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Summary of Contents for PERSTA DRI 21
- Page 1 Operating instructions High pressure swing check valve Read the instructions prior to performing any task!
- Page 2 Mülheimer Str. 18 59581 Warstein-Belecke, Germany Telephone: +49 2902 762-02 Fax: +49 2902 767-03 Email: info@persta.de Internet: www.persta.com Translation of the original operating instructions Dok.-Nr. 6402.DE.STD.03.2013, 2, en_GB © Stahl-Armaturen PERSTA GmbH 2013 High pressure swing check valve DRI 20.05.2021...
- Page 3 This manual applies to the following versions of the series 640 AB of the high pressure swing check valve DRI: Designation Series Nominal Pressure rate Class diameter (DN) [mm] DRI 21 640 AB 50–300/250 PD 21 £2500 DRI 26 640 AB 65–300 PD 25 / PD 40 £4500...
- Page 4 Supplemental directives Customer Service - Stahl-Arma- Mülheimer Str. 18 turen PERSTA GmbH 59581 Warstein Telephone: +49 2902 762-02 Fax: +49 2902 767-03 E-mail: info@persta.de Revision overview Revision number Change/Supplemented informa- Date tion “ Intended Updates to chapter 05/05/2021 use”. High pressure swing check valve DRI...
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Page 5: Table Of Contents
Table of contents Table of contents Overview................7 Safety................... 9 2.1 Symbols in this manual..........9 2.2 Intended use............... 11 2.3 Safety signs..............12 2.4 Residual risks............. 13 2.4.1 Basic dangers at the workplace....... 13 2.4.2 Mechanical hazards..........14 2.4.3 Thermal dangers............14 2.4.4 Hazards due to hazardous substances and oper- ating materials............ - Page 6 Table of contents 7.2 Maintenance schedule..........44 7.3 Maintenance tasks............45 7.3.1 Visually checking the valve........45 7.3.2 Replacing the gasket of the pressure sealing bonnet..............46 7.4 After maintenance............51 Faults and fault correction..........53 8.1 Safety notices for fault correction....... 53 8.2 Fault table..............
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Page 7: Overview
Overview Overview Fig. 1: High pressure swing check valve Brief description - high pressure The valve designated as high pressure swing check valve is swing check valve DRI designed for installation in pipes. By using the high pressure swing check valve the flow of a medium is allowed in only one direction within the pipe. - Page 8 Overview Hoist Hoist with sufficient load-bearing capacity for transporting valves and components. Pin puncher Mandrel-like tool for punching out the segment rings. Pull-off device Pull-off device for removing the swing check valve from the body and mounting the swing check valve. The pull-off device grasps through the retaining ring and lifts the retaining ring with the swing check valve out of the body from below.
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Page 9: Safety
Safety Symbols in this manual Safety 2.1 Symbols in this manual Safety instructions Safety instructions are indicated by symbols in this manual. The safety instructions are introduced by signal words that indicate the scope of the hazard. DANGER! This combination of symbol and signal word indi- cates a hazardous situation that, if not avoided, will result in death or serious injury. - Page 10 Safety Symbols in this manual Example: Loosen the bolt. CAUTION! Risk of getting trapped by the cover! Close the cover carefully. Tighten the bolt. Tips and recommendations This symbol indicates useful tips and recommen- dations as well as information on efficient and trouble-free operation.
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Page 11: Intended Use
Safety Intended use 2.2 Intended use Valves of the specified series are designed for installation in pipes under the following conditions: Operation of the valve as an open/close valve. Installation in horizontal pipes. Installation in vertical pipes with flow direction from bottom to top. -
Page 12: Safety Signs
Safety Safety signs Misuse WARNING! Danger in the event of misuse! Misuse of the valve can cause dangerous situa- tions. – Connect the pipes so that they are free of ten- sion. – Pay attention to the correct installation position of the valve. -
Page 13: Residual Risks
Safety Residual risks > Basic dangers at the workplace Customer-specific markings Additional markings (e.g. max. temperature limits) are available on customer request. 2.4 Residual risks The valve has been developed and manufactured to the state-of- the-art and in accordance with generally accepted rules of safety. Nevertheless residual risks remain that require careful handling. -
Page 14: Mechanical Hazards
Safety Residual risks > Thermal dangers 2.4.2 Mechanical hazards Heavy weight of the valve WARNING! Danger of injury due to the heavy weight of the valve! The heavy weight of the valve, and of its compo- nents, can result in severe injuries. –... -
Page 15: Hazards Due To Hazardous Substances And Operating Materials
Safety Residual risks > Hazards due to hazardous substances and operating materials 2.4.4 Hazards due to hazardous substances and operating materials Pumping medium WARNING! Danger of injury due to pumping medium under pressure! In operating status, as well as in decommissioned status, depending on the version of the valve, inju- ries can occur due to medium escaping under high pressure. -
Page 16: Behaviour In The Event Of An Emergency
Safety Responsibility of the operating company Anticorrosive WARNING! Anticorrosive is a health hazard! Direct contact with the anticorrosive used can have health implications. – Handle anticorrosive in accordance with the instructions in the manufacturer’s safety data sheet. – Wear protective equipment: Protective gloves, safety footwear, protective goggles, protective work clothing. - Page 17 Safety Responsibility of the operating company Obligations of the operating com- The valve is used commercially. The operating company of the pany valve is therefore subject to the legal occupational health and safety obligations. In addition to the safety instructions in this manual, the local occu- pational health and safety, accident prevention and environmental protection regulations that apply to the valve’s area of application must be observed.
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Page 18: Personnel Requirements
Safety Personnel requirements 2.7 Personnel requirements WARNING! Danger of injury due to inadequate personnel qualification! If unqualified personnel perform tasks on the machine or are present in the danger zone, dan- gers occur that can cause severe injury and signifi- cant material damage. - Page 19 Safety Personnel requirements Trained person (operator) The trained person (operator) has been instructed, and can provide evidence of this, by the operating company on how to handle the plant and the potential hazards associated with improper behav- iour. This knowledge will be refreshed in regular training provided by the operating company.
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Page 20: Personal Protective Equipment
Safety Personal protective equipment 2.8 Personal protective equipment Personal protective equipment is used to protect personnel from impairments to health and safety at work. During the various tasks performed on and with the machine, per- sonnel must wear personal protective equipment, to which special reference is made in the individual sections of this manual. -
Page 21: Spare Parts
Storage of spare parts Ä Chapter 4.4 “Storage of spare parts” Please see on page 30 for information on storing spare parts. Ordering spare parts Order spare parts from Stahl-Armaturen PERSTA GmbH, with specification of valve type, Year of manufacture, Nominal diameter,... -
Page 22: Environmental Protection
Safety Environmental protection 2.10 Environmental protection ENVIRONMENT! Hazards for the environment due to improper handling of environmentally-harmful sub- stances! If environmentally-harmful substances are handled incorrectly, particularly if they are disposed of incorrectly, significant environmental damage can occur. – Always comply with the instructions cited below for handling and disposal of environmentally- harmful substances. -
Page 23: Functional Description
Functional description Mode of operation of the high pressure swing check valve Functional description 3.1 Mode of operation of the high pressure swing check valve Fig. 2: Sectional view - high pressure swing check valve Flow direction Body Return flow direction blocked Swing check plate In the body (Fig. -
Page 24: Seal To The Outside
Functional description Seal to the outside 3.2 Seal to the outside Pressure sealing bonnet Fig. 3: Pressure sealing bonnet Cover Elastic gasket ring Support ring Segment ring Clamping lid Screws The body is sealed against the environment via the pressure sealing bonnet. -
Page 25: Connections
Functional description Connections 3.3 Connections Connection in the pipe Depending on the version the high pressure swing check valve can be mounted in the pipe, as Butt-weld valve, Flanged valve, Special connection valve 20.05.2021 High pressure swing check valve DRI... - Page 26 Functional description Connections High pressure swing check valve DRI 20.05.2021...
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Page 27: Transport And Storage
Transport and storage Safety notices for transport and storage Transport and storage 4.1 Safety notices for transport and storage Heavy weight of the valve WARNING! Danger of injury due to the heavy weight of the valve! The heavy weight of the valve, and of its compo- nents, can result in severe injuries. -
Page 28: Transport Of Packages
Transport and storage Transport of packages 4.2 Transport of packages Depending on the size, valves are delivered individually or on a pallet. Transporting individual valves Using ring bolts/ring nuts Depending on the version, ring nuts and/or ring bolts are included in the scope of delivery. –... - Page 29 Transport and storage Transport of packages Transporting the valve without the Personnel: Trained person (hoist) inserted cover Protective equipment: Industrial hard hat Protective gloves Safety footwear Special tool: Sling gear Hoist Ring bolts Screw the supplied ring bolts (Fig. 5/2) into the thread open- ings (Fig.
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Page 30: Storage Of The Valve
Transport and storage Storage of spare parts 4.3 Storage of the valve Storage of the valve Store valves under the following conditions: Do not store outdoors. Store in a dry and dust-free location. Do not expose to any aggressive media. Protect from direct sunlight. -
Page 31: Installation
– Do not unscrew threaded connections on the valve. – For maintenance tasks or when unscrewing threaded connections, contact – Stahl-Armaturen PERSTA GmbH customer service (contact details p. 3) to request the tightening torques, specifying the serial number, or – refer to the manufacturer’s website (address on page 2). -
Page 32: Before The Installation
Installation Before the installation Heavy weight of the valve WARNING! Danger of injury due to the heavy weight of the valve! The heavy weight of the valve, and of its compo- nents, can result in severe injuries. – Transport valves with a suitable hoist or forklift. –... -
Page 33: Installing The Valve
Installation After the installation 5.3 Installing the valve Personnel: Pipeline engineer Trained person (hoist) Protective equipment: Protective work clothing Protective gloves Industrial hard hat Safety footwear Special tool: Sling gear Hoist Prepare the respective pipe section for the installation. Use a hoist ( Ä... -
Page 34: Pickling The Valve
Installation After the installation > Pickling the valve WARNING! Gloss paint is a health hazard! Direct contact with the gloss paint used can have health implications. – Handle gloss paint in accordance with the instructions in the manufacturer’s safety data sheet. -
Page 35: Painting The Valve
Installation After the installation > Applying thermal insulation 5.4.2 Painting the valve Ensure that the operating company’s specialised personnel paint the valve. Use suitable (compatible) painting systems. 5.4.3 Executing the system pressure test and leak test Personnel: Pipeline engineer Protective equipment: Industrial hard hat Safety goggles Protective work clothing... - Page 36 Installation After the installation > Applying thermal insulation High pressure swing check valve DRI 20.05.2021...
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Page 37: Commissioning
Commissioning Safety notices for commissioning Commissioning 6.1 Safety notices for commissioning Danger of freezing WARNING! Danger of injury due to pipes shattering at freezing temperatures! As a result of pipes shattering at freezing tempera- tures, severe injuries can be caused by fluid under high pressure. - Page 38 Commissioning Safety notices for commissioning Failure to comply with the heating- up times/cooling times WARNING! Danger of injury due to failure to comply with the heating-up times/cooling times! Insufficient heating-up times/cooling times may lead to impermissible deformations of the valve and reduction of the total service life.
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Page 39: Prior To Commissioning
Commissioning Executing the commissioning process 6.2 Prior to commissioning Personnel: Pipeline engineer Protective equipment: Industrial hard hat Safety goggles Protective work clothing Protective gloves Safety footwear ensuring that the overall system is released for operation. 6.3 Executing the commissioning process Personnel: Pipeline engineer Industrial mechanic (high pressure... - Page 40 Commissioning Executing the commissioning process If necessary, recheck tightening torque in accordance with the manufacturer’s specifications. Tighten clamping nuts (Fig. 6/2) hand tight. Fig. 6: Retightening nuts High pressure swing check valve DRI 20.05.2021...
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Page 41: Maintenance
Maintenance Safety instructions for maintenance Maintenance 7.1 Safety instructions for maintenance Improperly executed maintenance tasks WARNING! Danger of injury due to improperly executed maintenance tasks! Improper maintenance can cause severe injury or significant material damage. – Before starting tasks: – ensure that there is adequate free space for installation, –... - Page 42 – Do not unscrew threaded connections on the valve. – For maintenance tasks or when unscrewing threaded connections, contact – Stahl-Armaturen PERSTA GmbH customer service (contact details p. 3) to request the tightening torques, specifying the serial number, or – refer to the manufacturer’s website (address on page 2).
- Page 43 – Only use original spare parts from Stahl-Arma- turen PERSTA GmbH or spare parts approved by Stahl-Armaturen PERSTA GmbH. – If you have any questions or if anything is unclear, always contact our customer service organisation (contact details on page 3).
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Page 44: Maintenance Schedule
If regular inspections indicate increased wear, the required mainte- nance intervals must be reduced appropriately in accordance with the actual indications of wear. For questions concerning mainte- nance tasks and intervals, contact Stahl-Armaturen PERSTA GmbH customer service (contact details p. 3). High pressure swing check valve DRI... -
Page 45: Maintenance Tasks
Maintenance Maintenance tasks > Visually checking the valve Interval Maintenance work Personnel Depending on activation Check the valve visually for leaks ( Ä Chapter 7.3.1 “Visually Trained person frequency, operating and checking the valve” on page 45) (operator) ambient conditions/speci- fied by the operating company Ä... -
Page 46: Replacing The Gasket Of The Pressure Sealing Bonnet
Maintenance Maintenance tasks > Replacing the gasket of the pressure sealing bonnet 7.3.2 Replacing the gasket of the pressure sealing bonnet Personnel: Industrial mechanic (high pressure valves) Trained person (hoist) Protective equip- Industrial hard hat ment: Safety goggles Protective work clothing Protective gloves Safety footwear Special tool:... - Page 47 Maintenance Maintenance tasks > Replacing the gasket of the pressure sealing bonnet Screw the ring bolts (Fig. 8/2) into the threaded bores (Fig. 8/1) on the clamping lid. CAUTION! Danger of injury due to falling clamping lid! Ensure that the ring bolts (Fig. 8/2) are fully screwed into the clamping lid.
- Page 48 Maintenance Maintenance tasks > Replacing the gasket of the pressure sealing bonnet Dismount cover Screw the supplied ring nuts (Fig. 10/2) onto the stud bolts (Fig. 10/1) of the cover. Ensure that the thread of the ring nuts (Fig. 10/2) is fully screwed onto the stud bolts (Fig.
- Page 49 Maintenance Maintenance tasks > Replacing the gasket of the pressure sealing bonnet Screw the supplied ring nuts (Fig. 12/3) onto the stud bolts of the cover. Attach the ring nuts (Fig. 12/3) to the hoist and lift the cover (Fig. 12/2) with mounted support and gasket ring over the body (Fig.
- Page 50 Maintenance Maintenance tasks > Replacing the gasket of the pressure sealing bonnet Loosely screw together the clamping lid (Fig. 14/3) with washers and nuts (Fig. 14/2) onto the stud bolts (Fig. 14/1) of the cover. Fig. 14: Bolting the clamping lid WARNING! Danger due to the wrong screw tightening torque!
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Page 51: After Maintenance
Maintenance After maintenance 7.4 After maintenance Executing final tests after replace- ment Personnel: Industrial mechanic (high pressure valves) Protective equip- Industrial hard hat ment: Safety goggles Protective work clothing Protective gloves Safety footwear Prerequisite: Maintenance tasks are concluded. Charge the valve with permissible test pressure. Ensure that the valve does not leak. - Page 52 Maintenance After maintenance High pressure swing check valve DRI 20.05.2021...
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Page 53: Faults And Fault Correction
– the valve is depressurised – the valve has cooled-down/warmed-up to ambient temperature. – If in doubt, obtain the assistance of experienced persons or contact Stahl-Armaturen PERSTA GmbH Customer Service. – Comply with the following before restarting the system: – Ensure that all fault correction tasks have... - Page 54 Faults and fault correction Safety notices for fault correction Thermal dangers WARNING! Danger of injury due to high/low temperatures! Depending on the insert of the valve or of the pipe, injuries can occur due to the high or low tempera- ture of the components.
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Page 55: Fault Table
(high not close tight eliminated by Stahlarmaturen PERSTA pressure valves) GmbH customer service (contact details p. 3) or an external specialised company. Ä Chapter 8.3.1 “Dismounting the swing check valve”... - Page 56 Faults and fault correction Fault table Fault descrip- Cause Remedy Personnel tion Ä Chapter 8.3.2 “Mounting the swing check Swing check Mimic element of valve” on page 59 valve does not swing check valve is open defective Leakage of the Sealing gasket is Dismount the pressure sealing bonnet.
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Page 57: Fault Correction Work
– Separating the swing check valve and retaining ring, as well as – Processing of the swing check valve should be executed by an external specialised company or by Stahl-Armaturen PERSTA GmbH Customer Service. Personnel: Industrial mechanic (high pressure valves) - Page 58 Faults and fault correction Fault correction work > Dismounting the swing check valve Unbend the washers (Fig. 16/2). Unscrew the bolts (Fig. 16/1) and remove them from the body with the washers (Fig. 16/2). Fig. 16: Looking into the body from above Push the retaining washers (Fig.
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Page 59: Mounting The Swing Check Valve
– Processing of the swing check valve as well as – attachment of the swing check valve on the retaining ring should be executed by an external specialised company or by Stahl-Armaturen PERSTA GmbH Customer Service. Personnel: Industrial mechanic (high pressure... - Page 60 Faults and fault correction Fault correction work > Mounting the swing check valve Place the retaining washers (Fig. 18/2) on the retaining ring (Fig. 18/1) and push into the grooves (Fig. 18/3) in the body. Fig. 18: Mounting the retaining washers Fasten the retaining washers (Fig.
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Page 61: Dismantling, Disposal
Dismantling, disposal Safety notice for dismantling and disposal Dismantling, disposal 9.1 Safety notice for dismantling and disposal Pumping medium WARNING! Danger of injury due to pumping medium under pressure! In operating status, as well as in decommissioned status, depending on the version of the valve, inju- ries can occur due to medium escaping under high pressure. - Page 62 – Secure the components so that they do not fall down or fall over. – If anything is unclear obtain the assistance of Stahl-Armaturen contact PERSTA GmbH cus- tomer service (contact details p. 3). Heavy weight of the valve WARNING!
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Page 63: Dismantling
Dismantling, disposal Dismantling Suspended loads WARNING! Danger of injury due to suspended loads! Suspended loads can cause dangerous situations that can result in severe injuries. – Do not step under suspended loads. – Wear protective equipment: Industrial hard hat, safety footwear. –... -
Page 64: Disposal
Dismantling, disposal Disposal 9.3 Disposal If a return or disposal agreement has not been concluded, then recycle dismantled components: Scrap metals. Recycle plastic elements. Sort and dispose of all other components according to material condition. ENVIRONMENT! Hazards for the environment due to improper disposal! Hazards for the environment can occur due to improper disposal. -
Page 65: Index
Index Index Shut-off device ..... . . 55 Brief description ......7 Butt-weld valve . - Page 66 Index Storage ....... 30 Storing the valve ......30 Tools .
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