OMe_RKS_gen

8/7/2019 OMe_RKS_gen

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Operating and maintenance manual

For RKS plunger valve

Welded construction



Falkner Armaturenvertriebs GmbHA-4320 Perg / Technologiepark 17Phone: +43 7262 9396 3320

Fax: +43 7262 9396 3329e-mail: [email protected]

Internet: www.gur-valves.com

Operating and maintenance manual page 2 of 9 RKS-

1. General Characteristics

1.1. Design

Type RKS plunger valve with variable operator devices as counter weight for closing and hydraulic cylinder for opening, manual bygearbox or electric actuator. Welded, manufactured parts with externalequipments to install in water systems. Soft sealing system is for water application on different pressure rates for normal temperature use.

Design details:

- eccentric driving shaft and crank

- welded construction housing

- welded construction piston

- normally opened position

- pressure balanced isolating and flow-control piston

- piston is guided by double metallic bronze rings

- excellent flow-control or pressure-reducer abilities

- seat ring is plugged into the body and supported by counter flange

- main sealing element is EPDM / NBR rubber profile sealing

- long lasting and wear-free sealing

-with lever and counterweight - single side /option/

- hydraulic cylinder with end-damping function /option/

- with gearbox and electric actuator /option/

- linear sensor ensure accurate control /option/

- inductive sensors at end positions /option/

- slotted cylinder for water dispersing /option/

- de-aeration and drainage screws

Operating details:

Valve with hydraulic operation device

The valve is normally in closed position by counterweight if there is nooil pressure supplied into the cylinder. Opening of the valve (piston) isdone by hydraulic cylinder in case there is oil pressure supplied. Min.oil pressure is 80 bar!

Hydraulic cylinder has end-damping ability when main valve is inclosing phase, at last ~40 mm of stroke. End-damping strength isadjustable by set-screw on hydraulic cylinder which ensures fine andsmooth closing avoiding damage of valves parts and/or equipments.

Inductive sensors at both end positions open/closed.







Valve with manual gearbox and/or electric actuator

Valves are equipped by worm and/or spur gearbox combination and ahand wheel in order to reach low torque values. Mechanical positionindicator placed at side of gearbox is showing the actual position of thedisk. Gearboxes have a protection class of IP67.

Electrical actuator optionally installed and limit switched are adjusted byfactory. Electrical connections that are going to be supply actuatorsshould be made according to the wiring diagrams that are supplied withthe actuators. Connections should be made before connecting thevalve to the pipeline. Before making electrical connection the valveshould be opened halfway with the emergency hand wheel. After

completion of electrical connections valve should be operated to openthe open button is pressed or vice-versa then the phase connectionshould be changed. Actuators with reversing contactors will correct thephase connection even if they are connected faulty.Limit switch and torque switch adjustments must never be altered.These settings are factory made for optimum operation conditions. Anychanges in these adjustments can cause serious damage to the valveand the actuator.Valve disk position can easily be checked from the mechanical positionindicator on the valve gearbox and / or electric actuator feedbacksystem. If valve reaches its full closed position and there is still leakagefrom valve, than sealing material on disk should be checked and

replaced if necessary.There should not be any solid particles in the medium. Solid particles inthe medium can cause serious damage to the sealing.

Warning: Unlike gate valves, sealing can not be provided byforcing the hand wheel . When the valve reaches its full closedposition adjustment nut inside the gearbox and limit switches inactuator reaches its end position. Further force applied maydamage operation unit and / or valve.

Piston is all time guided by bronze rings therefore even under heavily

stressed position smooth and “stuck-free” operation assured.







1.2. Operating and testing conditions

Medium: water Medium temperature: °CDesign temperature: acc. to drawing

Operating pressure: bar gDesign pressure: acc. to drawing

Hydrostatic testing:Casing: 1,5 x PNSeat: 1,1 x PN

2. Description of main parts

2.1. Housing: Welded design – S235JR carbon steel

2.2. Piston:Welded design - 1.4301 stainless steel

2.3. Retaining ring: Stainless steel 1.4301

2.4. Disc sealing ring:Rubber profile made from EPDM / NBR

2.5. Shaft and shaft bearing:

The shaft is sitting in the bearing pipe with snug fit, fixed by keys andpivoted. The bearings are assembled into the body with friction-set.Bushings are maintenance free, DU+PTFE.Shaft material is 1.4021.

2.6. Shaft sealing:

By NBR O-rings and PU lip gaskets.

2.7. Seat ring:

Stainless steel 1.4301.

For detailed material specification please refer attached parts list.







3. Operation mechanism and application

Secure closing of the plunger valve is assured by the force which isprovided by counter weight or actuator. The valve will remain closeduntil hydraulic oil pressure is not been provided. In case of emergencysituation, power failure or hydraulic supply unit malfunction thecounterweight will automatically close the valve.

Hydraulic cylinder is furthermore equipped with an additional endposition damping device which is about the last 5 – 10% of the pistonstroke. END DAMPING IS PRE-ADJUSTED!!! DO NOT ADJUST ENDDAMPING WITHOUT CONSULTING SUPPLIER!

The lineal magnetic sensor is mounted to the operation system. It is

connecting into the installed switch box and it is supplying the order signal for control electric unit.

For electrically actuated valve please refer attached documentationsupplied by the producer of electric device.

The valve is suitable for flow-volume regulation, which is depends onpiston’s position.

4. Materials: according to data sheets and/or parts list

5. Coating:Valve - inside and outside sand blasted SA2.5

zinc primer and epoxy coating

Lever and counter weight - sand blasted SA2.5zinc primer and epoxy coating

Supporter - sand blasted SA2.5zinc primer and epoxy coating

6. Main measurements: according to the assembly drawing

7. Maintenance and inspection

The plunger valve is basically maintenance free. No lubricating pointsare provided. It is strongly recommended to make following inspectionsregularly:

- Make a full visual inspection of valve every month. Checkcondition of valve and equipments.

- Make a full operation circle open/closed at least in every 3months.

- Check for any leakage at the valve and equipments regularly.

- Check tightness of flanges, shaft sealing and hydraulic joints.

- Supervise connections and bolts regularly, if necessary tighten

them.







Depending on environment, hydraulic piston should be regularly

checked for dirt, sand or similar covers and cleaned with tissuesoaked in degreasing, non aggressive medium.

8. Failure and repair

The valve can be expected to operate reliably and safely provided thatall joints and connections have been made properly. Nevertheless,accidental events (e.g. occurrences not included in the scope of delivery) may lead to valve failures.

Mechanical failure

In view of the strict safety margins observed in the valve design,mechanical failure is liable to occur only in the case of high improper operation or unforeseeable events. If a mechanical failure should occur follow these instructions:

1. The valve didn't close / open normally

- It’s possible that something is between the body seat,slotted cylinder or piston. Check valve inside parts for solid particles.

- Check if electric actuator is under voltage and workingproperly.

- Check if nothing is blocks counterweight of moving and

hydraulic cylinder is connected correctly to oil system.- Check that operating mechanism (gearbox, supporter,

lever, inside supporters and connecting rods) are notblocked by some other things (i.e. tools).

2. Electric actuator or gearbox is damaged

- Contact the supplier or change the part by well trainedtechnical staff.

3. Hydraulic cylinder is damaged

- Contact the supplier for reparation or new hydrauliccylinder then replace by well trained technical staff.

4. Surface protection is damaged

-Clear damaged surface then repair coating with twocomponent epoxy.

5. Mechanical damage

- Contact supplier;6. Leakage

- see point 10 (replacement of seals)

IF PISTON, OPERATOR DEVICE OR HYDRAULIC STUCKED ORNOT ABLE TO OPERATE SMOOTHLY IN NORMAL WAY, NEVERTRY TO MOVE OR OPERATE THEM BY FORCE! WARILY CHECKOPERATION MECHANISM AND FIX PROBLEM BEFORESTARTING OPERATION!

WE RECOMMEND THAT ANY MAJOR REPAIR SHOULD BE MADEAT OUR WORKSHOP OR BY OUR TECHNICAL STAFF AT SITE.







9. Tests

The valve was manufactured and tested acc. DIN 3230 Tail 3. standardor in compliance with customer’s request.

10. Replacement of seals

10.1 Main sealing replacement (see assembly drawing) - depressurise the system and deactivate operation device (hydraulic

cylinder, electric actuator), make sure that they will not able tooperate valve during reparation procedure- disassembly valve from pipeline system- pull out and remove seat ring (pos.10)- loosen and remove fixing bolts (pos.37, 38) then retaining ring

(pos.3)- if necessary place suitable temporary bolts to position of set

screws. They will be used as guides to help detaching retaining ring(pos. 3) from piston.

- replace main sealing ring (pos.11)- re-assemble parts in reverse order

10.2 Replacement of piston lip-gaskets- depressurise the system and deactivate operation device (hydraulic

cylinder, electric actuator), make sure that they will not able tooperate valve during reparation procedure

- disassembly valve from pipeline system- pull out and remove seat ring (pos. 10)- remove fixing pin and bridge (pos.13 and 17)- pull piston (pos.2) out from the body- replace two lip-gaskets (pos.48) (Take care the positions of two

gaskets when replacing!)- re-assemble parts in reverse order

10.3 Replacement of shaft sealings

Shaft has double sealing system (primary and secondary) which isensure long and reliable operation for long time without having leakage.Replacement of shaft sealing is require complete dismount of operationdevice which can be complicated. In case of leakage is realized pleasecontact company FALKNER for technical support.

WE RECOMMEND THAT ANY MAJOR REPAIR SHOULD BE MADEAT OUR WORKSHOP OR BY OUR TECHNICAL STAFF AT SITE.







11. Mounting instruction

The plunger valve will be delivered in „ready for use” condition. Theinstallation process is simple. Please keep the following instructions inprior before assembly:

- Unpack valve and equipments than check condition of all parts. Donot install valve if you recognized any damaged or missing parts!

- Make sure that pipeline is clear and free from impurities.

- Before installation check if there is enough space for movingoperator device and to have free access all around the valve.

- Keep in priority the correct flow direction marked on assembly

drawings.- Clean the valve sealing surfaces.

- Counter flanges must be parallel and fit to valve standards.

- Use correct sealing material for flanges according to applicablemedium and temperature.

- Tighten connecting bolts evenly and crosswise.

12. Storage

During storage period the valve has to be protected against impurities,direct sunlight, rain, frost and other weather circumstance.

If valve is stored for longer than twelve months it is necessary toreplace sealings and gaskets in the valve and hydraulic beforeinstallation.

If valve is going to be kept in stock for a time leave the valve disc in aslightly open position.If valve will be stored sitting on its flange connection, make sure thatvalve is stored on a wooden pallet to protect flange surface againstmechanical damages.

Never lift valve from hand wheel, gearbox or actuator. This may cause

serious damage and it is extremely dangerous for persons around thevalve.







12. Important safety information

In and outside of valve there are moving parts (lever,supporter, counterweight, hydraulic, operator device, disc,shafts etc.). Because of it, every person in valve proximityhas to be careful and should be aware that those parts maysuddenly start to move without any warning. Be careful of burn injuries; the valve may be hot due to medium inside.Some parts may have significantly higher temperature thanothers (i.e. body). Before starting ANY maintenance or reparation operation, parts such as hydraulic and pipelineitself MUST NOT be pressurised and all actuation must be

disabled, so emergency closing or/and opening functions cannot be started.

Valve should not be installed in area which is permanentlyaccessible by personnel OR area without clearly displayedwarnings for dangerous moving objects!!!

Compensating oil tank should not be exposed to directsunlight and it should be protected from it. Max. temperatureof oil inside should not exceed 60°C!

Any repairing has to be performed by skilled personnel.

Never loosen bolts and screws in pressurised pipeline; thesame applies for any existing hydraulic devices.

Counterweight has to be removed or it has to be supportedby beam in case of reparation of valve.

In case of inside repairing, the counterweight has to bedismounted.

Before any maintenance read this operational andmaintenance manual.

Falkner Armaturenvertriebs GmbH.AUSTRIA

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