Cepex PVC-U Installation And Maintenance Instructions Manual

ENGLISH
INDUSTRIAL BUTTERFLY VALVE
INDUSTRIAL BUTTERFLY VALVE
INSTALLATION AND
PVC-U (EPDM/FPM)
MAINTENANCE
PVC-C (EPDM/FPM)
INSTRUCTIONS
PPH
0045
1. DEFINITION
Butterfly valve for isolating or regulating the flow in liquid handling systems. The liquid can flow in both directions.
Design based on the EN ISO 16136 Standard in accordance with the 97/23/EC Directive.
The valve is available with PVC-U, PVC-C and PP discs and EPDM and FPM sealing gaskets. The choice of material for the disc and gasket
depends on the type of liquid to be carried and on the working temperature of the liquid, in accordance with the chemical resistance tables
available on our website and the pressure/temperature chart in this Manual (G4.1).
2. WARNINGS
• Carefully read these instructions before handling the valve and observe their recommendations. Any damage caused by failure to
observe these instructions is not covered by the warranty.
• All connection and handling tasks must be performed by qualified personnel.
• The maximum service life of the valve is specified in EN ISO 16136. It is verified on the production plant by aging tests specified in the
standard.
• Correct installation and handling of the valve, as well as adherence to the maximum pressure and temperature conditions specified in
this manual are essential for preserving the service life of the valve.
• The driven liquid must be compatible with the valve materials. Consult chemical resistance charts published by Cepex or consult the
technical department.
• Using tools for opening or closing the manual valve control is not recommended. This process must be done manually.
• Before carrying out any maintenance operations on the pipe or valve, ensure that the system is depressurised by releasing the pressu-
re and emptying the pipes, following the specific safety regulations of each product.
• Turning the handle when the safety lock is in place could damage the valve.
• Avoid shocks during transport, since they may damage the body and mechanism of the valve. Store the valve in the original packa-
ging, protected against humidity and direct sunlight.
• Before installation, check that the valve is undamaged and that it contains all the parts required for installation.
• After long periods of inactivity, check the grease on the gasket and follow the maintenance instructions set out in this manual. The
grease must be compatible with the valve materials.
• It is important to avoid rapid closure of valves to eliminate the possibility of water hammer causing damage to the pipeline.
• When using the valve as the final element of a installation, take into account the risks of the liquid and control the pressure and tem-
perature, according to the standards of safety of each product.
3. COMPONENTS
Fig. 1
13
16
15
18
17
3
2
4. TECHNICAL SPECIFICATIONS
DN65-DN200 (2½"-8"): PN10 (150 psi) at 20 °C liquid tempera-
ture.
DN250-DN300 (9"-12"): PN6 (90 psi) at 20 °C liquid temperature.
The working pressure of the valve reduces with increasing li-
quid temperature, as shown in the accompanying chart.
Maximum torque at the output of the gearbox = 500 Nm
(Ratio = 37:1).
Pressure / Temperature Chart. (G 4.1)
psi bar
PVC-U
PVC-C
PP-H
DN63-DN200
DN250-DN315
0 10 20 30 40 50 60 70 80 90
32 50 68 86 104 122 140 158 176 194
Temperatura
Pressure loss table (T4.1)
D DN Kv (l/min) Cv (GPM)
63-75 (2 1/2") DN65 1800 126
90 (3") DN80 4020 282
110 (4") DN100 8280 580
125-140 (5") DN125 11760 826
160 (6") DN150 16200 1134
200-225 (8") DN200 33000 2311
250 (10") DN250 5200 3655
315 (12") DN300 78571 5502
Operating torque table (N·m)
Valve operating torque
Operating torque values at rated pressure (PN)
and 20 °C in as new direct from the factory condi-
tion. Installation (flange tightening) and operating
(pressure and temperature) conditions will affect
lbf·inch
these values. If automation of operation is required,
please contact the manufacturer.
(EPDM/FPM)
(T3.1)
N DESCRIPTION MATERIAL
19
22
1 Body PP-GR
14
2 Sealing gasket EPDM / FPM
3 Disc PVC-U / PP / PVC-C
20
4 Bearing PP-GR
5
5 PP-GR
Auxiliary bearing
8
6 Shaft AISI-630
11
7 Cap PP
9
8 Ring DIN-471 AISI-304
4
9 O-ring EPDM / FPM
10 AISI-304
Lower washer
21
11 O-ring EPDM / FPM
12 Screw DIN-912 AISI-304
6
13 Handle PP-GR
14 Washer DIN-6798 AISI-304
1
15 Lever POM
16 Pin AISI-304
17 Throttle plate PP-GR
18 Safety lock POM
10
19 Handle cap PP
12
20 Screw DIN-912 AISI-304
7
21 Nut DIN-934 AISI-304
22 Screw DIN-912 AISI-304
23 Aluminium (housing)
Gear box
24 Screw DIN-912 AISI-304
Kv / % opening (G 4.2)
100
90
80
70
60
50
40
30
20
10
0
0 10
DN65
DN100
DN150
Pressure loss chart (G 4.3)
ºC
100
ºF
212
1
0,1
0,01
0,001
10 100 1000 10000
Caudal (l/min)
Flow (l/min)
(T4.3)
DN65 DN80 DN100 DN125 DN150 DN200
N·m 25 28 35 85 110
248 310 752
221 974
ENGLISH
5. DIMENSIONS.
Fig. 2 DN65-200
A
B
DN A
T 5.1
(mm)
65 201
80 232
100 255
125 284
150 314
200 378
250 450
300 545
Valve design Flanged dimensions
ISO 16136: 2005 EN 558-1,ANSI B16.5 Class 150,JIS B2220, BS/E
6. INSTALLATION AND COMMISSIONING
Before starting the installation process, check that you have all the parts needed for the valve assembly, and that the materials, connection
type and nominal pressure are suitable for the installation.
For solvent or welded connections, ensure also that the parts to be connected are of the same material and that you are using the correct
solvent or welding tools.
To install the valve, follow best installation practice recommendations provided on the Cepex website, paying particular attention to thermal
expansion and pipe alignment.
When filling the pipes with liquid, check that all the air is purged from the system and that the initial pressure does not exceed the nominal
pressure of the valve, or of the system element with the lowest nominal pressure rating.
Valve assembly using standard ISO-DIN, ANSI, JIS and BS/E flanges. Flat gaskets are not needed in the socket couplings, as they are
incorporated in the valve itself. Observe the tightening sequence of the screws on the flanges (Fig. 5) and the maximum tightening torque.
It is essential that all the screws are installed in order to ensure proper operation of the valve.
The PP/PE sockets for butt welding must be chamfered as indicated in the diagram (Fig. 6) and table (T6.2), to ensure correct opening and
closing of the disc.
Install the valve once the sockets are solvent-bonded and dry, to avoid problems with the adhesive (entry of the latter into the valve).
Flanges must be well centred on the valve (pay special attention to measurements DN100-DN125 and DN200). Assembly misalignment
could cause problems with the valve operation.
Fig. 4
Fig. 6
PP/PE sockets
DN65- DN250-
DN200 DN300
1 1
x
1 1
1 1
2 2
1 1
1 1
1 1
7. OPERATION AND MAINTENANCE INSTRUCTIONS
1 1
4 8
It is recommended that the condition of the sealing gasket is checked regularly, since it may display signs of mechanical wear due to
pressure, handling and contact with the liquid. The sealing gasket should be greased in the disc contact area (the grease must be compatible
1 1
with the materials of the gasket and the disc). It is also advisable to check regularly that the flange fixing nuts are tightened correctly, as per
2 4
the recommended torque values specified above (T6.1).
In long periods of inactivity, and in case that the installation allows it, maintain the valve slightly open.
1 1
The manual gearbox is maintenance-free and greased for life.
1 - To operate the valve, unlock the handle (13) removing the pin (16) and pulling the lever (15) upwards, releasing its teeth from the throttle
plate (15) then turning the handle in the appropriate direction.
1 -
To lock the valve, re-insert the pin (16) and, optionally, secure with a padlock.
1 -
7.1 Replacing the Sealing Gasket
1 - Should it be necessary to replace the sealing gasket, proceed as follows:
· Ensure that the system is depressurised by releasing the pressure and emptying the pipes, following the
1 -
specific safety regulations of each product. Also check the temperature of the liquid and follow safety stan-
dards of temperature.
1 -
· Remove the valve from the installation.
1 -
· Remove the handle as per 7.2, screws (20), nuts (21) and throttle plate (17).
· Remove the ring (8). Take off the cap (7) and remove the screw (12).
2 2
· Tap on the shaft (6) with a rubber mallet until the bearing (4) is exposed from the bottom (Fig. 7).
2 2 · Once the bearing is out, remove the shaft (6), turn it and re-insert it (Fig. 8) from the bottom.
· Tap again until the bearings (4 and 5) emerge from the top. Remove the shaft again.
1 -
· Remove the disc by pressing in the direction of the liquid.
· Remove the sealing gasket. Fit the new sealing gasket; it needs to be warped and placed so that it lines up
- 1
with the shaft, according to the indication tab of the gasket (Fig. 9).
- 4
WARNING: Before installing the new gasket, check the condition of the O-rings (9 and 11).
7.2 Assembling and Removing the Handle
To assemble the handle:
Flow / valve opening · Fit the handle on the shaft while holding the lever. Place it so that, with the valve closed, the handle indicator
Caudal / Apertura
shows 90º on the throttle plate (17).
· Fit the washer (14), screw (22) and cap (19).
To remove the handle:
· Remove the round cap (19) from the handle, the screw (22) and the washer (14).
· Press the lever (15) fully upwards so that its teeth are fully disengaged from the teeth on the throttle plate (17).
· Remove the handle from the shaft (6).
9. TROUBLESHOOTING
FAULT
The disc does not fully open or close.
20 30 40 50 60 70 80 90 100
% valve opening / % apertura
DN80
DN125
DN200, DN250, DN300
Excessive opening or closing torque.
The valve is not fully watertight at
the sockets.
100000
The valve is not completely
watertight at the sealing gasket .
DN250 DN300
110 180 250
974 1593 2213
INDUSTRIAL BUTTERFLY VALVE
M
Fig. 3 DN250-300
N
L
G
S
E
E
DN
C
F
K
H
B C E F G H K
156 120 40 18 112 48 125-145
190 136 40 19 112 52 150-170
212 148 40 19 112 59 180-192
238 164 40 22 112 66 190-215
265 180 40 24 112 72 240
320 217 50 23 136 73 270-298
453 525 250 29 488 114 329-355
477 616 250 29 578 114 384-427
Valve connections
EN 1090-1
Fig. 5
DN D min. x
Pipe and chamfer
65 50.5 30º
measurements
80 70 30º
T 6.2
100 91.5 30º
125 113 30º
150 141 30º
200 191.5 20º
250 226 20º
300 296.5 20º
T 9.1
POSSIBLE CAUSE
The sockets were not correctly bevelled.
Foreign materials in the compartment (adhesive, etc.).
The valve has been inactive for a long time.
Overtemperature or chemical attack cause damage to
the gasket.
Excessive flange torque.
Misalignment between sockets and valve.
Misalignment between sockets and valve.
Flange screws not tight enough.
Inadequate chemicals.
Temperature out of range.
Excess pressure.
Conduction of abrasive elements.
Damaged sealing gasket.
CODE: C599084 - VERSION: 1.3 - DATE: 05/05/2016
COPYRIGHT © CEPEX, S.A.U. - ALL RIGHTS RESERVED
E
E
DN
F
K
H
B
L M N E' S HOLES
220 70 9 35 10 4
245 70 9 35 12 8
245 70 9 35 16 8
320 70 9 35 20 8
320 70 9 35 20 8
391 102 11 47 26 8
- - - 57 18 12
- - - 57 18 12
Other connections Actuator coupling (optional)
ISO15494, ISO15493, ISO10931 EN/ISO 5211
Screws and screw tightening torque T 6.1
D DN inch Screws (A2) Torque Torque
(N·m) (inch·lbs)
63 65 - 4xM16x120 25 221
75 65 2 1/2" 4xM16x140 25 221
90 80 3" 8xM16x150 25 221
110 100 4" 8xM16x160 30 265
125 125 - 8xM16x170 35 310
140 125 5" 8xM16x170 35 310
160 150 6" 8xM20x200 40 354
200 200 - 8xM20x210 50 442
225 200 8" 8xM20x230 50 442
250 250 - 12xM20x270 80 708
280 250 10" 12xM20x270 80 708
315 300 12" 12xM20x310 80 708
Fig. 7 Fig. 8
Fig. 9
FAULT CLEARANCE
Disassemble the valve and bevel the sockets as indicated
in table T6.2.
Disassemble the valve and check for obstructions in the
disc and gasket contact area.
Operate with an auxiliary release key (not plastic handle).
Disassemble the valve and lubricate the sealing gasket.
Check the chemical compatibility of the liquid with the
disc and the working temperature. Replace the gasket.
Tighten flanges as indicated in section 6.
Disassemble the valve and reassemble with concentric
alignment (observe the correct tightening sequence and
torque).
Disassemble the valve and reassemble with concentric
alignment (observe the correct tightening sequence and
torque).
Tighten flanges as indicated in section 6.
Check compliance with the specifications in this
document.
Replace the gasket.