g oil Machined flange facings are protected against outside influences with a strippa ble varnish 3 1 2 Austenitic valves Valves made out of stainless austenitic cast steel will be deliv ered without coating 3 2 Transport The valves are delivered with their connecting holes shut by cover caps See that valves are not thrown or exposed to hard crushes Valves will be supplied as ready for operation ATTENTION During transport and intermediate storage valves have to be closed Connecting holes have to be s
11. hut up by suitable means cover caps foils in order to avoid any damage to the valve seats Please see on this the rise prescriptions on page 7 Valve weights are indicated in the corresponding manufacturer documents type sheets paragraph 4 1 lt Corresponding docu ments gt acknowledgement After delivery respectively before assembly the valves have to be inspected in order to exclude any transportation damage 3 3 Storage The storage intermediate storage of the valves has to be ef fected in a way that it can work perfectly even after a longer storage period For this purpose it is necessary to keep the valve closed in order to protect the seat fac ings to take measures against soiling dust sand mortar re spectively building materials frost and corrosion e g us ing plastic foils When storing valves with soft gaskets seat and or stem seal of elastomer the storage regulations for elastomer DIN 7716 have to be observed 5 the store must be dry free of dust and moderately venti lated Store temperature should not go over 25 C stocks on hand have to be used up in order to avoid long storage periods as already mentioned above the valves have to be in closed position during the storage However the soft clo sure elements should be shut with little power in order to avoid a rush ageing of the elastomer Issue 09 2011 KLAUS UNION GmbH amp Co KG Page 3 7 ae R 4 1
12. ication limits ATTENTION Depending on the materials the pressure tem perature graduations rating tables of the respective materials are to be taken in consideration Moreover application is limited depending on the choice of the seal material and it is influenced by the material combination of the connecting elements bolts and nuts 5 Installation 5 1 Generalities ATTENTION The pipeline has to be installed in a way that inju rious shearing and bending forces during installation and activ ity are kept away from the valve bodies 1 This is to avoid leakiness and destruction of the body ATTENTION Before installation the cover caps have to be re moved from the connecting holes The flange facings must be clean and undamaged Before in stallation of the valves the strippable varnishes have to be re moved The connecting flange gaskets must be well central A ised BA 1731 1733 Swing check valves_Rev 2_EN doc Page 4 7 Only bolts and gaskets of admissible materials may be used For the flange connections all flange drill holes have to be used stems stuffing boxes and accessories must be painted function affects During any construction work the valves have to be protected from dust sand and any other construction material Please cover with suitable means When varnishing the pipelines no bolts and nuts Exterior levers and weights and all other attachments mus
13. lve 7 Maintenance Commissioning 7 1 Safety instructions During all commissioning and maintenance works on the valves the following safety instructions as well as the general indica tions under paragraph 2 lt Safety gt must be observed ATTENTION In any case also in emergency only suitable spare parts and tools have to be used otherwise a perfect func tion of the valves is not guaranteed 7 1 1 Valve disassembly Before dismounting from the pipelines or before commissioning and repair works are made directly on the valves more pre cisely before loosing the bolted bonnet connection BA 1731 1733 Swing check valves_Rev 2_EN doc Page 5 7 before loosing the bolts of the stuffing box gland respec tively the packing bolts or the stem nuts before loosing shutting opening and pressure release threaded plugs The valves have to be completely discharged from pressure and have to be cooled down until the evaporation temperature of the medium is lower than all the chambers getting in contact with it Then any scald can be excluded Opening a valve under pressure is a lethal danger In case those toxic or easily inflammable mediums are conveyed or mediums the residues of which in contact with humidity of the air can lead to corrosion damages the valves have to be drained and flushed respectively ventilated If necessary protecting clothes and protective masks have to be worn Due to the install
14. nd tightness test acc to EN 12266 DIN 3230 part 3 Issue 09 2011 KLAUS UNION GmbH amp Co KG 8 Malfunctions and their elimination 8 1 Generalities All repair and maintenance works have to be done with suitable tools and original spare parts The safety instructions in par 2 and 7 have to be observed 8 2 Malfunctions Elimination Porosity of closing device In hard sealing valves Renew the seat facings of the closure elements and body seat by means of suitable grinding devices The grind in procedure of body and disc sealing facing must be per formed until a continuous and bearing facing becomes visible In soft sealing valves Renew the closure element seal ring Leakage of cover gasket Retighten the bolted bonnet connections Renew the gasket Before inserting a new seal ring or gasket the faces of cover and body must be carefully cleaned ATTENTION No additional auxiliary sealing means must be used for seal rings For non sticking coating only means explic itly recommended by the seal manufacturer have to be used For any further information please contact KLAUS UNION GmbH amp Co KG Leakage of stuffing box packing Retighten the stuffing box packing with the nuts to the stuffing box gland respectively with the packing bolts Hereby it has to be taken care that the friction force at the shaft does not increase very much Additional packing of the stuffing box loo
15. new plants and especially after repair works has to be flushed with valves completely open in order to re move solid matters respectively welding bead which are harm ful to seat facing 6 1 2 Operation Swing check valves are automatic valves which are opened by the flow medium stream or closed in opposite direction When the valve swings open it is limited by a block in the body to such an extent that the valve can fall back into its seat due to its own weight ATTENTION In the case of the design with lever and weight the moving parts may cause very fast movements 6 1 3 Function check up The following functions have to be checked up In the case of swing check valves with lever and weight the stuffing box packing efficiency has to be checked up before the first loading by full working pressure and temperature If neces sary the stuffing box gland must be retightened The sealing efficiency of the bolted bonnet connections with the gasket must be examined after the first loading warming up of the valve Maintenance free valves too If necessary the bolted bonnet connections have to be gently crosswise and evenly tightened 6 2 Putting out of operation During longer standstill periods liquids whose form can change in concentration due to polymerisation crystallisation solidifica tion or the like have to be let out of the line system If neces sary the line system has to be rinsed by completely open va
16. o be taken care that no impurity get inside of the body or even stay there oth erwise the seat facings and the stem sealing can be damaged ATTENTION During welding works valves have to be as wide open as to exclude any contact between the sealing parts oth erwise the seats can get fused IATTENTION If welding works are done in the proximity of soft seated valves it has to be taken care that the valves are not warmed up over the temperature limits indicated in the type sheet Reason damage of the seat facings ATTENTION The welding cable opposite pole must be at tached by no means to any functioning parts of the valves oth erwise scorching can be caused The insert depth of valves with socket weld ends has to be ob served accordingly to the referring standard A gap between pipe end and socket base serve as prevention from inadmissi ble welding seam strain Issue 09 2011 KLAUS UNION GmbH amp Co KG 6 Operation putting into and out of operation See also indications in paragraph 5 lt Installation gt 6 1 Operation putting into operation 6 1 1 Generalities Before putting the valve into operation its material pressure and temperature data have to be compared with the operation terms of the pipeline Eventually appearing shock pressures water hammer should not exceed the maximal admissi ble pressure Protective measures have to be pro vided The line system of
17. sen the nuts and lift the stuffing box gland or loosen the packing bolt Before repacking the stuffing box chamber has to be carefully cleaned Slotted packing rings have to be inserted with the cut located in opposite position between one ring and the other precisely 120 180 BA 1731 1733 Swing check valves_Rev 2_EN doc Page 6 7 Issue 09 2011 KLAUS UNION GmbH amp Co KG Page 7 7 Lifting a valve for installation in horizontal pipelines examples Picture 1 The lifting belts 1 and 2 must be twisted round the body bonnet flange In order to maintain the valves in the shown position and to prevent them from falling vertically the two lifting belts 3 and 4 should be twisted around the body connecting flanges and lead to the hook uN Valves must not be lifted by the attached components e g lever or weight Lifting belt 1 Lifting belt Lifting belt 3 Lifting belt 3 Lifting belt 2 Lifting belt 2 Lifting belt 4 Lifting belt 4 Picture 1 Lifting a valve for installation in vertical pipelines examples Picture 2 The lifting belts 1 and 2 must be twisted round the body Lifting belt 3 serves to hold the valves in vertical position Lifting belt 1 Lifting belt 1 Lifting belt 3 Lifting belt 3 Lifting belt 2 Lifting belt 2 u Ww Picture 2 BA 1731 1733 S
18. t not be used as steps Valves and pipelines working in high temperatures gt 50 C or low lt 0 C must be protected from con tact by insulating Alternatively the danger must be indicated by warning boards on the valve side ATTENTION If in air conditioning cooling and refrigerating sys tems any condensation water respectively danger of icing ap pears a specialistic and diffusion tight insulation of the whole valve has to be provided Icing causes a blocking of the valve operation capabilities 5 2 Installation position Swing check valves are preferably installed in horizontally laid pipelines Here the cover must face upwards in order to en sure the hanging direction of the valve disc Swing check valves have a defined flow direction which is dis played on the body by a direction arrow 5 3 Prevention of inadmissible overpressure KLAUS UNION valves are basically only suitable in operating conditions which are shown in the corresponding pressure temperature tables Appropriate measures must be taken to ensure no inadmissible load on the valves develops due to pipeline positioning or bad operating conditions 5 4 Welding instructions pipeline assembly For welding works on the valves the pipeline manufacturer is responsible ATTENTION Whenever the valves with butt welding ends or socket weld ends are welded and during welding works at the pipelines with already installed valves it has t
19. wing check valves_Rev 2_EN doc Issue 09 2011
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