Summary of Contents for SCHUCK U
- Page 1 Franz Schuck GmbH Installation/operation manual Type U ball valve Translation of the original Operation Manual Keep for future use!
- Page 2 The manual must be read, understood and observed by the user. We emphasize that Franz Schuck GmbH assumes no liability for damage or malfunctions arising from non-compliance with this manual.
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Page 3: Table Of Contents
Table of Contents Table of Contents Chapter 1 Preliminary remarks Legal notes Application range Chapter 2 Safety Fundamental safety instructions 2.1.1 General 2.1.2 Intended use 2.1.3 Organizational measures 2.1.3.1 Special hazard points 2.1.3.2 Workplace and personal protective gear Chapter 3 Description System overview 3.1.1... - Page 4 Table of Contents 4.2.4 Valve installation 4.2.5 Connection and start-up of actuator and control system Testing 4-10 4.3.1 Function test 4-10 4.3.2 Pressure/leak tightness test 4-10 Chapter 5 Operation Safety instructions for operation Operation 5.2.1 Open/close valve Chapter 6 Maintenance Inspection 6.1.1 Regular maintenance...
- Page 5 Table of Contents Marking of packages 7.5.1 Marking of packages according to DIN 55402 and ISO R 780 Schuck symbols – transporting and unpacking packages 7.5.2 2013-02-09...
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Page 6: Preliminary Remarks
GmbH. The manufacturer guarantee becomes void if this prohibition is not com- plied with! Application range This operation manual applies to the Franz Schuck GmbH product described in this manual. The appropriate operation manuals for optional accessories must also be ob- served. -
Page 7: Chapter 2 Safety
The guarantee becomes void if this prohibition is not complied with! • This product has been manufactured according to the recognized rules of technology and according to internal Schuck quality standards; the product is shipped from the factory in a perfect technical condition •... - Page 8 Type U ball valve Safety / Fundamental safety instructions • Valves must be effectively covered and/or protected when work is being carried out that could lead to contamination or damage to the valve, the assembled parts and/or the anti-corrosion protection...
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Page 9: Intended Use
Any operating conditions or applications which differ from those prescribed are only valid with the agreement of Franz Schuck GmbH! 2013-02-09... -
Page 10: Organizational Measures
Type U ball valve Safety / Fundamental safety instructions 2.1.3 Organizational measures 2.1.3.1 Special hazard points There is no immediate danger from a valve that is installed and serviced according to instructions. • Danger from escaping media – depending on the working medium, fire or explosion hazards can arise from electrical contact, naked flames, light and/or smoking... -
Page 11: Workplace And Personal Protective Gear
Make sure all safety and hazard signs are complete and legible! No modifications, attachments or conversions which could impair safety may be implemented without authorization from Franz Schuck GmbH! This also applies to the assembly and the adjustment of safety devices and safety valves as well as for welding on load-bearing parts. -
Page 12: Chapter 3 Description
Depending on the design, the ball valve is used as shut-off device in pipelines for the transport of gaseous or liquid media. Components of the version with weld ends 120nn106 Fig. 3-1 System overview type U ball valve 1 Actuating stem 3 Drainage (optional) 2 Vent connection (optional) 2013-02-09... - Page 13 Type U ball valve Description / System overview Components of the version with flanges 120nn111 Fig. 3-2 System overview type U ball valve 1 Actuating stem 5 Injection head for secondary sealant on 2 Injection head for secondary sealant for the seat (optional)
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Page 14: Identification Plate
Type U ball valve Description / System overview 3.1.1 Identification plate For valves specified for above ground installation, the identification plate is at- tached to the housing body; on the underground model, it is also optionally posi- tioned in the upper area of the pipe or extension. -
Page 15: Construction And Design
For gaseous media, seat rings with a double piston effect are usually used; for liquid media, seat rings with a single piston effect are used. Combinations are also possible. In the case of U type ball valves it is possible to retrofit/replace the seat rings or the sealing system. 3.1.4 Sealing out the atmosphere The actuating stem is double-sealed against the atmosphere in the cover. -
Page 16: Actuation
Type U ball valve Description / System overview 3.1.6 Actuation Depending on the order, the ball valve can either be supplied with manual actu- ation (hand wheel or hand lever) or with an electrical/pneumatic/hydraulic valve actuator. The ball valve is usually opened by an anticlockwise 90° rotation on the actuating stem. -
Page 17: Chapter 4 Assembly
Type U ball valve Assembly 4 Assembly For questions regarding assembly, please contact: Franz Schuck GmbH Daimlerstraße 5 – 7 89555 Steinheim GERMANY Phone +49 (7329) 950-0 Fax +49 (7329) 950-161 info@schuck-group.com www.schuck-group.com DANGER Risk of injury from bursting components/system parts! - Page 18 Type U ball valve Assembly DANGER Danger of electric shock! Do not connect the system to power before the earth resistance and the earthing connection has been tested, examined and approved by the customer. CAUTION Danger of hardness increase of the steel when welding without pre-heating the weld junction at temperatures exceeding 80 °C!
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Page 19: Preparation
Type U ball valve Assembly / Preparation Preparation DANGER LIFE HAZARD from suspended loads or shifting of loads! Proceed cautiously when transporting the valve! To lift the ball valve only use appropriate lifting devices as well as the designated lifting points. -
Page 20: Inspection
Inspection Procedure 1. Check the delivery notes to make sure that the delivery is complete. 2. If there are any discrepancies, contact Franz Schuck GmbH immediately. 3. Check the delivery immediately on receipt for damage incurred during trans- port. In the event of damage, observe the stipulations of the insurance company which, among other things, prescribe that evidence of damage is confirmed... - Page 21 Type U ball valve Assembly / Preparation Overview 120nn107 Fig. 4-1 Transporting type U ball valves 1 Mounting 4 Suspension eye 2 Lifting device 5 Lifting rope 3 Ball valve 2013-02-09...
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Page 22: Installation
Type U ball valve Assembly / Installation Installation CAUTION Damage to the component in the case of mechanical overloading! The component is not designed as fixed point/support of the pipeline. Extra support on the pipeline is required. 4.2.1 General installation instructions Unless otherwise agreed, the valve is designed to be installed in horizontal pipelines by default. -
Page 23: Ball Valves With Weld Ends
Type U ball valve Assembly / Installation 4.2.2 Ball valves with weld ends For delivery, the weld ends have been provided with anti-corrosion protection. The weld ends must be carefully cleaned before being welded into the pipeline. L = ØD + 400 mm 120nn109 Fig. -
Page 24: Ball Valves With Flanges
Type U ball valve Assembly / Installation 4.2.3 Ball valves with flanges For delivery, the flange sealing surfaces have been provided with anti-corrosion protection. The flange sealing surfaces must be carefully cleaned before being installed in the pipeline. The flange seals and bolts must be suited for sealing strip shape, pressure, tem- perature and medium. -
Page 25: Valve Installation
Type U ball valve Assembly / Installation 4.2.4 Valve installation Prerequisite • The mechanical components of the system have been tested • All damage has been reported and remedied • General safety instructions have been observed prior to assembly/disassembly •... -
Page 26: Testing
Type U ball valve Assembly / Testing Testing 4.3.1 Function test Before applying pressure to the ball valve for the first time, a function test must be carried out when it is de-pressurized. Procedure 1. Clean the interior of the ball valve properly. -
Page 27: Chapter 5 Operation
Type U ball valve Operation 5 Operation Safety instructions for operation Comply with the safety instructions and protective measures specified in chapter 2 as well as the applicable legal regulations. DANGER Risk of injury from bursting components/system parts! If the permissible limit values are exceeded, the... -
Page 28: Operation
Type U ball valve Operation / Operation Operation In order to ensure long-term sealing action of the valve, make sure that the ball plug is always completely opened or closed and never operated in an intermediate position. Always adhere to the values stated on the identification plate ( Page 3-3, Fig. -
Page 29: Chapter 6 Maintenance
Life hazard in the case of escaping sour gas or sulphinic lye! The safety instructions must be unconditionally observed! For support in maintenance and optimization work, we recommend you contact the Franz Schuck GmbH service department. Franz Schuck GmbH Daimlerstraße 5 – 7... -
Page 30: Inspection
Type U ball valve Maintenance / Inspection Inspection 6.1.1 Regular maintenance Schuck ball valves are low-maintenance. Maintenance work is limited to: • regularly checking the seal tightness to the outside and inspecting the external anti-corrosion protection (visual inspection) • function test of the ball valve (at least once a year) Procedure To test the function, operate the ball valve once through its full stroke. -
Page 31: Double Block And Bleed Test
Type U ball valve Maintenance / Inspection 6.1.3 Double block and bleed test CAUTION Dangers to health and safety of operating and maintenance personnel. During the venting and discharge/drainage procedures, medium can escape under high pressure and with a considerable noise. -
Page 32: Sealing The Actuating Stem
Type U ball valve Maintenance / Inspection 6.1.4.2 Sealing the actuating stem Procedure When sealing the actuating stem, note that the sealant injection pressure may only be minimally above the operating pressure and that only a minimal amount is required. -
Page 33: Faults And Troubleshooting
Repair the ball valve in accordance with the repair procedure to replace sealings, seat rings or ball plugs. It is recommended to have this repair carried out by the Schuck service team. Leak in seat Actuator end position out of Re-adjust the actuator end positions ( alignment Actuator installation/operation manual). -
Page 34: Repairs
Maintenance / Repairs Repairs In principle, repair work may only be carried out by the Franz Schuck GmbH service team or by personnel trained by Franz Schuck GmbH. This is the only way to ensure that repairs are carried out correctly using original spare parts. -
Page 35: Appendix
Type U ball valve Appendix 7 Appendix Tightening sequence for flange bolts The bolt numbers represent the order in which they should be tightened. 4-Hole Flange 28-Hole Flange 8-Hole Flange 24-Hole Flange 12-Hole Flange 20-Hole 16-Hole Flange Flange 110nn010_en Fig. 7-1 Tightening sequence for flange bolts... -
Page 36: Conversion Factors
Type U ball valve Appendix / Conversion factors Conversion factors Value Unit Factor Conversion unit Length 0.03934 25.4 3.28084 0.3048 Weight 2.204622 0.453592 Pressure 14.5035 0.06895 145.035 0.006895 Temperature °C °F 1.8 °C + 32 °F °C (°F – 32) × 0.5556 Volume 0.06102... -
Page 37: Calculation Formula To Determine The Carbon Equivalent (Cev)
Type U ball valve Appendix / Calculation formula to determine the carbon equivalent (CEV) Calculation formula to determine the carbon equivalent (CEV) To avoid an increased hardness in the weld junctions during welding, it is required to pre-heat the weld-on ends depending among others on the carbon equivalent. -
Page 38: Sealant Requirement Per Ball Valve (Above Ground)
Type U ball valve Appendix / Sealant requirement per ball valve (above ground) Sealant requirement per ball valve (above ground) Sealant quantity Sealant quantity Sealant quantity for seats [cm for trunnion [cm for cover [cm 1000 1100 1200 1300 1400... - Page 39 Type U ball valve Appendix / Marking of packages Marking of packages 7.5.1 Marking of packages according to DIN 55402 and ISO R 780 Overview Marking of packages according to DIN 55402 and ISO R 780 Electrostatic sen- Do NOT use fork...
- Page 40 Type U ball valve Appendix / Marking of packages Schuck symbols – transporting and unpacking packages 7.5.2 Overview Schuck symbols – transporting and unpacking packages – Use edge protec- Do not use chains Do not destroy tors pipes Schuck symbols – transporting and unpacking packages Tab.
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