Samson EB 20a Mounting And Operating Instructions

Ball valve br 20a din and ansi version to combine with actuators

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MOUNTING AND

OPERATING INSTRUCTIONS

EB 20a

Translation of the original manual

Ball valve BR 20a DIN and ANSI version

to combine with actuators

May 2022 edition

PFEIFFER Chemie-Armaturenbau GmbH · Hooghe Weg 41 · 47906 Kempen

Phone: 02152 2005-0 · Fax: 02152 1580

sales-pfeiffer-de@samsongroup.com · www.pfeiffer-armaturen.com

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Page 1 MOUNTING AND OPERATING INSTRUCTIONS EB 20a Translation of the original manual Ball valve BR 20a DIN and ANSI version to combine with actuators May 2022 edition PFEIFFER Chemie-Armaturenbau GmbH · Hooghe Weg 41 · 47906 Kempen Phone: 02152 2005-0 · Fax: 02152 1580...
Page 2 Note regarding this installation and operating manual This Installation and Operating Manual (EB) provides guidance for safe assembly and operation. The notes and instructions in this EB are binding when handling PFEIFFER devices. The ﬁ gures and illustrations in this EB are ex- amples and must therefore be considered as such.
Page 3: Table Of Contents
Content Content Safety instructions and safety measures Notes regarding possible severe personnel injury Notes regarding possible personnel injury Notes regarding possible property damage Warning notes on the device Markings on the device Type plates 2.1.1 Ball valve type plates 2.1.2 Actuator type plate Material marking Design and principle of operation...
Page 4 Content Start up Operation Malfunction Detecting and rectifying errors Carrying out emergency measures Servicing Periodic tests Maintenance work 9.2.1 Replacing the seal rings and ball Ordering spare parts and consumables 10 Decommissioning 10-1 11 Removal 11-1 11.1 Removing the ball valve from the pipe 11-1 11.2 Disassembling the actuator...
Page 5: Safety Instructions And Safety Measures
Safety instructions and safety measures pressurised pipes who are familiar with the assembly, commis- Safety instructions and safety measures sioning and operation of this product. − Specialist personnel in terms of this installation and operating Intended use manual are persons who, on the basis of their vocational ed- The PFEIFFER ball valve BR 20a is manually operated in combi- ucation, knowledge and experience and knowledge of the nation with an actuator for the regulation of the volume ﬂ...
Page 6: Notes Regarding Possible Severe Personnel Injury
Safety instructions and safety measures − The ball valve is only used as intended as described in this 1.1 Notes regarding possible severe per- chapter. sonnel injury − An actuator unit that is subsequently installed on the ball valve is adapted to it and the max. torque is observed, and is DANGER correctly adjusted in the end positions, and in particular in the opening position of the ball valve.
Page 7: Notes Regarding Possible Property Damage
Safety instructions and safety measures WARNING WARNING Danger of crushing due to moving parts! Deviation of the breakaway and actuating forces due to The ball valve contains moving parts (actuator and control shaft non-actuation of the ball valve! as well as the hand lever) that can lead to crushing if reaching Depending on the period of time of non-actuation, the breaka- into it.
Page 8: Warning Notes On The Device
Safety instructions and safety measures Instructions for retightening the body screws NOTE Damage to the ball valve due to an impermissible pressure in- crease! The ball valve body may contain small amounts of medium in the closed and open position. Use a ball valve with an optional relief bore if it is possible that the closed area of the ball ﬁ...
Page 9: Markings On The Device
Markings on the device Markings on the device Each ball valve usually has the following marking. Table 2-1: Marking on the type plate and on the body of the ball valve Pos. Marking Remark Manufacturer PFEIFFER Address see Chapter “15.3 Service” Valve type BR (and number value) e.g.
Page 10: Type Plates
Markings on the device 2.1 Type plates 2.1.1 Ball valve type plates Figure 2-1: Type plate (82150ae) for DN 15 ... 25 and NPS½ ... 1 Figure 2-2: Type plate (82149ae) for DN 40 ... 200 and NPS1½ ... 8 2.1.2 Actuator type plate See the corresponding actuator documentation.
Page 11: Design And Principle Of Operation
Design and principle of operation Design and principle of operation 3.1 Variants − Body made of other materials, e.g. 1.4571 Function and principle of operation − Lined bottom drain valve BR 21a The media can ﬂ ow in both directions through the BR 20a ball −...
Page 12: Attachments
Design and principle of operation 3.3 Attachments Info The following accessories are available for the ball valve either The position and arrangement of the individual parts shown in individually or in combinations: the drawings must be observed during assembly. − Locking device −...
Page 13 Design and principle of operation Figure 3-1: Sectional drawing of the ball valve in the DIN version, DN 15 ... 100 Table 3-1: Parts list of the ball valve in the DIN version, DN 15 ... 100 Pos. Designation Pos. Designation Body with lining O-ring...
Page 14: Assembly Of The Din Ball Valve, Dn 150
Design and principle of operation The further assembly procedure depends on the respective ver- Place the preassembled stufﬁ ng box lower section and above sion. the ball stem onto the provided recess in the assembled body halves. First the ball valve in a “standard version” will be described, and then the ball valve with a “double stufﬁ...
Page 15 Design and principle of operation Figure 3-2: Sectional drawing of the ball valve in the DIN version, DN 150 ... 200 Table 3-2: Parts list of the ball valve in the DIN version, DN 150 ... 200 Pos. Designation Pos. Designation Body with lining Stufﬁ...
Page 16: Assembly Of The Ansi Ball Valve
Design and principle of operation Place the ball (2) on the seal ring of a body half (1a or 1b). Tighten the screws (4) on the body halves (1a and 1b). Insert the control shaft into the shaft bore on the side of the Info stufﬁ...
Page 17 Design and principle of operation Figure 3-3: Sectional drawing of the ball valve in the ANSI version Table 3-3: Parts list of the ball valve in the ANSI version Pos. Designation Pos. Designation Body with lining Stufﬁ ng box ﬂ ange Ball with coating Screw Seat ring...
Page 18 Design and principle of operation Fasten the body halves together with screws (4), washers After approx. 24 hours, retighten the screws (4) on the body (28), spring washers (6) and nuts (5) so they are hand-tight. halves. The arrangement of the spring washers can be found on the drawing, see Figure 3-3.
Page 19: Shipment And On-Site Transport
Shipment and on-site transport Shipment and on-site transport WARNING The work described in this chapter may only be performed by Overturning of the lifting equipment and damage to the load specialist personnel qualiﬁ ed to perform the corresponding task. lifting equipment by exceeding the lifting capacity! −...
Page 20: Lifting Points On The Body
Shipment and on-site transport Figure 4-1: Lifting points on the ball valve Conditions for lifting 4.3.3 Lifting points on the body Use a hook with a safety clamp as the suspension element so Fasten a lifting sling to each ﬂ ange of the housing and on the that the sling cannot slip off the hook during lifting and trans- suspension element (e.g.
Page 21: Storing The Ball Valve
Shipment and on-site transport Move the ball valve at a constant speed to the installation site. Install the ball valve in the pipe, see chapter 5.4 After installation in the pipe: check that the ﬂ anges are ﬁ rmly tightened and that the ball valve holds in the pipe. Remove the lifting slings.
Page 22 Shipment and on-site transport EB 20a_EN May 2022 edition Subject to technical changes...
Page 23: Installation
Installation Venting Installation Vents are screwed into the exhaust air connections of pneumatic The work described in this chapter may only be performed by and electropneumatic devices to ensure that the generated ex- specialist personnel qualiﬁ ed to perform the corresponding task. haust air can be released to the outside (protection against over- The following instructions apply additionally for ball valves.
Page 24: Installing The Ball Valve In The Pipe
Installation The ball valve can be used in both directions if a direction ar- WARNING row is not applied. Danger and damage due to use of an electrical actuator! DANGER Make sure that the actuator in the end positions is turned off by the limit switch signal.
Page 25: Installing The Ball Valve
Installation Carry out venting on the side that faces away from the work- 5.4.3 Installation instructions for lined gate ing area of operating personnel. ball valves with heat pack When installing peripheral devices, make sure that they can be operated from the working area of operating personnel. Info When installing the lined ball valves with heat packs in the pipe, a corresponding straight outlet pipe section must be included.
Page 26: Pressure Test Of The Pipe Section
Installation the residual energy of the actuator (spring tension) before re- 5.5.3 Swivelling movement leasing the blockage, see the corresponding actuator docu- The rotary movement of the actuator- and control shaft must be mentation. linear without any jerky movements. Prior to disassembly of the actuator, bring the ball valve into the fail-safe position.
Page 27: Start Up
Start-up Commissioning/recommissioning Start up The PTFE plastic sealing surfaces tend to ﬂ ow. After commis- The work described in this chapter may only be performed by sioning and reaching the operating temperature, tighten all specialist personnel qualiﬁ ed to perform the corresponding task. ﬂ...
Page 28 Start-up EB 20a_EN May 2022 edition Subject to technical changes...
Page 29: Operation
Operation − For the manual operation or manual override of the actuator Operation (if present), normal manual forces are sufﬁ cient and the use As soon as the commissioning/recommissioning work is com- of extensions to increase the actuation torque is not permit- plete, see Chapter “6 Commissioning”, the ball valve is ready for ted.
Page 30 Operation EB 20a_EN May 2022 edition Subject to technical changes...
Page 31: Malfunction
Malfunction Malfunction When rectifying the faults, chapter “1 Safety instructions and safety measures” must be observed. 8.1 Detecting and rectifying errors Type of fault Possible cause Measures Leaks in the pipe connection The ﬂ ange connection of the Tighten the ﬂ ange screws. lined ball valve is leaky NOTE An excessive tightening torque when retightening the ﬂ...
Page 32: Carrying Out Emergency Measures
Malfunction Type of fault Possible cause Measures Malfunction The actuator unit or control Check the actuator unit and control command. does not react The actuator and control are Remove and inspect the valve, see chapter “1 Safety instructions and safety measures”. Remove the actuator unit and measure and check the ball valve torque.
Page 33: Servicing
Servicing Servicing NOTE The work described in this chapter may only be performed by Damage to the ball valve due to excessively high or low tight- specialist personnel qualiﬁ ed to perform the corresponding task. ening torques! The following documents are required in addition for the mainte- The ball valve components must be tightened with speciﬁ...
Page 34: Maintenance Work
Servicing Measures in the case of a negative Test test result Check the rotary movement of If the actuator- and control shaft are the actuator- and control shaft blocked, remove the blockage. for smooth movement. WARNING! If the actuator- and con- trol shaft are blocked (e.g.
Page 35: Decommissioning
Decommissioning Observe the following points during decommissioning: 10 Decommissioning To decommission the ball valve for maintenance and repair work The work described in this chapter may only be performed by or for disassembly, perform the following steps: specialist personnel qualiﬁ ed to perform the corresponding task. Close the valves upstream and downstream of the ball valve so that no medium ﬂ...
Page 36 Decommissioning EB 20a_EN 10-2 May 2022 edition Subject to technical changes...
Page 37: Removal
Removal 11 Removal 11.1 Removing the ball valve from the pipe The work described in this chapter may only be performed by Loosen the ﬂ ange connection. specialist personnel qualiﬁ ed to perform the corresponding task. Remove the ball valve from the pipe, see Chapter “4.3 Trans- porting and lifting the ball valve”.
Page 38 Removal EB 20a_EN 11-2 May 2022 edition Subject to technical changes...
Page 39: Repairs
Repairs 12 Repairs 12.1.2 Ball valve with “double stufﬁ ng box” If the ball valve no longer works properly or if it does not work at Leak in the test connection all, it is defective and must be repaired or replaced. If a leak is found in the test connection of the stufﬁ...
Page 40 Repairs Figure 12-1: BR 20a ball valve EB 20a_EN 12-2 May 2022 edition Subject to technical changes...
Page 41: Replacing The V-Ring Packing In The Case Of A Ansi Ball Valve
Repairs Table 12-1: Parts list Pos. Designation Pos. Designation Pos. Designation Body with lining Stufﬁ ng box ﬂ ange Set of spring washers Ball with coating Screw Thrust ring Seat ring Hand lever V-ring packing Screw/ stud bolt Center ring O-ring PTFE bush Stufﬁ...
Page 42: Sending Devices To Pfeiffer
Repairs 12.5 Sending devices to PFEIFFER Defective ball valves can be sent to PFEIFFER for repair. Proceed as follows to send devices: WARNING Danger due to a contaminated ball valve! When returning a used valve to PFEIFFER for service, decon- taminate the ball valve properly in advance.
Page 43: Disposal
Disposal 13 Disposal For disposal, observe the local, national and international regulations. Do not dispose of old components, lubricant and hazardous materials with domestic waste. EB 20a_EN 13-1 May 2022 edition Subject to technical changes...
Page 44 Disposal EB 20a_EN 13-2 May 2022 edition Subject to technical changes...
Page 45: Certifi Cates
Certiﬁ cates 14 Certiﬁ cates The declaration of conformity is available on the following pages: − Declaration of conformity according to Pressure Equipment Directive 2014/68/EU for automated valves, see page 14-2. − Declaration of conformity according to Pressure Equipment Directive 2014/68/EU for manually operated valves, see page 14-3.
Page 46 Certiﬁ cates EB 20a_EN 14-2 May 2022 edition Subject to technical changes...
Page 47 Certiﬁ cates EB 20a_EN 14-3 May 2022 edition Subject to technical changes...
Page 48 Certiﬁ cates EB 20a_EN 14-4 May 2022 edition Subject to technical changes...
Page 49 Certiﬁ cates EB 20a_EN 14-5 May 2022 edition Subject to technical changes...
Page 50 Certiﬁ cates EB 20a_EN 14-6 May 2022 edition Subject to technical changes...
Page 51: Annex
Annex Table 15-1: Tightening torques for body connections 15 Annex Nominal size Connection Tightening torque 15.1 Tightening torques, lubricant and tools DN 15 1 to 4 25 Nm 1 to 6 25 Nm DN 25 15.1.1 Tightening torques 7 to 8 35 Nm NPS1 1 to 4...
Page 52: Lubricant
Annex 15.1.2 Lubricant Table 15-4: Recommended lubricant Temperature range Lubricant Screws and nuts -10 ... +200°C Microgleit, GP350 Not suitable for grease-free ball valves or for use with oxygen Stem sealing -10 ... +200°C Water-free grease (e.g. halo- and parts in carbon grease) contact with me- 15.1.3 Tools...
Page 53: Spare Parts Of The Ball Valve In The Din Version, Dn 15
Annex 15.2.1 Spare parts of the ball valve in the DIN version, DN 15 ... 100 Figure 15-2: Exploded drawing of the ball valve in the DIN version, DN 15 ... 100 Table 15-5: Recommend spare parts for the ball valve in the DIN version, DN 15 ... 100 In the spare parts set for In the spare parts for 2 year Pos.
Page 54: Spare Parts Of The Ball Valve In The Din Version, Dn 150
Annex 15.2.2 Spare parts of the ball valve in the DIN version, DN 150 ... 200 Figure 15-3: Exploded drawing of the ball valve in the DIN version, DN 150 ... 200 Table 15-6: Recommend spare parts for the ball valve in the DIN version, DN 150 ... 200 In the spare parts set for In the spare parts for 2 year Pos.
Page 55: Spare Parts Of The Ball Valve In The Ansi Version
Annex 15.2.3 Spare parts of the ball valve in the ANSI version Figure 15-4: Exploded drawing of the ball valve in the ANSI version Table 15-7: Recommend spare parts for the ball valve in the ANSI version In the spare parts set for In the spare parts for 2 year Pos.
Page 56: Spare Parts Of The Ball Valve With Double Stuffi Ng Box
Annex 15.2.4 Spare parts of the ball valve with double stufﬁ ng box Figure 15-5: Exploded drawing of the ball valve with double stufﬁ ng box EB 20a_EN 15-6 May 2022 edition Subject to technical changes...
Page 57: Service
Annex Table 15-8: Recommended spare parts for the ball valve with double stufﬁ ng box In the spare parts set for In the spare parts for 2 year Pos. Designation Material commissioning operation Body with lining EN-JS 1049 / PTFE Ball with coating 1.4313 / PTFE •...
Page 58 Annex Further information The indicated data sheets and further information are available, also in English, at the following address: PFEIFFER Chemie-Armaturenbau GmbH Hooghe Weg 41 • 47906 Kempen • Germany Phone: +49 2152 2005-0 • Fax +49 2152 1580 E-Mail: sales-pfeiffer-de@samsongroup.com Internet: www.pfeiffer-armaturen.com EB 20a_EN 15-8...
Page 59 EB 20a_EN May 2022 edition Subject to technical changes...
Page 60 PFEIFFER Chemie-Armaturenbau GmbH Hooghe Weg 41 · 47906 Kempen · Germany Phone: +49 2152 2005-0 · Fax: +49 2152 1580 E-Mail: sales-pfeiffer-de@samsongroup.com · Internet: www.pfeiffer-armaturen.com EB 20a_EN May 2022 edition Subject to technical changes...

Samson EB 20a Mounting And Operating Instructions

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