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GESTRA ZK 29 Installation Instructions Manual

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Control Valve
ZK 29
Original Installation Instructions
810685-05

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Summary of Contents for GESTRA ZK 29

  • Page 1 Control Valve ZK 29 Original Installation Instructions 810685-05...

  • Page 2: Table Of Contents

    Contents Foreword ............................3 Availability ............................. 3 Formatting features in the document ...................... 3 Shown and described types of equipment ....................3 Safety ..............................4 Use for the intended purpose ......................... 4 Basic safety notes ..........................4 Information on property damage or malfunctions ..................6 Qualification of personnel ........................

  • Page 3: Foreword

    Foreword document This installation & operating manual (IOM) will help you use the control valve ZK 29 and its variants Certain text elements of this installation & operating (referred to as "equipment" in this document) safely manual feature a specific typographic design. You and efficiently for its intended purpose.

  • Page 4: Safety

    Basic safety notes Safety Explosion hazard Use for the intended purpose  Explosion risk if equipment is used that is not The equipment is designed for controlling and suitable for the environmental conditions. When regulating the level, pressure and flowrate of fluids using the equipment in explosion risk areas in heat and process control systems.
  • Page 5  If the equipment is used in contaminated areas temperature ratings see name plate and the Technical Data there is a risk of severe injuries or death caused section " ". by harmful substances in or on the equipment.  The equipment may be damaged if the Before working on the equipment make sure connection of the equipment with the pipe is not that it is completely decontaminated.

  • Page 6: Information On Property Damage Or Malfunctions

    Protective gear Risk of minor injuries  Sharp edges on component parts can cause The required protective gear depends on the types cuts. Always wear industrial gloves when of fluid used and the regulations on site. For more servicing the equipment. information on suitable protective clothing and ...

  • Page 7: Formatting Features For Warnings Of Property Damage

    Formatting features for warnings  Nozzle If the equipment is fitted with a rotary actuator, the of property damage bonnet and the upper part of the equipment form a functional unit. Attention! If the equipment is fitted with a pneumatic diaphragm actuator, you can detach the bonnet This information warns of a situation from the cover.
  • Page 8 Example of type designations "ZK 29-D50/14" Straight-through equipment DN50 with plug-in connection form B1 to EN ISO 5210 for an electric rotary actuator. "ZK 29-E/20" Angle-type equipment with pneumatic diaphragm actuator. In most cases the equipment described in this IOM is of the straight-through type and has a spindle bearing for an electric rotary actuator.
  • Page 9 Component parts Designation Designation Mechanical connection for actuator, in Cover equipment with rotary actuator this is a Name plate spindle bearing (shown here) Flow direction arrow (on both sides) Pneumatic diaphragm actuator Body Bonnet...
  • Page 10 The yoke is fitted with the following items: Designation Spindle Scale marking indicator Scale...
  • Page 11 The design and mounting of the stuffing-box packing is different in equipment with rotary actuator and equipment with pneumatic diaphragm actuator Stuffing box in equipment with rotary actuator Designation Designation Stuffing box gland Base bushing Packing rings Hinged bolts Distance sleeve...
  • Page 12 Stuffing box in equipment with pneumatic diaphragm actuator Designation Designation Packing rings Packing gland Base bushing Grooved ring Union nut...
  • Page 13 The following items are fitted inside the equipment: Designation Designation Body gasket Gasket Hexagon-head screws with lock wire Stem Thrust ring Seat ring Anti-wear element (sleeve or ring - Sleeve insert (pinned together with rivet) depending on equipment type)
  • Page 14 Optional extras The following items are available as optional extras: The stem lift in equipment fitted with a  Grease nipple (only on actuator with handwheel pneumatic diaphragm actuator can be or electric rotary actuator) limited by means of a handwheel attached to the actuator.
  • Page 15 Name plate ATEX Directive The following items are indicated on the name The equipment has classification: CE Ex II 2G/D c X. plate: For use in potentially explosive atmospheres in  Manufacturer zones (surrounding atmosphere to Directive  Type designation 1999/92/EC) 1, 2, 21 and 22, please read and observe the following information: ...

  • Page 16: Task And Function

    Task and function Purpose The equipment is designed to reduce pressure in pipes through which the following fluids flow:  water  steam  condensed water In addition the equipment can control the flowrate and the fluid level. The equipment can stop the fluid flow completely, effecting a pipe seal to attain bubble-tight shut off.

  • Page 17: Storing The Equipment

    Storing the equipment Transporting the equipment  Please observe the following items when storing DANGER the equipment:  Make sure that the equipment is completely Risk of bruises if the equipment or disconnected. component parts fall down.  Before storage make sure that the equipment is ...

  • Page 18: Mounting And Connecting The Equipment

    For more information on the weight of the If you do not have the sealing plugs equipment see the attached documents. For more supplied with the equipment use information on the weight of the actuator see the appropriate seal caps to seal off the documents provided by the actuator manufacturer.

  • Page 19: Connecting The Equipment

     Switch the installation off and protect it against The equipment is designed for installation unauthorised or unintended re-activation. with the stem in vertical position and the actuator mounted on top. Connecting the equipment Other installation positions are possible.  Contact the manufacturer if you want to DANGER mount the equipment in a different position of installation.

  • Page 20: Checking The Function

     Make sure that only qualified personnel carries The stem must perform at least one full valve out the heat treatment. stroke.  After the heat treatment you may insulate the  Change, if necessary, the actuator settings as equipment if necessary. indicated in the operating manual of the actuator.
  • Page 21 In equipment with other actuators the stuffing box can be adjusted via the hinged bolts. The following section describes how to adjust the stuffing box in equipment with electric rotary actuator. The adjustment procedure is the same for other types of equipment. The torque required for tightening the stuffing box screws depends on the type.
  • Page 22 Adjusting the mechanical stroke limiter You can adjust the lowest stem position using the optional stroke limiter (8) on the spindle. This ensures that an adjustable minimum quantity of medium continually flows through the equipment. The optional stroke limiter is only available for equipment with a rotary actuator.

  • Page 23: Operating The Equipment

    Turning the sleeve insert In equipment with a mechanical stroke limiter, you can determine the minimum stroke. The equipment can be adapted to the operating conditions.  To do so, proceed as described in the section Adjusting the mechanical stroke limiter "...
  • Page 24 A qualified person must be acquainted with and DANGER experienced in the following:  Working on pressure equipment Personnel working on pipes are exposed to safety risks and may suffer severe injuries,  Lifting loads poisoning or even loss of life. ...

  • Page 25: Maintaining The Equipment

    Maintaining the equipment Maintenance schedule Interval Component Activity 2 months Spindle Move spindle by at least one complete stroke. 3 months Stuffing box seal Visually inspect to ensure tightness. Retighten a leaky stuffing box, replace if necessary. Visually inspect the following points: ...

  • Page 26: Rinse The Equipment

    Lubricating the equipment For details on how to order spare parts refer to the parts list. Attention!  The gaskets of the equipment must be replaced in any case. Equipment may be damaged if unsuitable  Re-assemble the equipment as described from lubricant is used.
  • Page 27 Preparing equipment for rinsing Attention! Remove all parts from the body before rinsing the equipment. Equipment may be damaged by unsuitable  Disassemble the equipment as described from cleaning fluid. page 28onwards.  Rinse the pipe with the same fluid that ...

  • Page 28: Disassembling The Equipment

    Disassembling the equipment Preparing the equipment for disassembly You have to disassemble the equipment if you want DANGER Personnel working on pipes are exposed to  rinse the pipes and the equipment safety risks and may suffer severe injuries,  service component parts poisoning or even loss of life.
  • Page 29 The space required for disassembling and DANGER re-assembling the equipment depends on the optional extras and the type of Risk of bruises if the equipment or actuator. component parts fall down. For more information on the required service space see the attached drawings. ...
  • Page 30 Detaching actuator parts and removing the Equipment that cannot be retrofitted with an electric actuator is provided with a handwheel which is firmly attached to the If the equipment is fitted with an actuator first threaded bush. remove the actuator. ...
  • Page 31 The following steps are the same for both types of actuator.  Remove the sealing fluid line (if mounted) from the connection (29).  Unscrew the hexagon nuts (40) of the stud bolts (41) on the cover. You can now take the bonnet with stem off the body.
  • Page 32 Removing inner parts Equipment of size DN 50 The procedure for removing the internals depends  Remove the locking wire (43) from the hexagon- on the size of the equipment. head cap screws (20).  Loosen the hexagon-head cap screws (1). Equipment of size DN 25 ...
  • Page 33  Take the retaining ring (44) out of the body. Equipment of size DN 80  Take the thrust ring (21) out of the body.  Remove the locking wire (43) from the hexagon head bolts (20).  Take the body gasket (19) out of the body. ...
  • Page 34  Take the protective sleeve against wear (22) out Equipment of size DN 100–150 of the body.  Remove the locking wire (43) from the hexagon  Take the pinned sleeve insert (26) out of the head bolts (20). body. ...
  • Page 35  Take the ring (58) out of the body. Removing the gland seal  Take the pinned sleeve insert (26) out of the You only have to dismount the stuffing box body. if you want to exchange parts of the ...
  • Page 36  Replace all worn or damaged parts. The number of pure graphite rings depends on the size of the equipment.  Clean all dirty parts.  Make a note of the type and order of the Removing the stuffing box in equipment with individual packing rings for their later pneumatic diaphragm actuator re-installation.

  • Page 37: Assembling The Equipment

    Detaching the stem from the spindle Attention! The stem and spindle are connected by a rivet pin. Only separate the stem and The packing rings may get damaged. spindle in order to replace damaged parts.  Make sure you do not damage the ...
  • Page 38  Make sure that the sealing surfaces of the stem Mounting the gland packing and seat are correctly surfaced in relation to one another. Attention!  Check all component parts. Malfunctions may occur if the packing  Replace all gaskets and all worn or damaged rings are damaged.
  • Page 39 The number of pure graphite rings depends on the size of the equipment. The exact number is indicated in the parts list.  For more detailed information please contact the manufacturer.  Put the following parts of the stuffing-box packing into the stuffing-box bore: ...
  • Page 40 Mounting the stuffing box in equipment with The number of pure graphite rings pneumatic diaphragm actuator depends on the size of the equipment. The exact number is indicated in the parts Attention! list.  For more detailed information please The stem may be damaged if not installed contact the manufacturer.
  • Page 41 Installing inner parts DANGER Risk of bruises if the equipment or component parts fall down.  Use suitable lifting gear when moving or lifting the equipment and/or component parts.  Make sure that the equipment cannot topple over.  Make sure that nobody is standing below the lifted equipment.
  • Page 42 Mounting internals of equipment size DN 25  Put the protective sleeve against wear (22) onto the sleeve insert and make sure that the marking notch (56) is centrally aligned and points towards the outlet.  Apply lubricant to the socket-head cap screw (42).
  • Page 43 Mounting internals of equipment size DN 50  Put the protective sleeve against wear (22) onto the sleeve insert and make sure that the marking notch (56) is centrally aligned and points towards the outlet.  Put the thrust ring (21) into the body. ...
  • Page 44 Mounting internals of equipment size DN 80  Place the protective sleeve against wear (22) on the sleeve insert.  Align the protective sleeve against wear so that the hole (57) is positioned above the slot in the outermost sleeve. ...
  • Page 45 Mounting internals of equipment sizes DN 100  Secure the hexagon-head cap screws with the and 150 locking wire (43).  Put the ring (58) onto the sleeve insert.  Put the thrust ring (21) into the body.  Insert the large parts of the segmented ring (46) into the body.
  • Page 46 Fitting the cap in equipment with a rotary actuator DANGER Risk of bruises if the equipment or component parts fall down.  Use suitable lifting gear when moving or lifting the equipment and/or component parts.  Make sure that the equipment cannot topple over.
  • Page 47  Tighten the nuts crosswise and evenly to the specified torque.  With each round of tightening, check that the spindle moves easily in the gland seal.  Screw the sealing fluid line (if provided) to the connection for the sealing fluid. ...
  • Page 48  Tighten the nuts crosswise and evenly to the specified torque.  With each round of tightening, check that the spindle moves easily in the gland seal.  Screw the sealing fluid line (if provided) to the connection for the sealing fluid. ...
  • Page 49 Installing the pneumatic diaphragm actuator Attention! DANGER The equipment may suffer damage or malfunctions if actuator parts are not Risk of bruises if the equipment or correctly aligned. component parts fall down.  Make sure that the spindle is  Use suitable lifting gear when moving connected flush with the actuator or lifting the equipment and/or spindle.

  • Page 50: Servicing The Equipment And Installing Spare Parts

    Servicing the equipment and installing spare parts You may exchange the following component parts in case of wear or damage: The material specification and stock code numbers of the component parts are indicated in the supplied parts list.  Disassemble the equipment as described from page 28onwards.

  • Page 51: Troubleshooting

    Troubleshooting Problem Cause Remedy The stem moves with difficulty Malfunction in actuator. Follow the instructions in the operating or jerky. manual for the actuator. The actuator switches off Malfunction in controller. Follow the instructions in the operating automatically. manual for the controller. The stuffing box packing Slightly loosen the stuffing-box screw.

  • Page 52: Putting The Equipment Out Of Operation

    Putting the equipment out of Caution operation Environmental damage may be caused by Removing harmful substances poisonous fluid residues.  Before disposing of the equipment DANGER make sure that it is clean and free of fluid residues. If the equipment is used in contaminated ...
  • Page 53 DANGER WARNING Risk of bruises if the equipment or Risk of severe injuries or death if the component parts fall down. actuator is not removed correctly.  Always wear protective gear when  Before working on the actuator cut off working on the equipment.

  • Page 54: Disposing Of The Equipment

    Disposing of the equipment Caution Environmental damage may be caused by poisonous fluid residues.  Before disposing of the equipment make sure that it is clean and free of fluid residues.  For the disposal of all materials observe the pertinent legal regulations concerning waste disposal.

  • Page 55: Fluid Flowrate And Differential Pressure

    Fluid flowrate and differential pressure Flowrates, cold water Differential pressure Flowrate The chart shows the max. flowrates of cold water at the extreme regulation position with linear characteristic curves and maximum Kv value.
  • Page 56 Flowrates, hot water, ts–5 K Differential pressure (assuming discharge to atmospheric pressure) For higher back pressure take a correction factor into account. The ascertained flowrate is reduced by the correction factor. Flowrate The chart shows the max. flowrates of hot water at the extreme regulation position with linear characteristic curves and maximum Kv value.

  • Page 57: Pressure & Temperature Ratings

    European Directives in our Declaration of Conformity or our Declaration of Incorporation. To request the valid Declaration of Conformity or Declaration of Incorporation, please contact: GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon +49 421 3503-0...
  • Page 60 Agencies all over the world: www.gestra.de GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon +49 421 3503-0 Telefax +49 421 3503-393 E-Mail info@de.gestra.com www.gestra.de 810685-05/07-2017 kx_mm (808539-05) © GESTRA AG Bremen Printed in Germany...

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