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Weka TgxV DN250 Installation, Operation And Maintenance Manual

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Installation, operation
and maintenance
manual
Valves type TgxV DN250/PN6

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Summary of Contents for Weka TgxV DN250

  • Page 1 Installation, operation and maintenance manual Valves type TgxV DN250/PN6...

  • Page 2: Table Of Contents

    Assembly and disassembly of the valve ......................17 6.6.1 Disassembly of the PM actuator, Samson type, Po..................17 6.6.2 Disassembly of a TgxV DN250/PN6 valve ....................21 6.6.3 Replacing a flow plug or seat seal........................ 24 6.6.4 Assembly of a TgxV DN250/PN6 valve ......................27 6.6.5...
  • Page 3 Maximal allowed pressure ............................. 36 Maintenance ................................37 General information ............................37 Orifice hole and/or guard connection ........................ 37 Spare parts ................................37 EU Declaration of conformity ..........................38 WEKA_IOM_C-0068_TgxV_DN250_PN6_EN / 17.04.2020 3 / 38...

  • Page 4: General Information

    The present manual applies to valves of type -TgxV with nominal widths from DN250 pressure levels up to PN6, equipped with a pneumatic diaphragm actuator. Contact data For more information on the product, please contact WEKA AG Schürlistrasse 8 CH-8344 Baeretswil T: +41 43 833 43 43 cryo@weka-ag.ch...

  • Page 5: Safety

    Safety General safety information The manual contains detailed descriptions for safe and correct installation, operation and maintenance of the product. Read the manual carefully and thoroughly to become familiar with the product. The manufacturer accepts no liability for damage caused as a result of failure to comply with the safety information and warnings.

  • Page 6: Intended Use

    Only operate the product according to this manual, the specifications from our order confirmation and the technical drawing. • Only use original WEKA spare parts for maintenance and repair of the product. The following must be ensured prior to installation and any maintenance work: •...

  • Page 7: Qualification Of Personnel

    Qualification of personnel The product is exclusively intended for application within systems and facilities where the required work is performed by trained and qualified experts. Experts are persons who are familiar with installation, commissioning and operation of this product and who have the appropriate qualifications for their tasks, e.g. •...

  • Page 8: Transport, Storage And Packaging

    Transport, storage and packaging Transport The valve is transported in wooden box and must be kept in the original WEKA packaging throughout the transport. Transport below -40 °C and/or above +80 °C is not permitted. Storage The valves must be stored in a dry and dust-free environment. Storage below -40 °C and/or above +80 °C is not permitted.

  • Page 9: Designation Of The Valve Components

    Designation of the valve components WEKA_IOM_C-0068_TgxV_DN250_PN6_EN / 17.04.2020 9 / 38...

  • Page 10: Installation, Assembly And Disassembly Of Valves

    To detect any transport damage at an early stage, a shock indicator has been applied to the wooden box. If the wooden box or the shock indicator are damaged, the WEKA AG company should be contacted To unpack the valve from the wooden box, please follow the instructions Fixation of the lifting material Attach the lifting loops to the yoke of the valve.
  • Page 11 Uprightening the valve Align the valve slowly and evenly until it is vertical. Loosen the four screws at the bottom of the wooden box. Now you can lift the valve out of the box. WEKA_IOM_C-0068_TgxV_DN250_PN6_EN / 17.04.2020 11 / 38...
  • Page 12 To remove the device, the 4 screws should be removed with allen wrench, 8mm. The other two screws are on the back side of the valve housing. Now lift the valve out of the device. The WEKA AG company recommends to keep the device. WEKA_IOM_C-0068_TgxV_DN250_PN6_EN / 17.04.2020 12 / 38...

  • Page 13: General Information

    If this cannot be guaranteed, we recommend disassembling the actuator and valve inserts according to chapter 6.6.2 Disassembly of a TgxV DN250/PN6 valve. It must be ensured that insert and actuator are stored packed in a dry and dust-free place.

  • Page 14: Installation Welding Of The Housing

    Installation welding of the housing The valves must be carefully welded in by spot welding and minimum energy input to avoid deformation due to thermal distortion at the valve housing. The valve housing may be cooled with a damp cloth during welding.
  • Page 15 Additional tips for reducing welding heat: For welding procedure 141, TIG welding: • Ensure low heat input • For sockets with 2 mm wall thickness, use approx. 48-52 amps. • The diameter of the filler wire should be 1-2 mm These values are only intended as guidelines.

  • Page 16: Allowed Displacement

    Allowed displacement The following information shows the permissible pipe forces F(max) or moments Mb(max) which may act on the valve with a cryogenic length of 1400 mm. The maximum deflection (r max) for a valve is calculated based on the forces or torques. The permissible forces or torques for different cryogenic lengths can be determined using the intercept theorem.

  • Page 17: Assembly And Disassembly Of The Valve

    Tools The required tools are listed in the respective chapters. Special tools or special auxiliary agents can be ordered from WEKA AG. They are not included in the scope of delivery. Previous knowledge A certain amount of previous knowledge of mechanical handling is mandatory to prevent damage to the valve.
  • Page 18 Step Picture Description Additional note: Depending on the nominal width of the valve, the components may slightly vary in appearance. However, the steps remain the same. If position controller is used: Unscrew the blue marked screw with an Allen- type wrench, 5mm The plate can be removed together with the spacer and bracket.
  • Page 19 Connect the compressed air line to the actuator. The maximum and minimum air pressure values are provided in the customer drawing. Depending on the additional parts for the actuator, the air connection can be at a different location. Please note: The maximum air pressure of 6 bar must not be exceeded;...
  • Page 20 Remove the compressed air line from the actuator. Attention: The actuator and the coupling are moving parts. Risk of injury! Keep your hands off. The dimension "X" must be measured from the upper edge of the coupling to the yoke stop During assembly of the valve, the dimension "X"...

  • Page 21: Disassembly Of A Tgxv Dn250/Pn6 Valve

    Disassembly of a TgxV DN250/PN6 valve 6.6.2 The disassembled components must be stored in a clean place. Damage to the sealing surfaces requires great effort and expenditure to remedy. Required tools and auxiliary agents Allen wrench, 14mm Open-end spanner SW13.
  • Page 22 Carefully lift the transport protection device with WEKA-no. 46933 (blue marked) over the actuator spindle and push it down. The device must be pressed down completely and rest completely on the piston.
  • Page 23 Lift the insert using a crane mounting tool. Special tools can be purchased from WEKA AG (WEKA-No. 2838) Attention Carefully lift the insert out of the housing and guide it with one hand! Damage to the flow plug or other parts must always be avoided.

  • Page 24: Replacing A Flow Plug Or Seat Seal

    6.6.3 For this purpose, the valve and/or the insert must be completely disassembled. To this end, see chapter 6.6.2 Disassembly of a TgxV DN250/PN6 valve. The insert should lie securely on a table or something similar. Required tools and auxiliary agents...
  • Page 25 Attention: Always wear goggles when using compressed air. Clean the sealing surface and the seal using rubbing alcohol. WEKA AG recommends using a lint-free cloth! Re-assemble the new seat seal. Please note: Hard objects, such as metal tools or dirt particles may damage the sealing surface.
  • Page 26 Re-assemble flow plug. Attention: This step must be taken with caution. Incorrect handling may cause damage to the seat seal. Re-assemble the new secure washers and the screws. Grease the thread of the screws with Gleitmo 599. Attention: Secure washer must be aligned as shown in the picture The small tang must...

  • Page 27: Assembly Of A Tgxv Dn250/Pn6 Valve

    Assembly of a TgxV DN250/PN6 valve 6.6.4 Required tools and auxiliary agents Rubbing alcohol Lint-free cloth Vacuum grease Gleitmo 599 Allen wrench, 14mm Open-end spanner SW13. Transport protection device with WEKA-no. 46933 Crane mounting tool (WEKA-no. 2838) Step Picture Description Additional note: Depending on the nominal width of the valve, the components may slightly vary in appearance.
  • Page 28 Slightly grease the o-ring with vacuum grease. Assemble the o-ring. Assemble the insert in the housing. Lift the insert using a crane mounting tool. Special tools can be purchased from WEKA AG. (WEKA-no. 2838) Attention Carefully move the insert into the...
  • Page 29 Grease all screws with Gleitmo 599. Re-assemble the flange. Assemble all washers and screws. Tighten all screw with an allen wrench, 14mm Torque 135 Nm. Clean the orifice opening using rubbing alcohol. Assemble the plug with an open-end spanner SW13. WEKA_IOM_C-0068_TgxV_DN250_PN6_EN / 17.04.2020 29 / 38...

  • Page 30: Assembly Of The Pm Actuator, Samson Type, Po

    Assembly of the PM actuator, Samson type, Po 6.6.5 Prior to beginning with your work, you must first determine whether the actuator is Po (normally closed, pressure tend to open) or Ps (normally open, pressure tend to close), because there is a difference in the work steps for the two types. This information can be found on the type plate of the actuator.
  • Page 31 Connect the compressed air line to the actuator. The maximum and minimum air pressure values are provided in the customer drawing. Depending on the additional parts for the actuator, the air connection can be at a different location. Please note: The maximum air pressure of 6 bar must not be exceeded;...
  • Page 32 Remove the compressed air line from the actuator Attention: The actuator and the coupling are moving parts. Risk of injury! Keep your hands off. Mount the coupling between actuator stem and insert. Tighten the two screws at the coupling with an open-end spanner SW24 ATTENTION: The insert must not be turned during...

  • Page 33: Replacing The Seals

    Replacing the complete insert To replace the insert, first, the actuator needs to be disassembled, then, the instructions in chapter 6.6.2 Disassembly of a TgxV DN250/PN6 valve must be followed until the insert is exposed and free to be removed.
  • Page 34 Back-up rings are blue marked Replacing the seal of the orifice hole For the required tools, please see chapter 6.6.2 Disassembly of a TgxV DN250/PN6 valve. First, the orifice hole must be opened, then the plug seal must be removed. Finally, some new PTFE band muss be added around the plug.

  • Page 35: Marking Of The Valve

    Marking of the valve The valve housing is marked with following information: Manufacturer sign Order number Tag number Year of manufacture Material DN XXX / PN XX PED marking Commissioning and operation General information To ensure long service life of the valves, the following information must be observed: •...

  • Page 36: Electrical And Pneumatic Additional Components

    The valves are already initialized with the positioner. WEKA AG recommends re-initializing the position controllers during commissioning of the valves. For instructions for this process, either contact WEKA AG or download them directly from the homepage of the position controller supplier.

  • Page 37: Maintenance

    The recommended spare parts are listed in the valve drawing and can be generally supplied within a few days. However, WEKA AG recommends keeping a set of seals, comprising the seat seal, dynamic seal, static seal and static safety seal (see drawings), in stock.

  • Page 38: Eu Declaration Of Conformity

    EU Declaration of conformity WEKA_IOM_C-0068_TgxV_DN250_PN6_EN / 17.04.2020 38 / 38...

This manual is also suitable for:

Pn6

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