MAPAGGeneral instruction manualfor heavy-duty valves(section 1)

Installation, Maintenance and Operating Instructions

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Table of Contents1 Proper use ............................................................... 32 Configurations ........................................................ 33 Visual check ............................................................ 44 Marking ..................................................................... 55 Installation ............................................................... 5

5.1 Planning ......................................................... 55.2 Preparations ................................................... 55.3 Fitting............................................................... 65.4 Permissible tightening moments.................... 7

6 Removal ................................................................... 76.1 Preparations ................................................... 76.2 Removal .......................................................... 7

7 Re-installation .......................................................... 88 Troubleshooting ...................................................... 89 Safety instructions ...............................................1010 Spare parts .............................................................10

Read these instructions first!These instructions provide information about safe handling and operation of the valve.

If you require additional assistance, please contact the manufacturer or manufacturer’s rapresentative.

Addresses and phone numbers are printed on the back cover

Save these instructions!

Subject to change without notice.

All trademarks are property of their respective owners.

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1 Proper useThe butterfly valve supplied to you has been speciallydesigned to satisfy the requirements that are specifiedin the documentation relating to this order, particularlyas regards the operating parameters pressure, temper-ature and medium. If pipes are by mistake subjected toa wrong medium, a higher pressure level or a higher orlower temperature, this can lead to destruction of thecomplete unit. The damaged parts then have to bereplaced immediately.

There must be no contamination of the pipes and themedium used at any time. If there is, this may have anadverse effect on the tightness of the butterfly valveseal.

One of the requirements which proper use of the butter-fly valve involves is that the operating, installation andmaintenance personnel have read and understood thisinstruction manual.

All installation work must be carried out by appropri-ately trained skilled personnel.

In operating temperatures higher than 50 °C or lowerthan -50 °C, the valves must be insulated to prevent therisk of injury caused by contact (security) and to main-tain the function of the valve (varying heat expansion).

The insulation must be designed such that the tempera-ture generated by the medium does not exceed 50 °C onits outside. We do not accept any liability for structuralalterations that are made without the express approval ofthe Linde AG MAPAG plant. Please make sure that youalways use genuine spare parts. If you intend to use thebutterfly valve for a different medium, different tempera-tures or different pressure levels than originally speci-fied, please find out in advance from our specialistswhether the butterfly valve is suitable for the require-ments concerned. We will be delighted to advise you.

We do not accept any liability for injuries and damageto property that are caused by improper use of the but-terfly valve.

2 ConfigurationsThe butterfly valve is supplied in one of four possibleconfigurations: a flange configuration, a sandwich con-figuration, a monoflange configuration or a configura-tion with welding ends.

Information about the installation and removal of bodyswith welding ends can be found in section 2 of theinstruction manual for model E and model K valves.

Fig. 1 Flange

Fig. 2 Sandwich / Wafer

Fig. 3 Monoflange / Lug

Fig. 4 Welding ends

Important note:If you are operating the butterfly valve in high orlow temperature ranges, we recommend that youprovide the butterfly valve with external insulation, asthere is otherwise a considerable danger ofinjury. When there is a manual actuator system, thehand wheel may only be operated wearing suitablegloves in such cases!

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The butterfly valve is normally delivered complete withan actuator unit. Special parts or spare parts are onlysupplied if they have been included in the order confir-mation.

Fig. 5 Flange-configuration butterfly valve with apneumatic actuator. As an alternative, thevalve can also be operated by a hand wheelor by an electric or hydraulic actuator.

3 Visual checkBefore it left the MAPAG plant, the butterfly valve waschecked by our quality assurance department to makesure it works properly and does not leak. It was also setappropriately in accordance with the documentationprepared for the order in question.

Please check the butterfly valve for any transport dam-age before you install it. If you find that any of the partsdelivered have been damaged, please inform our spe-cialists immediately.

Check that the butterfly valve is working properly beforeyou install it. To do this, proceed as follows:

□ You may need ropes to lift the butterfly valve,depending on its size and weight.

Fig. 6 Preparing for the function test

□ Set the butterfly valve up in a vertical position.

Fig. 7 Function test

□ Connect the energy supply system now. Make surethat the actuator opens into the correct direction ofmovement.

Make sure you always attach lifting ropes to thebody (see illustration). The shaft could be damaged if you attach ropes to the actuator.

It is possible that the butterfly valve may move inan uncontrolled way in the course of the functiontest. It is therefore important to make sure that thebutterfly valve cannot under any circumstancesmove or even tip over during the function test.

The general rule is: opening anti-clockwise,,closing clockwise (it is possible that a differentarrangement may be specified in individualcases).

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Fig. 8 Direction of actuator movement

□ Check whether the butterfly valve is working prop-erly. Open and close the butterfly valve severaltimes. The stop that is provided in the actuatormakes sure that the shut-off disc cannot be turnedbeyond the closed position as set at the factory.

□ Switch the energy supply off after the function testhas been completed.

Please contact our specialists if the butterfly valve doesnot work smoothly in the function test.

4 MarkingThe following marks have been made to identify theposition of the disc when the unit has been installed:

□ CLOSED sign with a coloured mark on the body(with an extension on the top flange of the lengthingjoint in the case of insulated valves).

□ Coloured mark on the valve shaft.

Fig. 9 Direction of actuator movement and posi-tion of the shut-off disc

If these two red marks are aligned with each other, thenthe valve position is „Closed“. The sealing element is onthe side of the body on which the „Closed“ sign is pro-vided.

5 InstallationAll butterfly valve installation work must be carried outby appropriately trained skilled personnel.

5.1 PlanningConsider the following points before you start to installthe butterfly valve:

□ You must install the butterfly valve in such a way thatthe actuator is accessible at all times.

□ If you are operating the butterfly valves in high or lowtemperature ranges, we recommend that you pro-vide the butterfly valve with external insulation, asthere is otherwise a considerable danger of injury.When there is a manual actuator system, the handwheel may only be operated wearing suitable gloves.

□ The energy supply to actuators that are operatedelectrically, pneumatically or hydraulically must notbe connected until the butterfly valve has beeninstalled.

□ The holes in the flanges at the ends of both pipesmust be aligned precisely and the sealing surfacesof the opposite flanges must be parallel to eachother. The holes in the flanges must not be out ofline with each other at all, so that the butterfly valveis not subjected to tension of any kind when it isinstalled.

Fig. 10 Alignment of the pipe flanges

5.2 PreparationsMake sure that the pipes are not contaminated in anyway before you install the butterfly valve. Contaminationof any kind - such as welding residue, rust or dirt - canhave an adverse effect on the tightness of the butterflyvalve and can damage the sealing surface of the shut-off disc or the sealing elements. When the butterflyvalve is in operation, the medium must not carry anycontaminants with it that might be deposited in thesealing area either.

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If the shut-off disc projects beyond the fitting length ofthe unit, the butterfly valve has to be closed before it isinstalled (pneumatically, hydraulically etc.). It is essen-tial that you make sure the energy supply facilities areattached securely and cannot under any circum-stances be damaged or torn off during the installationoperations. If the energy supply is suddenly inter-rupted, the valve opens abruptly. This can cause seri-ous injury or material damage.

You need lifting tackle to fit larger butterfly valves in thenecessary pipe. Information about the weight of thebutterfly valve can be found in the documentation com-piled for the order in question.

Fig. 11 Equipment for lifting thebutterfly valve

5.3 FittingCarry out the following procedure when you are fittingthe butterfly valve:

□ Turn the butterfly valve in such a way that the arrow(P) on the body points in the pressure direction (seethe illustration „Pressure direction“).

Pressure direction

□ Close the butterfly valve for the duration of the instal-lation operations. When it is open, the sealing sur-face of the shut-off disc may project out of the bodyand be damaged when the valve is being fitted.

□ Use a o-ring that is suitable for your application onboth sides of the butterfly valve between the bodyand the opposing flanges. The two o-rings are notsupplied as standard. We can supply the requiredo-rings to you on request.

□ Tighten the opposing flange nuts or bolts diagonallyand evenly using a torque wrench.

□ Connect the energy supply in a final operation.

Fig. 12 Installation of spindle extension for coldapplications in vertical or min one holeabove the horizontal! (The gas volume tobe at the highest point)

Be careful when fitting valves with the safety set-ting „Spring opening“

Always attach lifting ropes to the body - neverattach them to the actuator, because this mightdamage the shaft.

Example of how to connect the pipe flanges diagonally when there are twelve holes in each flange

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5.4 Permissible tightening torquesPermissible tightening torques for bolts in steel cate-gory A2-70.2 and A4-70 with a metric coarse pitchthread in accordance with DIN 13, 70 % utilisation ofthe Rp 0.2, coefficient of friction 0.16.

1) Figures corresponding to 100 % of the 0.2 % proof stress

6 Removal

The butterfly valve must be closed during installationand removal operations in order to avoid damage to it.

6.1 PreparationsThe following conditions have to be met before youremove the butterfly valve:

□ Make sure that the pipes are depressurised andempty.

□ Find out what medium last ran through the butterflyvalve. There may be residues in the valve. Makesure that there is no danger of poisoning or burningif you come into contact with such residues. If nec-essary, protect yourself by wearing appropriate pro-tective clothing, safety goggles and breathing equipment.

If you are not removing the valve yourself, warn the staffwho is carrying out this assignment. Make protectiveclothing available to them if necessary.

6.2 RemovalCarry out the following operations in the specified orderwhen you are removing the butterfly valve:

□ Close the butterfly valve.

□ If the actuator has to be taken off in order to removethe butterfly valve, mark the position of the actuatorto the shaft and to the shut-off disc on the adapterbefore removing the actuator (see illustration). Thiswill enable you to position the actuator again cor-rectly when your re-install it, so that it does notcause any malfunctioning of the system.

Ø Stressed cross-section

Stress1)

Force at TFE Pre-stress force Tightening torque

AS in mm2 Rp 0,2 in N Rm in N N NmM4 8.8 3 951 6 146 2 489 2.13

M5 14.2 6 390 9 940 4 026 4.19

M6 20.1 9 045 14 070 5 698 7.3

M8 36.6 16 470 25 620 10 376 17.5

M10 58.0 26 100 40 600 16 443 35.2

M12 84.3 37 935 59 010 23 899 60.3

M14 115.0 51 750 80 500 32 603 95.8

M16 157.0 70 650 109 900 44 510 146.2

M18 192.0 86 400 134 400 54 432 203.1

M20 245.0 110 250 171 500 69 458 285.7

M22 303.0 75 750 151 500 47 723 212.4

M24 353.0 88 250 176 500 55 598 273.9

M27 459.0 114 750 229 500 72 293 405.3

M30 561.0 140 250 280 500 85 358 549.0

There is a considerable danger of injury when anmaintenance work is being carried out due to theunintentional actuation of the remote control.

If you use a remote control to operate the butterflyvalve, you must install a device that interrupts theenergy supply in the actuator unit for safety rea-sons (e.g. an emergency stop switch).

If you are operating the butterfly valve in high orlow temperature ranges, we recommend that youprovide the butterfly valve with external insula-tion. If necessary, install an external temperaturegauge to provide protection against injury.

Check whether the butterfly valve has alreadycooled down or warmed up to such an extent thatthere is no further danger due to extreme tempera-tures.

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Fig. 13 Mark the position of the actuator to theshaft and to the shut-off disc on theadapter before removing the actuator.

□ Remove the actuator.

□ Secure the butterfly valve with ropes. Attach theropes to the body (and not to the shaft) of the butter-fly valve.

□ Separate the flanges of the butterfly valve by undo-ing the opposing bolts or nuts diagonally.

□ Transport the butterfly valve in such a way that itcannot be moved or damaged during the transportprocess.

Fig. 14 Securing the butterfly valve with ropes

7 Re-installationProceed as follows to re-install the butterfly valve:

□ Close the butterfly valve.

□ There is a round notch at the end of the actuatorshaft and on the body of the butterfly valve. Theround notch on the actuator shaft must point in thedirection of the round notch on the body when thevalve is installed again.

□ Move the actuator to its closed position.

Fig. 15 Installation marks

□ Make sure that you fit the actuator to the actuatorshaft in the right position. To do this, use the markthat you made on the adapter and the actuatorwhen you removed the butterfly valve.

□ Fit the butterfly valve between the pipes (see chap-ter 4 „Installation“).

8 TroubleshootingThe butterfly valve does not close tightly

1. Do not under any circumstances use force to closethe butterfly valve. There is too great a risk that dam-age may occur.

2. Check whether the energy supply has beenswitched on.

3. Check whether the closed position of the actuatorand the closed position of the shut-off disc match.

4. Check the sealing surface of the shut-off disc andthe sealing elements to see if they have been dam-aged. Remove the butterfly valve. Check whetherthere are any foreign bodies between the shut-offdisc and the sealing elements. Remove any foreignbodies or deposits that you find. Change any dam-aged parts.

You will find instructions about removing ......the butterfly valve .............................................. on page 10...in the chapter entitled ........................................... Removal...the sealing elements............ instruction manual, section 2...in the chapter entitled..............Replacement of the sealing elements...the shut-off disc .....................instruction manual, section 2...in the chapter entitled ........... Replacement of mechanical parts

Please follow the instructions given in the chapter enti-tled „Cleaning and maintenance“ in section 2 of theinstruction manual as well.

Switch the energy supply to the actuator off. To dothis, actuate the emergency stop switch for theactuator energy supply or guard the remote con-trol unit in such a way that no-one can switch theenergy supply system on again by mistake.

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Liquid or gas is escaping ...... from heavy-duty valves with a gland

Check whether the gland is still being pre-stressedeffectively by the disc springs. It is possible that the discsprings may be damaged. If this is the case, change thedisc springs. If the tension applied by the disc springs istoo small, tighten the nuts more securely - but not as faras the stop, because this would damage the discsprings. If the tension applied by the disc springs is cor-rect, then the packing is damaged. Change the packing.Instructions about removing the packing can be found inthe chapter entitled „Replacement of mechanical parts“in section 2 of the instruction manual.

Fig. 16 Heavy-duty valves with a gland

... from heavy-duty valves with an O-ring seal

Check whether the O-rings are damaged in the area ofthe bearing bushing. If so, change the O-rings and theu-ring.

Please read chapter 5 „Removal“ in this instructionmanual for information about the removal process.

Fig. 17 Heavy-duty valve with bearing bushing

Liquid or gas is escaping from the coverCheck whether the bolts on the cover have been tight-ened properly. Change the o-ring if necessary.

Please read chapter 5 „Removal“ in this instructionmanual for information about the removal process.

Fig. 18 Checking the tightness of the shaft

The medium is too cold when it is running throughthe valveThe minimum temperature for operating your butterflyvalve depends to a very large extent on the materialsused for your order. You will find information about theappropriate temperature range for your butterfly valvein the documentation compiled for your order.

The sealing element is chosen in accordance with thepermissible temperature of the medium depending onthe design of your system (see the order documentsand the table on page 14). If the medium is runningthrough the butterfly valve at a lower temperature bymistake, the sealing element may be damaged. In thissituation it is necessary to check the condition of thesealing element and to carry out a function test. Thesealing element may need to be replaced.

The medium is too hot when it is running throughthe valveThe maximum temperature for operating your butterflyvalve depends to a very large extent on the materialsused for your order. You will find information about themaximum operating temperature in the documentationcompiled for your order.

Irrespective of this maximum operating temperature,the elastic sealing element and the O-ring must not besubjected to temperatures higher than their specifiedmaximum limit. PTFE parts are designed to withstandtemperatures up to a maximum of 220 °C. These partsare destroyed if the medium is hotter than this. The but-terfly valve continues to close tightly with the metal seal-ing element (23a), but the elastic sealing element (23)and the O-ring (16) have to be replaced immediately.

Temperature resistance of the flexible sealing ele-ments

Important note!If the elastic parts are destroyed by an excessively hot medium, the medium may escape from the gland / bearing bushing and the cover.

FKM EPDM PTFE (pure)Minimum temperature -10 °C -60 °C -200 °C

Maximum temperature +180 °C +180 °C +220 °C

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9 Safety instructionsPlease observe the following safety instructions whenyou are installing, maintaining and operating the heavy-duty valve:

1. For safety reasons you are not allowed to make anychanges to the method of operation of the heavy-duty valve or to its actuator.

2. All installation work on the heavy-duty valve must becarried out by appropriately trained skilled person-nel.

3. When a function test is being made, there is a dan-ger that the heavy-duty valve may suddenly move inan uncontrolled way due to the supply of energy.Make sure therefore that the valve cannot under anycircumstances move or even tip over during thefunction test.

4. Be careful when fitting valves with the safety setting„Spring opening“. If the shut-off disc projectsbeyond the fitting length of the unit, the butterflyvalve has to be closed before it is installed (pneu-matically, hydraulically etc.). It is essential that youmake sure the energy supply facilities are attachedsecurely and cannot under any circumstances bedamaged or torn off during the installation opera-tions. If the energy supply is suddenly interrupted,the valve opens abruptly. The can cause serious injury or material damage.

5. There is a considerable danger of injury when anymaintenance work is being carried out due to theunintentional actuation of the remote control. If youare planning to use a remote control unit in opera-tion of the heavy-duty valve, you will need to incor-porate an additional emergency stop switch in theactuator as a locking facility.

6. Make sure that cleaning agents cannot cause anyundesirable chemical reactions in combination withpossible residues in the heavy-duty valve.

7. When you are working in the area of the sealing sur-face of the shut-off disc, secure the shut-off discwith wooden wedges in order to eliminate the dan-ger of crushing. Make sure that you do not damagethe sealing area of the shut-off disc while you aredoing this.

8. If the o-rings are destroyed by a medium that is toohot, the medium that is being used may escapefrom the shafts.

10 Spare partsMost of the spare parts depend on the technical speci-fication of your system.

Every time you place an order for spare parts, pleaseindicate to us therefore not only the identificationnumber from the spare parts list but also the Mapagorder number under which the heavy-duty valve wasplanned and supplied to you.

Our guarantee commitments only apply if genuinespare parts are used.

Metso Automation Inc.Europe, Vanha Porvoontie 229, P.O. Box 304, FI-01301 VANTAA, Finland. Tel. +358 20 483 150. Fax +358 20 483 151

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Tel. +971 4 883 6974. Fax +971 4 883 6836www.metso.com/valves