NON-LUBRICATED 3ZVALVES3Z VALVES … Diverter Valve Manual.pdf1 INLET BALL VALVE 2 OUTLET BALL VALVE 3 PIPEUNION 7 ... Inject through grease fitting on top of ... check into the status

NON-LUBRICATED3Z VALVES 4WAY DIVERTER VALVES3Z VALVES – 4WAY DIVERTER VALVES

INSTALLATION, OPERATIONAND MAINTENANCE MANUAL

3Z CORPORATION3Z CORPORATION254, SIHWA VENTURE-RO, SIHEUNG-SI, GYENOGGI-DO, SOUTH KOREA(TEL) +82.2.333.1212 (FAX) +82.2.333.4111E-mail : [email protected] Web:http://www.3zvalve.com

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

DOC.NO. 3ZQM-E-06 1/19

REV. NO. B

ISSUED AUGUST. 21, 2017

CONTENTS

1. STRUCTURE OF 4WAY DIVERTER VALVE

2. INSTALLATION

3 OPERATION3. OPERATION

4. MATERIALS OF CONSTRUCTION

5. MAINTENANCE AND REPAIR



REV. NO. B


1. STRUCTURE

Slip & Viton Seal :

Indicator :Indicate the direction of the plug.

Slip & Viton Seal :Viton seal, molded on Slip perform Double block and bleed function. There is no abrasion, since slip seal is pull away from body before the plug is rotating

Handle & operator :It is designed for easy operation and minimize the possibility for line shock

Plug & Trunnion :It is designed to trunion

for line shock

Bottom cover :The bottom cover is

gtype to maintain correct alignment of the plugwhen opening and closing.

SIZE 2”~8”

The bottom cover is removable for replacement of slip seal without disassemble from pipe line

(In Line repairability)

Gland & packing :Use graphite packing to meet

SIZE 10”~24”

Use graphite packing to meet fire safe design and Viton o-ring.O-ring material can be changed as per customer requirement.



REV. NO. B


2. INSTALLATION

1) 4-way diverter valve being carried, a rope, wire, and shackle should be strong enough to sustain the total weight.

2) 4-way diverter valve should be installed with the firm groundwork..

3) Flanged ends type valves should be installed with standard gasket, and the bolts should be tightened by diagonal axis successively.

4) When 4-way diverter is installed to Metering system, it should be matched inlet or outlet of prover with “IN” or “OUT” of the valve port. If there is fault in installation, valve can be damaged by severe flow and there can be pressure drop when the plug is rotating.

5) When the valve is installed horizontally or inverted, the differential check system should be installed toward to valve upstream..



REV. NO. B


3. OPERATON

3-1. Plug Operation

3-1-1. Turn the handle to close position, mechanism is lifted up with plug

3-1-2.By lifting up the plug, slip is pull away from the surface of body seat.

SIZE 2”~8”

3-1-3.The plug is rotate to clockwise direction.

SIZE 10”~24”

3-1-4.After the plug rotate3-1-5 After the plug rotate 90˚, it is going down.

3-1-5.Slip is seated to the surface of body seat by plug.



REV. NO. B

ISSUED AUGUST. 21,2017

3-2. Proof of Seal Integrity.

NO PARTS

1 INLET BALL VALVE

2 OUTLET BALL VALVE

3 PIPE UNION

7

6 3 PIPE UNION

4 OUTLET RELIEF VALVE

5 INLET RELIEF VALVE

6 NEEDLE VAVLE

7 DIFFERENTIAL PRESSURE GAUGE

5

4

6

3-2-1. Ball Valve for inlet should be opened always.

3-2-2. Ball Valve for outlet should be opened always.

3-2-3. Relief Valve for inlet should beinstalled toward to Body.

3

installed toward to Body.

3-2-4. Relief Valve for outlet should beinstalled toward to flow direction.

3-2-5. Gauge용 Needle Valve for gauge should be closed always.

3-2-6 Install pipe union for convenient

2

1

3-2-6. Install pipe union for convenient of replacing pipe.

3-2-7. Open needle valve to check proof of seal integrity.

3-2-8.Check the indicator of differential pressure gauge after operating of valve. The indicator shall be indicate between 1 bar and 3 bar within 30 seconds.

3-2-9. If the indicator is dropped or did not maintain the position, you must check below3 2 9. If the indicator is dropped or did not maintain the position, you must check below point.A. External leakage.B. Fault of Open & Close Limit setting.C. Leakage of check valveD. Defect of GaugeE. Seal Leakage.



REV. NO. B


4. MATERIAL OF CONSTRUCTION

4-1. SIZE 2”~8”NO PARTS MATERIAL

1 BODY Carbon Steel2 PLUG Carbon Steel3 STEM Alloy Steel4 TOP COVER Carbon Steel

b l

19

5 BOTTOM COVER Carbon Steel6 SLIP Ductile Iron7 SLIP SEAL Viton8 BUSHING GRAY IRON9 GASKET GRAPHITE10 O-RING VITON11 COVER BOLT B712 HOUSING BOLT B713 GLAND C b St l

16

18

20

13 GLAND Carbon Steel14 GLAND PACKING GRAPHITE15 HOUSING Carbon Steel16 OPERATOR Alloy Steel17 GUIDE Alloy Steel18 HOUSING COVER Carbon Steel19 INDICATOR Carbon Steel20 GEAR OPERATOR STEEL

8

13

14

15

17

3

8

410

11

12

9

7

6

2

5

1

SIZE 2”~8”



REV. NO. B


NO PARTS MATERIAL

1 BODY Carbon Steel2 PLUG Carbon Steel3 STEM Alloy Steel4 TOP COVER Carbon Steel

b l

19

4-2. SIZE 10”~24”

5 BOTTOM COVER Carbon Steel6 STOPPER Carbon Steel7 PLUG SEAL Viton8 BUSHING GRAY IRON9 GASKET GRAPHITE10 PLUG SEAL PLATE Carbon Steel11 COVER BOLT B712 HOUSING BOLT B713 GLAND C b St l

17

18

20

13 GLAND Carbon Steel14 GLAND PACKING Graphite15 HOUSING Carbon Steel16 OPERATOR Alloy Steel17 GUIDE Alloy Steel18 HOUSING COVER Carbon Steel19 INDICATOR Carbon Steel20 GEAR OPERATOR STEEL

11

15

16

3

8

14

12

13

7

2

6

4

1

10

SIZE 10”~24”9

2

5

1



REV. NO. B


5. MAINTENANCE AND REPAIR

5-1. Inject grease every six months.

Inject through grease fitting on top of housing.

5-2. Replace Mechanism and Packing for 2”~8”

5-2-1 Remove pressure inside of body5 2 1. Remove pressure inside of body.

5-2-2. Remove weather seal from housing

5-2-3. Remove plug pin from operator

5-2-4. Remove housing cover bolt from housing.

5-2-5. Remove mechanism from top cover.



REV. NO. B


5-2-6. Remove gland bolt.

5-2-7. Remove gland and packing.(Use new packing, when re-assembly.)(Use new packing, when re assembly.)

5-3. Replace slip after removing bottom cover for 2”~8”

5 3 1 Turn the operator to lift up the plug enough

5 3. ep ace s p a te e o g botto co e o 8

5-3-1. Turn the operator to lift up the plug enough.

5-3-2. Remove drain plug from bottom cover and drain the fluid inside of body.

5-3-3. Remove bottom cover bolt from cover.


DOC.NO. 3ZQM-E-0610/19

REV. NO. B


5-3-4. Remove bottom cover from body.

5-3-5. Remove bottom gasket from body.(Use new packing, when re-assembly.)(Use new packing, when re assembly.)

5-3-6. Replace to new slip after remove old one from body.

5-4. Replace plug seal after removing Mechanism and Top Cover for 10”~24”

5-4-1. Turn the operator to pull away plug from body(Make the plug to free fall.)

5-4-2. Remove drain plug from bottom cover and drain5 4 2. Remove drain plug from bottom cover and drain the fluid inside of body..



REV. NO. B


5-4-3. Remove weather seal from housing.

5 4 4 Remove plug pin from operator5-4-4. Remove plug pin from operator.

5-4-5. Remove housing cover bolt from housing.

5-4-6. Remove mechanism from top cover.

5-4-7. Remove gland bolt.

5-4-8 Remove gland and packing5 4 8. Remove gland and packing.(Use new packing, when re-assembly.)



REV. NO. B


5-4-9. Remove top cover bolt from top cover.

5-4-10. Remove top cover from body.

5-4-11. Remove gasket for fire safe.(Use new gasket when re-assembly.)

5-4-12. Remove plug from body.p g y

5-5. Replace plug seal for 10”~24”

5-5-1. Remove bolt for plug side plate from plug.



REV. NO. B


5-5-2 Remove plug side plate from plug5-5-2. Remove plug side plate from plug.

5-5-3. Remove bolt for plug top plate from plug.

5-5-4. Remove plug top plate from plug.



REV. NO. B


5-5-4. Remove bolt for plug bottom plate from plug.

5-5-5. Remove plug bottom plate from plug.p g p p g

5-5-6. Remove plug seal from plug.

5-5-7 Replace to new plug seal5 5 7. Replace to new plug seal.



REV. NO. B


6. Special disassembly

6-1. Replace slip after removing top cover for 2”~ 8”

6 1 1 Check the indicator to see is the valve is open6-1-1. Check the indicator to see is the valve is open or close first.

6-1-2. Make sure that the valve is close and then remove the cap of Plug pin.

6-1-3. Check the location of Plug pin in the status of full on and of full close.



REV. NO. B



6-1-4. Make the location of the plug part going up by operating the valve in the direction of open or close In case of plug pin it needs to be lifted up to the point you are able toof open or close. In case of plug pin, it needs to be lifted up to the point you are able to disassemble.

6-1-5. Disassemble the plug pin after removing the plug snap ring.

6-1-6. Close inlet ball valve and outlet ball valve.



REV. NO. B



6-1-7. Disassemble the proof of seal integrity system by rotating pipe union.

6-1-8. Take the mechanism off the valve after disassembling the housing bolt.



REV. NO. B



6 1 9 Disassemble the gland part by unscrewing the bolt6-1-9. Disassemble the gland part by unscrewing the bolt.

6-1-10. Disassemble the top cover part by unscrewing cover bolt.

6-1-11. Lift the top cover using the eye nut.



REV. NO. B



6-1-12. Once you disassemble the top cover, remove the gasket. When looking into the spiral wound gasket, you can reuse the part if there is no flaw inside.

6-1-13. After taking the plug and slip off the body part, check into the status of the part of body and slip. Reassemble the device in reverse order of disassembly.

Documents

NON-LUBRICATED 3ZVALVES3Z VALVES … Diverter Valve Manual.pdf1 INLET BALL VALVE 2 OUTLET BALL VALVE 3 PIPEUNION 7 ... Inject through grease fitting on top of ... check into the status