Butterfly Valves Waferdesign Manual o&m

7/28/2019 Butterfly Valves Waferdesign Manual o&m

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Installation,Operationand

MaintenanceManualforWafer-type

BUTTERFLY YALVES-


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Installation, perationandMaintenance anualforWafer-typeButterflyValves

1.0 STORAGEOn leccipt.check hat hc valvesand accessories rrentact.Ensurethat the valve is in a 'crack-open' position so that the clastomerseat s not under compression.and at the same irne the disc doesnot protrude outside r,alve bodv.

End protectors(stickers) on either side of the valr.e should bekept n tact and be removed onlv at the time of installation.Directexposure o sunlight can deteriorate he elastomer.The valves should be stored in a covered area. If covered area isnot available. an!. \.rv,aterroof coverin-smaterial should be spreador.er he valves and the r,alvesshould be kept on a wooden palletat least6" above the sround level.Do not applv tar. paint. grease or an_vother material inside thel alve or on the shaft as this rvould impair the perfcrrmanceof thevalve.While transporting the valve from stora-se rea to installation site.it should not be dra-egedon the ground.


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2.0 CONSTRUCTIONAIL Wafer ype butterfly valvesareof compactdesignanJ lightweight.The rubber ined butterfly valvesprovide ight shuroff. 'I'hediscseats n to an integrallymouldedelastomern thebody.Thediscis operated y a shaftdriven internally.The typical valve constructions shownbelo'*,.

VYEATHERSEALACETALBEARINGs@. sETscREwBODYTOP SHAFTDISCDISC BEARINGBODYLININGBOTTOM SIIAFTCIRINCRETAININGPIN

IMPORTANTThesevalves do not require a separate lange gasketwhilemounting on to the pipeline.The elastomerseat tself projectsoutside he body so as to form a gasket.When the companionflangeson eithersideare ightened,heelastomer etscompressedandprovides equiredsealing.AIL wafer ypeButterflyvalvescanbe categorisednto four typesdependingon the type of application.This manualcovers thefollowing types:


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a. Slimseal - used or generalpurpose.b. Chemseal used n chemicaland corrosiveservicesc. Cleanseal for food & hygienic servicesd. Aquaseal for air conditioning& refrigeration ndustry

3.0 INSTALLATIONa. Handle hevalve with appropriate ifting equipment.Use ifting

lugs/eyebolts only for handling. Prop up thevalvetemporarilyif necessary. eep the valve in nearly closedposition whileinstalling.

b. Do not use opeor chain hroughvalveport.Use hebolt reliefholesat the top of the body for passing he rope or chain.c. Carefullycheck he cleanliness f the companion lange aces

andclean f necessary.d. Centre he valvesuch hat he shaft is in a centreposition.Donot usevalve as ack to pull thepipe nto alignment.e. Fit the flange bolting on both sidesand tighten.No gasket s

required separately.f. Ensure hevalve interiors and adjacentpiping arecleanedpriorto tightening he oints.g. Tighten he bolts,working diagonally to the required orque,

usinga torquewrench.h. Ensure hat the pipline stresses renot transferredon to the

valve as his canresult n leakageacross he seator difficultyin operation.

i. In newpipelineswhenweld neckcompanion langesareused,centre each flange bore to the valve bore and run the boltsthrough.Tack weld the pipesto the flanges and remove theboltings o take out the valve; then finish weld the flanges opipeso that he elastomer eat s not damaged y the welding.

j As no separate asket s required between he flanges, lat faceflanges are recommended. n case of valves with EPDM,Hypalon.Siliconeor Aqua nitrile, it must be ensuredhat theflange faces are totally free from grease/oilwhich will swellthe elastomers.


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3.1 Do's& Dont's

3.2 Sequenceof Flange TighteningThe sequenceo be followed for bolts tightening while installationof valve is shown below.

.:. ;;J , - -


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Insert 1bolts near to neck area and tighten the bolts as per thesequence ir,en n the figure evenlyandnor fully tightened.Check he valve is being concentric o the pipeline and ensuresmoothoperationof valve.If furtherbolts are to be tightened. ollow the similar sequencei.e. ighten hebolts diagonallyand not fully tightened.Now tighten all the bolts diagonallytill the clamping facesofflangeust touch he bodymetalend aces.Over tightening s notnecessarynd o be avoided.Thesevalvesare suitable or installationbetweenpipe flangeslistedbelow:I. BS 4504 PNIO/DINNDIO2. BS 4504 PNI6/DIN NDI63. ANSI816.1 Class 25 l

ANSI B16.5 Class1504. BSl0 - TableD5. BSl0 - TableE6. IS 6418Tables to 9'7. IS 6392Tables 0 to 20


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3.3 Lined Pipes and Heavy Walled pipes should have aMinimum nsidediameterwell clearof Dimension ZN"(ReferFigure shown Below) in Disc fullopen positaon.

Dimerrsions sizes n mm

When installing he valvebetween xistingpipe flanges. he langesarerequired o be spread ufficiently while placing he valvebetween hemto preventany damage o the sealingend face which actsas he gasket.Pipe ine is expectedo provicie or this flexibility.

V a l r c . ; i : e -50 65 80 100 l2-s 150 200 250 300 350 .100 450 500 5(X)"Z\" - lirrnn. ofpr(,trudinsdiSc

27 .t7 6l 83 t07 136 r85231 280 325 376 176 573


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4.0 VALVEMOUNTINGAIL Butterfly valvesare bi-directionaland can be mounted nverticalor horizontalor angularpipelineswith shaft n anyposition.Slurry ServiceThe valve is to be mountedon horizontalpipelinewith shaft nthehorizontalpositionwith lower discedgeopening n thedownstream ide or best esults.START-UPAfter installation,he pipelineshouldbe cleanedby compressedair or by flushing with water,keeping he valve fully open.Theuse of temporary filters on the upstream side of the disc isrecommendedo avoid any damage ausedby the transportationof abrasiveparticles.Ensure that the pipeline stresses re nottransferred o the valve asthis can distort the seatingand result nleakagearound he seator higher torque.HYDRAULIC ESTOF THE INSTALLATIONAIL Butterfly valvesare ndividually pressureestedn our factory.If a hydraulic estof the piping installation s ro be underraken,make sure hat the valve disc is in the openposition and checkthat hevalvematerial nstalled s compatiblewith the testmedium.Testpressure e limited to the maximumratedpressure.

OPERATIONManually perated alves(i ) AIL Butterflyvalvesupto 12" canbe operated y wrenchandsizesabove12" aresuppliedwith gearunit. GearUnit can be

fitted for any sizeon spqcific requestat the time of ordering.

5.0

6.0

7.07.1


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(ii) VALVES WITH FC LEVERAND LATCHARRANGEMENT:The generalconstructiondetailsof FC lever and atch fittedon to valve s shownbelow.

FC LI\JERt_.{TcH

\O'TCHED \DICATOR

Press he latch upward to release he latch from notchedindicator.At pressed onditionoperatehe valve. f thepressingis not done ully while operation,atch will gerdamaged ythe notched ndicator.

(iii)VALVES WITH FC LEVER HEAD ARRANGEMENT:The general onstruction etailsof FC lever ittedon to valveis shownbelow.

Ht\DLEFC LE\ER IIE.\D

NOTCHEDI\DIC,,lTOR

\OSE

Press hehandledown to releasehe everhead rom notchedindicator.At pressed onditionoperate he valve. f thepressingis not done fully while operation, ever headnosewill getdamagedby the notched ndicator.(iv) GEARED VALVES : All gearboxeshavean ndicatingpointeron the gearbox which shows he angularmovementof thedisc as well as the open/closed ositions.They also have apositivestop n both the openand closedpositions.

Whenclosing he valve, hehandwheel houldbe urnedonlyup to thatpositionwhere he ndicatingpointermatcheswiththe letters CLOSE" on thegearbox case.This by itself willensureproper sealing.There s no need o "slam" the hand


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wheel t i l l i t jams this pract ice s neither necessary orrecommended.Similar s the casewhenopening hevalve.

7.2 Electrically operated valvesElectrical actuatorsare fltted to the gear unit or directlymounted.For operational etailsconsult he manufacturer'snstructionmanual andthe appropriatewiring diagram.Ensure hat electricalconnections regivenas ndicated n thewiring diagram or the specificactuator.Before making a test run move the disc to an intermediarypositionby meansof the handwheel.Start he motor and see f the rvorkinedirection s correct.

7.3 LIMITSWITCHSETTINGTheactuatorimit switch s set n the acttlry.However. or valvesrvithextension pindle. ctuators approximately reset ndshouldbe resetat site. The presettingcan also be modified if requiredonce hevalvehasbeenput nto service.Do not disturb he mechanical tops n the quarter urn -eear nitwhich are factory set.

8.0 MAINTENANCEln normal use, hesevalvesare tnaintenanceree andrequirenoattention. hey are iterally 'fit & forget' valves.

8.1 Seat LeakIf there s a leakacross he seat.checkdisc surf-ace.f the disc sdamaged,t can be replacedas detailedbelou' :

8.2 Dismantling and Re-AssemblyGenerally here s no need o dismantleour valve:;.However, f itis desired, hevalvecan be dismantledand reassembled.To dismantle he valve,proceedas ollows.

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8.2.1 a) 50-300mmSL|MSEAL,HEMSEALCLEANSEALBUTTERFLYALVESTheconstruction f thisgroup s shown n the ollowing diagram:

WEATIIER. SEALACtsTALBEARINGSOC.SETSCTEWBODYTOPSIIAFTDISICDITICBEARTNGBODYIININGBOTTOMSIIAFTORINGR.ETAININGPIN

Dismantlingl. Remove he gearunit or actuator f fitted.The wrenchmaybe left in positionon wrenchoperated alves.2. Remove he socketsetscrewandpull out top shaft.3. Remove he bottom shaft-retaining in.4. Inserta long drift throughrherop shafthole anddrift outthe bottom shaft.5. Pull out thedisc.

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Re-Assembly1. Cleanbody, shafts,discetc.

2.3 .

4.

5 .6.7 .

NB: After cleaningandprior to assembly, ight applicationof siliconegreaseo all surfaces f all matingcomponentsis recommendedNo othergrease o be used,which maybe harmful to certainkinds of elastomers).'O'ring on bottom shaftshouldbe replacedwith new.For 50mm to 200mm stainless teeldisc fitted valves, ixnew PTFE bearing nto disc if the bearinghas sufferedanydamage.Pushdisc nto boreof body in fully openpositionandensurepositionof squarehole n disc owards op platform end ofbody.Fit top & bottom shaft, and ensure op shaft cross holeposition s perpendicualro the discposition.Align corresponding oles n body and bottom shaft & fi tnew bottomshaft-retaining in.Align groove n top shaftwith corresponding ole in bodyand ightennew socketset screw il l it touches he shaft&unscrew l2 tum to ensure t doesnot Jam' the shaft.Fix weathersealon top of valve.Fit operatingmechanism ndensure lockwise otation orcloseoperation.Check he disc/wrenchorientation s correct.Lever indicatesthepositionof disc n thevalve."Lever along hepipeline"will mean, disc open", and"acrossthepipeline" will mean,"disc closed". Check this featurewhile making 'disc toshaft'connection. f the discorientationwith lever s wrong,thedisc canbe rotated hrouqh 90" to correct he fault, afterdismantlins.

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(b) 350-600mm LIMSEALButterftyVatvesTheconstruciton f this group s shown n the ollowing diagram.:

BODYsoc. SETSCREWBODYBEARINGBODYLININGTOP SIIAFTDIIICDISC BEARINGBOTTOM SIIAFTRETAININGPINPLUG

NUTBOTTOM @VERPI.AIE

Dismantlingl. Remove he gearunit or actuator f fitted.2. Remove the socketset screwand pull out top shaft3. Remove he screwsand removebottomcoverplate, ockplate,plug & ring nut.4. Remove the bottom shaft-retainingpin.5. Insert a long drift through the top shaft hole and drift outthe bottomshaft.6. Pull out the disc.Re-Assemblyl. Cleanbody, shafts,discetc.

NB: After cleaningandprior to assembly, light applicationof silicone greaseo all surfaces f all matingcomponents

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8.2.3

is recommendedNo othergrease o be used. .r'hichmaybe harmful to certainkinds of elastomers).

2. Pushdisc nto boreof body n fully openpositionandensurepositionof square ole n disc owards op platformend ofbody.

3. Fit top & bottom shaft. and ensure op shaft cross holeposition s perpendicularo thediscposition.4. Align corresponding oles n body and bottom shaft& fitnew etaining in.5. Align groove n top shaft with corresponding ole n bodyand ightennew socketset screw ill it touches heshaft&unscrew /2 turn.6. Fix lock platewith gasketor 'o' ring to bottomplatformofbody.1. Lock the bottom shafl with plug and ring nut adjustingsuitably o avoidseat eak.8. Fix the bottom cover plate *'ith 'o' ring or -qasketo theplatformof body.9. Fit operatingmechanism ndensure lockwise otation orcloseoperation.(c) 50-300mm quasealButterflyValvesTheconstruction f this model s sho'*.nn the ollowins diasram:

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is recommendedNo other grease o be used.which maybe harmful to certainkindsof elastomers).

2. Pushdisc nto boreof body n fully openpositionandensurepositionof square ole n disc towards op platformend ofbody.

-3. Fit top & bottom shaft. and ensure op shaft cross holeposition s perpendicularo the discposition.4. Align corresponding oles n body and bottom shaft& fitnew etaining in.5. Align groove n top shaftw.ithcorresponding ole n bodyand ightennew socketset screw ill it touches he shaft&

unscrew /2 turn.6. Fix lock platewith gasketor 'o' ring to bottomplatformofbody.l. Lock the bottom shafi with plu-eand rin-enut adjustingsuitably'to voidseat eak.8. Fix the bottom cover platewith 'o' rin-eor ,gasketo theplatformof body.9. Fit operatingmechanism ndensure lockwise otation or

close perat ion.8.2.3 (c) 50-300mm Aquaseal Butterfly Valves

Theconstruction f this model s shown n the ollowing diagram:ROSS HOI-EWTmSilLAmlBImcrcPSffiMDYAODY UNC

Dts

BOTTOMSffi

omGHMGPN

TMDHOT

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3 .4.

Dismantl ingl. Removeoperatingmechanismomplete2. Removebottomshaft-retaining in & puli bottomshaftby

using appedhole at the bottom.Pull out top shaft& acetalbearingby usingcrosshole.After removing wo shafts hedisc can be pushedout fromthe bod1.'.

Re-Assemblyl. Cleanbody'. hafts. iscetc.

NB: Atier cleaningandprior to assembly. ightapplicationof silicone qreaseo all surfaces f all matingcomponentsis recommendedNo othergrease o be used.which maybe harmful to certainkinds of elastomers).'O' ring on bottom shaft & acetalbearing fbr top shafishouldbe replacedwith new.Pushdisc ntoboreof body n fully openpositionandensurepositionof squarehole n disc owards op platformend ofbody.Push he bottomshaft nto body anddisc shaftholes.Ali_en orresponding oles n body andbottomshaft & fitnerr retainingpin.Push he op shaft hrou-sh ody shafthole o locare n disc.Fix new acetalbearingat the top of body till it touches hetop shaft shoulder.Fix weathersealon the top of valve.Fix operatingmechanism ndensure lockwise otation orcloseoperation.Check the disc / wrench orientation s correct. Leverindicates hepositionof disc n the valve. "Lever along hepipeline"will mean, discopen",and"acrossthepipeline"will mean. discclosed".Check his eaturewhilemakins

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4.5 .6 .7 .8 .9 .10.

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'discto shaft'connection. f thedisc orientationwith leveris wrong, the disc can be rotated hrough 900 o correctthefault.

AFTER ASSEMBLING ANY SLIMSEAL, CHEMSEAL,CLEANSEAL OR AQUASEAL VALVE, THE FOLLOWINGPRECAUTIONSTO BE FOLLOWED TO ENSURETROUBLE FREEPERFORMANCE.

GENERAL PRECAUTIONSl. If any further cleaning s necessaryhis should be done with

diluteddetergent ollowed by water and should not be with ahydrocarbonor similar solvent.2. Checkcompleteoperationof valve and if necessary djust he'open'and'shut' positionsofgearboxes andactuatorso ensurecorrectoperation.

3. Pressureest he valve beforeputting t back o work' If in doubtabout he estprocedure, leaseeferBS : 5155 atestamendment.

4. Do not exposeelastomer eatso sunlightor ozone or extendedperiods In caseof blacknitrile liner, ts contactwith ozoneshouldbe totally avoided).

5. Foreignmaterial n the butterfly valve can damageelastomerseatwhen operated.Ensure valve interiors and adjacentpiping arethoroughlycleanedprior to installation.

6. Ensure he valves are not subjected o pressures bove ratedpressures f the valves Black nitrile - 16 bar;White nitrile - 14bar;Hypalon/Viton 12bar EPDM, Silicone- 6 bar: Aquaseal10bar).

7. Ensureend faces are suitably protectedby end protectors opreventdamageo disc and body lining while in storage.8. If pipelinesarebeingpurgedprior to commissioning,his shouldbe donewith the valves n the fully openposition.Care to betaken o ensure hat the purging pressuredoesnot exceed he testpressure f the valve.

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Butterfly Valves Waferdesign Manual o&m