Valvision AS: Damsgårdsveien 163A / 5160 Laksevåg / Norway 

Tlf: + 47 47 76 99 99 

[Dato]  PO: 4590026485 

STANDARD DOCUMENTATION ACC. TO TR2381 

o CERTIFICATES OF CONFORMANCEo INSTALLATION, OPERATING AND MAINTENANCE

INSTRUCTIONS FOR VALVES

o VALVE AND OPERATOR DRAWING

MATERIAL CERTIFICATESo

wT 5001/02 Page 1

Issued: 09/2016 KLINGER Fluid Control GmbH Am Kanal 8-10 » 2352 Gumpoldskirchen » Austria office@klinger.kfc.at » www.klinger.kfc.at » Tel: +43 2252 600-0

wT 5001/02 Page 2

Contents

1. Declaration of Conformity ............................................................................. 4

2. Individual Parts Designation ......................................................................... 5

3. Proper Use .................................................................................................. 6

4. Testing of KLINGER Valves .......................................................................... 6

5. Labeling of the Valves .................................................................................. 6

5.1 Information on Butterfly Valves .................................................................... 7

6. Safety Instructions ....................................................................................... 8

6.1 General Notes on Safety .............................................................................. 8

6.2 Safety Instructions for Operators ................................................................. 8

6.3 Hazard Warnings ......................................................................................... 9

7. Technical Data ........................................................................................... 11

7.1 Material codes ........................................................................................... 11

7.2 P/T Diagrams ............................................................................................ 11

7.3 Flow Values and KV Values ........................................................................ 12

8. Transportation and Storage ....................................................................... 14

9. Functional Principle .................................................................................... 15

10. Design Features ......................................................................................... 16

10.1 Additional loads ......................................................................................... 16

10.2 Rated Pressure/Design Temperature PS/TS .............................................. 16

10.3 Blow-out Precaution .................................................................................. 16

10.4 Antistatic Measures ................................................................................... 16

10.5 Cavitation .................................................................................................. 17

10.6 Pressure Blows resulting from Operation ................................................... 17

10.7 Welding Seam Factor ................................................................................ 17

10.8 Pressure-Load Cycle Figures ..................................................................... 17

10.9 Special Design Features ............................................................................ 17

10.10 Permissible Actuator Dimensions ............................................................... 17

10.11 Permissible Actuator Torques .................................................................... 18

11. Installation and Commissioning Instructions ............................................... 18

11.1 Installation with regard to Maintenance/Inspection ..................................... 19

11.2 Installation with the Pipeline System or other Pressure Devices .................. 19

11.3 Installation sketch for Lug-type valves ........................................................ 20

11.4 Installation sketch for Wafer-type valves .................................................... 20

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11.5 Mounting Instructions for Actuators ........................................................... 21

11.6 Fitting the Actuator .................................................................................... 21

12. First-time Startup Instructions .................................................................... 22

12.1 Standard Operation ................................................................................... 23

12.2 Shutting down ........................................................................................... 23

12.3 Improper Utilization ................................................................................... 23

12.4 Welding Instructions .................................................................................. 23

13. Service and Maintenance ........................................................................... 23

13.1 Dismantling for Seal Exchange on the Shifter Shaft .................................... 24

13.2 Repacking the Stuffing Box ....................................................................... 25

13.3 Torque Tables for Stuffing Boxes ............................................................... 25

13.4 Replacement of Bearings on Shift Shaft and Axle ...................................... 25

13.5 Single Part Dismantling for Exchange of the Sealing Element ..................... 26

13.6 Assembly .................................................................................................. 27

14. Factory Repairs ......................................................................................... 27

15. Spare Parts Orders .................................................................................... 27

16. Inspection and Recurring Testing ............................................................... 27

17. Disposal .................................................................................................... 28

18. Spare Parts List ......................................................................................... 28

wT 5001/02 Page 4

1. Declaration of Conformity

The manufacturer KLINGER Fluid Control GmbH, A-2352 Gumpoldskirchen, declares that the CONAXE series butterfly valves are designed for a maximum rated pressure of PS 0.5 bar above atmospheric pressure. They are therefore subject to the Pressure Equipment Directive 2014/68/EU. The valves are executed and dimensioned in accordance with EN 593. The applied conformity assessment procedure is Module H. CE 0408-marking is executed in accordance with the TÜV Austria Service GmbH.

We furthermore declare that this product does not meet all the requirements of the Machinery Directive in itself and that it is designed to be installed in another machine or facility. Putting the entire machine, into which our product has been installed, into operation prior to having declared its meeting the requirements of the Machinery Directive, is prohibited.

The butterfly valves may only be operated in accordance with the operation manual. In the event of changes to construction elements or components, the guarantee is lost.

The following standards were utilized for the design:

EN 593 Design standard for metallic butterfly valves

EN 558 Face-to-face length of valves

ISO 5211 Actuator flange for valves

EN 12266 Leak testing on the valve body

EN 12516 Calculation for pressure maintaining body sections with welding seam factor 0.7, if not otherwise explicitly demanded in another form.

EN 19 Marking of valves

EN 1092 Flange dimensions

For valves, which do not fall under the EU guideline 2014/68/EU and which are valves defined in accordance with “ANSI CLASS"; API609, API607, ASME 16.34, ANSI B16.5, ASME 16.47 and API 598 represent the design basis.

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2. Individual Parts Designation

Pos. Pcs. Name Pos. Pcs. Name

1 1 Wafer body CONAXE 14 4 Braided packing ring

2 1 Disc CONAXE 15 6 Radial packing ring

3 1 Clamp ring CONAXE 16 4 Stud bolt

4 1 TH seal CONAXE 17 4 Hexagon socket screw

5 1 Shift Shaft 18 2 Pin screw

6 1 Axle 19 16 Countersunk bolt

7 4 Gland ring 20 4 Hex nut

8 2 Packing gland 21 16 Belleville washer

9 2 Circlip 22 1 Square key

10 2 Gland flange 23 5 Bearing bush

11 1 Drive bracket 24 2 Packing gland

12 1 Type lable 25 4 Flat washer

13 1 Energizer

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3. Proper Use

This product is exclusively intended to shut off or convey media within the approved pressure and temperature limits after installation in a pipeline system. Please see the P/T diagram (pressure temperature diagram) for the permissible threshold values in accordance with the utilized materials. This operating manual must unconditionally be brought to the attention of the corresponding personnel! Prior to installation and putting into service for the first time, please read the operating manual carefully and pay attention to the hazard and safety notes!

! CAUTION

Should the hazard and safety notes of this operating manual not be complied with, this may result in the creation of hazards and loss of the manufacturer's warranty. Please contact the manufacturer under +43 2252 600-0 for further details.

Subject to technical alterations and misprints!

4. Testing of KLINGER Valves

KLINGER Valves are pressure-tested in accordance with EN 12266-1. The pressure test comprises the tests P10, P11 and P12. Testing the resistance to pressure of the disk (P20) is not included in the standard package.

5. Labeling of the Valves

Each valve is provided with the following data listed either on the body or on a type plate.

Designation Comment Manufacturer KLINGER Please see the operation manual for the

address Model e.g. CONAXE Manufacturer’s type designation Size DN and numeric value Numeric value in mm, e.g. DN 80 or inches,

e.g. 3“ PN / Class Numeric value for PN

/ Class Dimension standard for valves

T. Numeric value Provides the max. permissible temperature in °C

FA-No. Numbers / letters FA-No. serves identification purposes Material e.g. 1.0577 In accordance with material codes CE Market approval designation

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5.1 Information on Butterfly Valves

Test pressures resulting from the rated pressure PS. Test pressures: Strength test of the valve disc in wafer valves = 1.1 x PS. Strength test of the valve disc in lug valves 1.1 x PS. Strength and leak test of the body and the shaft inlet is at least 1.5 x PS.

To the extent that no other agreement has been reached with the ordering party, a permissible leak rate A in accordance with EN 12266-1 Test P12 in both pressure flow directions applies for soft seated valves (e.g. RTFE).

For metal seated valves, a permissible leak rate C applies for the specified pressure flow directions in accordance with EN 12266-1 Test P12.

Attention! Please note the directional arrow on the body

Testing in the direction opposite to the preferred pressure direction must be specified in the course of the order and is not part of the standard design.

As a rule, the test carried out using water at a room temperature of approx. 20 °C.

For valves ordered with specific testing, the test data and results are documented in the factory acceptance report in accordance with EN 10204- 3.1.

The flange connection is marked with PN. This defines the pitch circle, the number of bolt holes in the flange and the bolt hole diameter. The PN designation should not be confused with the dimensions of the flange. If PS < PN, then the lower value always applies as the maximum permissive for the flange connection. If PS > PN, then the lower value also applies as above.

Name plate example:

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6. Safety Instructions

This operation manual must be brought to the attention of the operating personnel.

6.1 General Notes on Safety

The same safety instructions apply for valves as for pipeline systems, into which they are installed. This operating manual exclusively focuses on safety instructions, which are to be additionally complied with for valves.

6.2 Safety Instructions for Operators

! Danger to Life

A valve with a permissive pressure/temperature range that is not sufficient for the operating conditions may not be operated! This range is to be derived from the P/T diagram. With regard to materials, pressures or temperatures not listed there, contacting the manufacturer is mandatory. Ignoring this regulation can result in life-threatening situations and can cause damage to the pipeline system.

! Danger to Life

It must be ensured that materials selected for the parts coming into contact with the media are suitable for the utilized media. The manufacturer takes no responsibility for damages resulting from corrosion or through aggressive media. Ignoring this regulation can result in life-threatening situations and can cause damage to the pipeline system.

The following items do not lie in the scope of responsibility of the manufacturer. As a consequence, when utilizing the valve, it must be ensured that

» the valve is only utilized in accordance with its proper use, as illustrated under "Proper Use".

» the actuator unit, which is subsequently mounted on the valve, is adjusted to the valve and correctly adjusted in the end position.

» when connecting a valve actuator to the power grid, the safety notices of the actuator manufacturer are complied with.

» the valves are correctly implemented into the system, especially those connected to the pipeline system by means of welding.

» no additional tensions bear on the valves. » the operation parameters and operating conditions have been clarified with the

manufacturer of the valve and that operating conditions such as vibrations, water hammers, pressure surges, erosion etc. are to be avoided.

» pipeline system connections and valves, which are operated at operating temperatures > 50 °C or < -20 °C, are protected against contact.

» during welding procedures, the safety regulations of the plant operator and/or plant constructor are to be complied with.

» the valve is only operated and maintained by trained personnel. » valves, which are utilized in hazardous media (inflammable, corrosive, harmful to

health etc.), are to be handled in accordance with their dangers. The corresponding handling regulations are the responsibility of the plant operator.

» all ergonomic hazards are to be considered by the plant operator, such as e.g. accessibility, gauges etc.

wT 5001/02 Page 9

» when applying internal pressure for the first time (pressure test, trial operation) a sufficient safety distance is to be maintained.

» when pressurized (medium), it is prohibited to open screw connections (with the exception of those on hand levers and handwheels).

» installation and removal of valves is only carried out with a depressurized and drained pipeline.

» all connections, following loosening, are again correctly tightened afterwards. » no screws are loosened on pressure-retaining parts, unless described so in the

operation manual. » no screwed connections are forcibly opened. » that during longer shutdown periods, in the event of freezing media, the valve is drained

and/or that depressurization is achieved in case of expanding media.

6.3 Hazard Warnings

Mechanical hazards:

» Beware of possible sharp or protruding parts posing risk of injury. » Extra care is required during putting into operation: Do not reach into the bore opening

during the valve closing process, as this poses a risk of injury. » Be careful of falling parts during transportation, maintenance and putting into

operation. » When manipulating lifting appliances, the safety regulations for lifting appliances must

be complied with. » Unauthorized and improper handling can result in undesired and spontaneous

pressure loss and can result in significant damage. » With regard to valves featuring a mounting bracket it must be ensured that moving

valve parts do not result in a risk of injury.

Electrical hazards:

» With regard to valves featuring electric actuators, the operating manual and the safety instructions of the actuator manufacturer must be complied with.

Thermal hazards:

» During operation, the surfaces of valves may feature high / low temperatures. Caution: Burn hazard.

» Caution: The hot surfaces can cause self-ignition of flammable materials through either contact or heat emission.

Hazard generated by noise:

» Depending on the application conditions, high levels of noise can be created by the cavitation processes, which bear the risk of hearing damage.

» Opening an internally pressurized valve can result in major noise exposure as a result of exiting media; hearing damage hazard.

Vibration hazard:

» Caution: Abrupt opening or closing of a valve can lead to undesired surges and vibrations in the pipe, which may possibly damage the valve or the pipeline system.

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Electromagnetic radiation hazard:

» The hazards resulting from possibly created electromagnetic radiation are to be consulted in the operating manual of the actuator manufacturer.

Hazards linked to the operational environment:

» The ambient atmosphere and the ambient temperature are to be set in a manner that has no negative influence on the valve, the actuator of the valve, and the medium.

Transportation hazards:

» Please see the chapter “Transportation and Storage” for transportation hazards.

Maintenance hazards:

» All maintenance and repair tasks with the exception of lubricating and subsequent sealing of stuffing boxes are without exception to be carried out in an unpressurized state. Where required, the valve may have to be drained prior to servicing.

» Valves may only be removed from pipeline systems in an unpressurized and empty state.

» Attention must be paid to exiting media when resealing. » Caution: (Fire and chemical) burn hazard and risk of poisoning caused by valves utilized

in dangerous media. Attention must be paid to medium residues during maintenance and putting into operation tasks.

» Maintenance and repairs may only be carried out by qualified personnel.

Placing out of operation hazards:

» When placing out of operation, the valves must be emptied fully and attention must be paid to hazards resulting from medium residue.

» Should valves be no longer used, they are to be disposed of correctly.

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7. Technical Data

7.1 Material codes

The main criterion of the material codes is the basic material of the body.

Symbol Body

20 1.0425 (P265GH) 25 1.0619 (GP240GH) 26 1.0566 (P355NL) / 1.1106 (NL2) 28 1.0577+N (S355J2+N)

32 Multicopmponent bronze (copper/aluminum/nickel)

62 1.4408 (CF8M) 64 1.4404 (AISI 316L) 65 1.4571 66 1.4539 67 Duplex 68 Super Duplex 70 1.4547 71 6Mo 90 ASTM B381F2 (unalloyed titan)

The above table also contains material codes unavailable for this product.

7.2 P/T Diagrams

Pressure/Temperature Diagram (P/T Diagram) for soft seated valves:

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7.3 Flow Values and KV Values

When dimensioning butterfly valves, the following maximum flow values in accordance with EN 593 and with a fully opened valve may not exceeded. Higher flow rate values are to be agreed upon during ordering and must be separately specified in the order confirmation. Liquid media, based on water 20 °C: Mean flow rate < 3,0 m/s. Gaseous media, based on air 20 °C: Mean flow rate < 40 m/s.

wT 5001/02 Page 13

7.3.1 KV Values for PS 20 Design

DN Size Kva value in [m³/h]

Kva value in US gallons/min

[mm] [inch] at P = 1 bar at P = 1 psi

50 2” 46 53 4.7

65 2 ½” 46 53 13.4

80 3” 130 150 3.9

100 4” 278 322 2.1

125 5” 572 664 1.2

150 6” 1123 1302 0.6

200 8” 2212 2566 0.5

250 10” 2838 3292 0.8

300 12” 5363 6221 0.4

350 14” 6621 7681 0.5

400 16” 8431 9780 0.6

450 18” 9852 11429 0.7

500 20” 12261 14222 0.7

600 24” 19556 22685 0.5

700 28” 27299 31667 0.5

750 30” 31641 36703 0.5

800 32” 36228 42024 0.5

900 36” 46429 53858 0.5

1000 40” 58127 67427 0.5

1200 48” 84667 98214 0.5

1300 52“ 94663 109809 0,5

7.3.2 KV Values for PS 50 Design

DN Size Kva value in [m³/h]

Kva value in US gallons/min

[mm] [inch] at P = 1 bar at P = 1 psi

50 2” 44 51 5.2

65 2 ½” 44 51 14.7

80 3” 59 69 18.6

100 4” 268 311 2.2

125 5” 600 696 1.1

150 6” 919 1066 1.0

200 8” 1707 1981 0.9

250 10” 2698 3129 0.9

300 12” 3889 4511 0.8

350 14” 5282 6127 0.9

400 16” 6877 7977 0.9

450 18” 8673 10060 0.9

500 20” 10670 12378 0.9

600 24” 15270 17713 0.9

! CAUTION

The diagrams list all possible operational limits of KLINGER valves. The application range of standard valves is -10 °C to +200 °C. For the temperature range from < -10 °C and from > 200 °C, special designs with suitable sealing systems exist.

wT 5001/02 Page 14

8. Transportation and Storage

Valves must generally be handled with great care. Specifically, no mechanically finished surfaces may be damaged. Protective coatings and layers serve to protect against corrosion and must not be damaged.

Steel valves are provided with a protective finish in accordance with their intended utilization by the factory. The flange areas are protected against damage.

Rust protection should only be removed immediately prior to installation. The rust protection within the valve should be removed with a grease solvent, e.g. soapy water. The safety notes and handling instructions of the solvent manufacturer must be complied with. Only solvents, which will not cause damage to the valve, may be used.

Local environmental protection requirements must be complied with.

Stainless steel valves must be especially protected against flash rust and contact rust. Incorrect storage can lead to the passivated external metal protective film being damaged and the creation of so-called localized corrosion during operation.

For manipulation purposes, lift lines suitable for the weight and the lifting aids (to the extent present) on the valve must be used. The valves are to be attached in a manner that negates the possibility of unintentional release or damage during transportation.

To the extent possible, avoid the utilization of iron chains, as these damage the protective coating.

The valves are to be removed from the transport packaging in accordance with the sketch. This also applies to installing the valve in the pipeline system.

The disc must be in the "closed" position during transport and protected against unintentional opening!

The unit weight of the valves is listed on the shipping note and/or in the transport documents (packing list). Storage in the default factory packaging. The valves are to be stored in closed rooms, in a non-aggressive atmosphere and protected against humidity and dirt.

wT 5001/02 Page 15

In the event that protective sheeting or shrinking foils are used, it must be ensured that the atmosphere under the sheets remains free of condensation by suitable means.

Suitable protective measures are recommended for storage in dusty rooms.

In order to negate the possibility of mix-ups, all stored parts should be labelled in accordance with the shipping notes and stored in the correct place.

The temperature in the storage rooms should not exceed the threshold values –20 °C and +50 °C. Quick changes in temperature are to be avoided whenever possible (condensation water).

Possible changes on the side of KLINGER, with an effect on storage, will be announced in a timely manner in the form of a circular.

The operation manual is a part of the delivery and must be stored with the item in order to ensure that all important information and documents are conveyed.

Damages resulting from incorrect storage or manipulation free KLINGER of the responsibilities derived from warranty, guarantee and product liability.

9. Functional Principle

The butterfly valve is installed between flanges or directly welded-in. In this context, the body forms the outer shell of the pressure system.

Depending on the body design, the butterfly valve can be either installed in as a wafer or lug. Executed as a welding-end design, it can also be directly welded in. Between the flange and the body, however, a seal suitable for the application has to be fitted. The butterfly disc, attached to the actuator shaft and the axle, is located within the body.

The actuator shaft and the axle rotate in low-maintenance friction bearings.

Seen from the actuator shaft, the butterfly disc opens counterclockwise and closes clockwise. The angle of pivotal movement is 90° degrees. The valve is closed when the butterfly disc makes contact with the stopper and the sealing ring is seated tightly against the valve seating.

The economical control range lies within an opening angle of between 20° and 70°. Control and choke positions under 15° are especially to be taken into consideration for reasons relating to operation.

In this context, noise development and impermissible cavitation must be checked for.

The inner pressure system is made tight to the atmosphere by means of stuffing boxes on the actuator shaft and the axle. The stuffing boxes are pre-stressed by means of disc springs and the stuffing box nuts are tightened to a pre-defined torque in order to generate consistent tightness over a longer period of time.

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The stuffing box may never be slackened during operation. Danger to life!

The set screw in the hub fixes the butterfly disc to the shaft and/or axle and serves as the inner blow-out protection of the shaft and/or axle. A circlip within a circular groove is located within the thrust piece of the stuffing box gland and forms the exterior blow-out protection. It only activates in the event of failure of the inner shaft protection.

An actuator bridge is mounted on the body. It serves to support an actuator with an ISO actuator flange. In accordance with the size of the actuator flange and the actuator shaft, the maximum permissible drive torques are as defined in the ISO 5211 norm.

The actuator bridge is defined as part of the valve and may not be removed.

Should additional components be required as a result of special design parameters, then this is listed under "Optional Modules".

10. Design Features

10.1 Additional loads

Based on correct installation of the valve and professional pipe laying, the valves are factory designed for the following additional loads:

» Axial force (Fz) in the direction of the pipeline: Fz= (π/4) x DN² x PS. » Additional bending and lateral forces are generally to be avoided.

10.2 Rated Pressure/Design Temperature PS/TS

The rated pressure PS with the corresponding design temperature TS must not be exceeded under any circumstances. The maximum rated and operating temperatures for the equipment and sealing materials must be complied with.

10.3 Blow-out Precaution

The factory-fitted inner and outer blow-out protection of the actuator shaft and the axle may not be removed during operation. This also applies to the actuator bridge.

10.4 Antistatic Measures

In order to protect against electrostatic charges, earthing has to be carried out on the actuator flange. In the event that no ground strap (option) is attached, earthing can be carried out with a screw-connection at the actuator bridge to the body. It must be ensured that conductivity is not negated by coatings or other electrical isolators.

wT 5001/02 Page 17

10.5 Cavitation

Damage resulting from cavitation must be avoided through correct operation. Impermissible flow rates and choke positions must be avoided during operation.

10.6 Pressure Blows resulting from Operation

In fast closing/opening valves, a pressure blow can be caused by a sudden change of the flow speed. The regulating times of actuators are to be selected in a manner that does not result in the permissible rated pressure being exceeded.

The following applies:

Static operating pressure + dynamic back pressure + increase in operating pressure must be less or at maximum equal the rated pressure PS.

10.7 Welding Seam Factor

Should no other value be agreed upon during ordering, the welding seam factor 0.7 applies. Welding seam inspections have been carried out in accordance with the requirements of the welding seam factor.

10.8 Pressure-Load Cycle Figures

In accordance with DIN 3840, the valves are designed for a mean pressure fluctuation range of 90 %. For steel with a permissible tension (K/S = material code / safety coefficient) of < 200 N/mm², this results in full pressure fluctuations of N = 12000 (N = Number of cycles). For smaller pressure fluctuation ranges and material codes, the lifecycle-extending factors in accordance with DIN 3840 can be correspondingly applied.

10.9 Special Design Features

10.9.1 Corrosion Allowances

» Pressure-retaining structural and C-steel is allocated a corrosion allowance of 2 mm.

» High-grade steel with a Cr-share of 13 % and above are provided corrosion allowances if explicitly ordered.

10.10 Permissible Actuator Dimensions

Valves fitted with an actuator per factory default have been inspected with regard to their actuator dimensions. If actuators are to be installed by the customer on the valve, then this must be coordinated with the manufacturer in advance and with regard to compatibility. Too great actuator dimensions exert an impermissible bending moment on the neck of the valve! In regions prone to earthquakes and in systems featuring high oscillations, the design must be inspected with regard to shock resistance.

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10.11 Permissible Actuator Torques

If not otherwise explicitly agreed upon in the order, the specifications of ISO 5211 (preference series) with an allowance of 20 % apply for the maximum permissible actuator torques.

ISO Actuator flange: F05 F07 F10 F12 F14 F16 F25 F30 F30A F35 F35A

Nominal torque in [ Nm ]:

125 250 500 1000 2000 4000 8000 12000 16000 32000 63000

Shaft diameter in [ mm ]

18 22 28 36 42 60 72 80 100 120 160

Max. perm. actuator torque in [ Nm ]

150 300 600 1200 2400 4800 9600 14400 18500 32000 63000

For the size of the actuator flange, please refer to the documentation drawing.

11. Installation and Commissioning Instructions

In order to protect against impurities and damage, the connections of the valve are covered. We recommend removal of these covers only prior to installation.

Valves with welding ends can generally be welded into a pipeline by means of fusing welding procedures. In this context, the welding and quality requirements and their norms (e.g. EN ISO 9606) are to be considered. As a consequence, welding may only be carried out by qualified personnel. Similarly, the safety regulations of the plant operator and/or the plant manufacturer are to be complied with.

The installation of valves with flange ends may only be carried out by qualified personnel in accordance with EN 1591. In this context it must be ensured that no additional tensions affect the valve, such as e.g. a too large distance between the to be screwed flanges.

Following installation and prior to putting into service it must be ensured that solids and impurities, which are not part of the medium, have been removed from the pipeline system and/or the facility.

Following putting into service, a pressure test and a function test must be carried out.

When putting valves into service in steam pipes, a correct draining of condensate must be carried out in order to negate the threat of a steam hammer. In extreme situations, a steam hammer can result in the breaking of the valve.

During all operating phases (start – operation – closing down) it must be ensured that abrupt temperature and pressure increases are avoided.

The highest permissible test pressure is 1.1 x PN if the valve is in a closed position. During testing of the pipe pressure (1.5 x PN) the valve must be open.

In principal the same minimum requirements that apply for the entire pipeline system apply to the valves. The valves are to be installed in a manner not resulting in harm to employees or third parties. Corresponding safety distances are to be complied with in accordance to applicable, national regulations of the country in which they are installed.

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11.1 Installation with regard to Maintenance/Inspection

The valves are to be installed in a manner which

» makes them accessible for visits and inspections. » access to the stuffing boxes allows for problem-free and safe maintenance. » the actuators are mounted in a manner which makes them operable without

hazard. » no impermissible forces and torques can affect the valve.

11.2 Installation with the Pipeline System or other Pressure Devices

Due to the floating design, the mounting position of the actuator shaft is always on a horizontal plane.

Should the valve be installed with the “shaft vertical”, then an axial support bearing is required and has to be agreed upon in the course of order!

Preferred installation position: Horizontal shaft

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11.3 Installation sketch for Lug-type valves

11.4 Installation sketch for Wafer-type valves

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Prior to installation, the valve must be cleaned. Possible transport damage should be checked for. Should damage relating to functionality be present, the valve may not be installed.

The valve is to be placed either from above or from the side between the flanges. In this context it must be ensured that sufficient space is present to accommodate the valve and the corresponding flange gaskets. Neither the valve nor the flange gaskets may be pushed in by force! Impermissible tension impairs the function of the valve and may result in a total failure. During installation, the disc must be in the "closed" position and protected against unintentional opening.

The specification of the flange gasket must be ascertained by the operator and is not the responsibility of the valve manufacturer.

When the valve has been inserted between the flanges together with the flange gaskets, alignment to the center of the pipeline must be checked for. As a rule, the body and the flange gaskets are pre-centered by the flange bolts.

It must be ensured that the disc does not make contact with the flange or pipeline. The flange gaskets may not protrude into the interior of the pipeline.

The flange connection must to be dimensioned in accordance with the pipeline and tightened crosswise. The forces applied in this manner may not impermissibly apply tension to the body.

If possible, carry out a manual function test (open/close). The valve must be freely pivotable across the entire pivotal range of 90°. Contact with other pipeline system parts is not permitted.

11.5 Mounting Instructions for Actuators

Factory-fitted actuators have already been adjusted and do not require further adjustment. Connecting the actuator must be carried out in compliance with the instructions of the actuator manufacturer. For trial operation purposes, it is recommended to first manually bring the valve into a mid-position to carry out a direction of rotation check.

11.6 Fitting the Actuator

The following basic rules apply for valves, which are fitted with an actuator only after reaching the construction site:

Only fully trained personnel may be charged with this task. Actuators may only be fitted and adjusted on valves removed from the pipeline. Inspection of the direction of rotation of the actuator:

» Direction of rotation "open" is counterclockwise » Direction of rotation "close" is clockwise

as seen from the actuator shaft of the valve.

Connection dimensions of the actuator and the valve are to be checked for compatibility. As a rule, butterfly valves from KLINGER Fluid Control GmbH feature a fully standardized interface in accordance with ISO 5211.

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Actuator and valve must be in the same position, (as a rule position "closed") prior to being bolted together.

Prior to work, the manufacturer must to be consulted regarding specific information.

The actuator must be adjusted in a manner allowing it to only run up to the stopper or stopper bar. Hitting or running over the stops is not permissible!

The limit of travel must be set on the actuator!

The "open" position is reached after traversing a path of 90° from the position "closed" and must be set in a manner that does not allow for traversing beyond this point.

As a rule and following installation, the actuator is initially set manually to the mid-position to check the direction of rotation. The end positions are set afterwards.

Connecting the actuator is carried out in compliance with the instructions of the actuator manufacturer.

! CAUTION

With regard to electrical actuators, it must be ensured that the end positions are limited by the path end switches and not by the torque end switches.

!

CAUTION The valve is closed clockwise. It is to be ensured that the 90° movement is precisely complied with in its OPEN-CLOSED end positions.

12. First-time Startup Instructions

The valve may only be put into operation after all preliminary work has been professionally carried out. The actuator connections and the installation into the pipeline must have been completed and inspected.

The correct state with regard to installation, installation conditions and operating mode must be ensured and verified.

Prior to putting into service, the valves are to be subjected to a pressure test in tandem with the pipework (provided by the customer). The disc must be brought into a partially opened position for this purpose.

The permissible test pressure is 1.5 x PS. (disc in partially opened position)

The permissible test pressure is 1.1 x PS, if the test will be carried out with a closed disc.

During the test, flange connections and stuffing boxes are especially to be inspected with regard to their tightness.

During startup it must be ensured that increases in temperature and pressure do not result in any impermissible loads (tension increases). During startup, the temperature increase should not be more than 100 °C/h. The valve is to be constantly monitored during the startup procedure and to be inspected with regard to its function.

wT 5001/02 Page 23

12.1 Standard Operation

The operator must ensure that the valves are operated by professional and trained personnel in order to avoid harm to employees or third parties.

During operation, the function of the valve and especially the tightness of the stuffing boxes must be inspected at regular intervals. If necessary, the stuffing boxes must be retightened. The valves must be operated at least once per month in order to identify deposits or faults at an early stage.

Should corrosion be visible, it has to be examined with regard to its hazard potential.

If a leak is identified in the closed position, this must immediately be remedied in order to avoid further erosion or damage.

Only use original spare parts. Damage to fixed installations (such as body, body seat, butterfly disc) may only be repaired by the manufacturer.

12.2 Shutting down

For shutdowns, the temperature and the pressure must be reduced in a manner that no impermissible loads (increase of tension) occur. The decrease in temperature should not exceed 100 °C/h.

12.3 Improper Utilization

If the valve is stressed by an event in excess of more than 10 % above its specified data, the valve must be inspected in its entirety. In some cases, the inspection may have to be carried out either together with or by the manufacturer.

12.4 Welding Instructions

The temperature of welding may not exceed 200 °C for nominal widths up to DN 350 at a distance of 115 mm, and for nominal widths DN 400, at a distance of 170 mm.

In this context, the welding and quality-technical requirements and their standards (e.g. EN ISO 9606) must be complied with. As a consequence, welding may only be carried out by qualified personnel.

13. Service and Maintenance

Maintenance and inspection intervals are to be determined by the operator dependent on the operating mode, as these valves can be utilized under a number of different operating conditions.

Maintenance and inspection work may only be carried out by trained personnel.

Prior to the start of service and maintenance work, it must be ensured that the pipeline system is without pressure and that no medium residues are contained within.

When removing an actuator, it is necessary to protect it against rotation prior to loosening of the connecting screws.

wT 5001/02 Page 24

Views: Stuffing box in quarter cutaway Exploded view Position Designation

1 Packing ring 2 Gland ring 3 Packing gland 4 Gland flange 5 Belleville washer 6 Stud bolt 7 Hex nut 8 Washer

13.1 Dismantling for Seal Exchange on the Shifter Shaft

Renewed reference to the safety regulations of the operation manual.

The build of the stuffing box is illustrated in the above drawing. Depending on the module size, the installation dimensions may vary. An overview of all components can be seen in the exploded view.

The stuffing box must be retightened by means of a torque wrench in the set maintenance intervals.

For this purpose, the adjuster nuts are tightened by the values provided in the table. It must be ensured that the stuffing box gland is not tightened one-sidedly. Following tightening of the stuffing box, the stuffing box gland must run in parallel to the body.

Stuffing boxes, which are already leaking must be replaced and repackaged. This may only be carried out with shut down and removed valves. Already mentioned safety regulations and instructions are to be complied with!

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wT 5001/02 Page 25

13.2 Repacking the Stuffing Box

Renewed reference to the safety regulations of the operation manual.

Loosen the nuts on the stuffing box gland and remove the stuffing box gland together with the thrust piece and the disc springs. Pull the gland rings and remove used packing rings with the packing extractor. Clean the stuffing box chamber and fill it with new packing rings. Insert the packing rings one after the other and in the case of cut packing rings, ensure that the joints are each offset by 180°. Push the gland ring over the shaft and install the packing gland together with the stuffing box gland and the disc springs. In a first step, tighten the adjuster nuts in an even manner until the packing is fully compressed. Then slacken again and operate the valve at least once. Evenly tighten the adjuster nuts with the torque wrench again and ensure that the stuffing box gland is oriented in parallel to the body.

13.3 Torque Tables for Stuffing Boxes

In order to identify the corresponding torque setting, only the stud bolt diameter needs to be measured in a first step. The modular dependencies are described by the stud bolt diameter.

13.3.1 Stuffing Box Tightening Torques for Rated Pressure PS 20

Stuffing box module for butterfly valves

F05 F07 F10 F12 F14 F16 F25 F30

Stud Bolt Stuffing box gland

M6 M8 M10 M12 M16 M20 M24 M27

Shaft diameter in [ mm ]

18 22 28 36 42 60 72 80

Torque Setting in [Nm]

3 6 10 18 30 65 90 115

13.3.2 Stuffing Box Tightening Torques for Rated Pressure PS 50

Stuffing box module for butterfly valves

F05 F07 F10 F12 F14 F16 F25 F30

Stud Bolt Stuffing box gland

M6 M8 M10 M12 M16 M20 M24 M27

Shaft diameterr in [ mm ]

18 22 28 36 42 60 72 80

Torque Setting in [Nm]

5 10 15 28 45 100 140 175

13.4 Replacement of Bearings on Shift Shaft and Axle

Renewed reference to the safety regulations of the operation manual.

If the bearings need to be replaced, the components are to be removed as illustrated in the exploded drawing. The bearings are pushed out and replaced by new ones. During installation, the components are fully cleaned. Furthermore, every component must be checked with regard to wear and damage. Damaged and worn-out components must be replaced with spare parts from the manufacturer. It should also be determined whether the wall thickness has been reduced by corrosion or chemical action. In such cases, a factory repair must be carried out.

wT 5001/02 Page 26

13.5 Single Part Dismantling for Exchange of the Sealing Element

Renewed reference to the safety regulations of the operation manual.

Only original spare parts are to be utilized in accordance with the sealing system at hand. The guarantee is otherwise rendered null and void immediately. Required and specific installation instructions are attached to the corresponding replacement part set. Prior to disassembly of the butterfly disc system, the valve first has to be removed from the pipeline system as previously illustrated, and the actuator removed. From the closed position, the butterfly valve must then be turned by an angle of approx. 170° in order to ensure free access to the retaining flange.

Exploded view of the sealing system 1 As illustrated in the exploded view, the retaining flange on the disc needs to be removed first, followed by the removal of the to be replaced seal. Now clean the sealing chamber and examine it for impermissible damage. Insert the new sealing set at the position designated for this purpose and screw the retaining flange tight again crosswise. Reassemble all parts in the reverse order and carry out a function as well as a leak test.

Tightening torque

Thread Pre-load [N] Tightening

torque [Nm]

M5 3000 3,8

M6 6200 6,7

M8 12200 16,3

M10 16300 33

M12 24200 56

M16 45000 135

wT 5001/02 Page 27

13.6 Assembly

Reassemble everything again in the reverse order of the instructions provided for disassembly and carry out a function as well as a leak test.

! CAUTION

All individual components, especially gaskets and surfaces of gaskets are to be inspected and, in the event of damage, to be replaced by new parts prior to assembly. Visible impurities on machined areas must be cleaned. Cleaned individual parts are to be evenly treated with a thin grease film prior to installation.

13.6.1 Standard Lubricants

O-Rings: Silicone grease OKS 1110 Other parts: MOLYKOTE 55 M

In special cases, the designated lubricant must be used for the order. e.g.: Oxygen applications Klüberalfa YV93-302 Gas applications Klüber Nontrop ZB91 Sterile steam applications Klüberalfa YV91

14. Factory Repairs

A factory repair is required for valves, in which more than the stuffing box, sealing systems and bearings need to be repaired. Build-up welding, repair welding and other tasks carried out on pressure-retaining or function-relevant components may only be executed by the manufacturer.

15. Spare Parts Orders

For the ordering of spare parts, refer to the parts list in the documentation drawings. In terms of additional information, the manufacturer requires the order and the serial number of the valve. The valve can always be positively identified by the serial number.

16. Inspection and Recurring Testing

With regard to functionality, the valve must always be examined and assessed in its entirety. During inspection, special attention must be paid to the tightness of the stuffing box. The pressure-bearing walls must be examined with regard to material erosion, cracks or wear and tear. Damaged or threatened components must be replaced with spare parts from the manufacturer.

To the extent that a shorter inspection interval is not otherwise stipulated by operator regulations, other national regulations or legal requirements, the inspection or recurring tests should be carried out after two years the latest. If higher load collectives are run than those specified in the design characteristics, the inspection intervals must be correspondingly shortened.

wT 5001/02 Page 28

17. Disposal

To the extent that other laws do not require a deviating treatment, the utilized materials should be separated in accordance with their properties and entered into the raw materials recycling process. The pre-requirement in this regard is that the raw materials have been correspondingly decontaminated on the order of the operator.

18. Spare Parts List

The table below provides an overview of the available spare parts variants. During ordering, the precise designation of the valve, the stuffing box, the sealing elements and the material code of the valve must be provided.

Nominal Width Stuffing Box Sealing Elements 50

65

80

100

125

150

200

250

300

350

400

450

500

600

available as a replacement part or as a spare parts set O not available as a replacement part or as a spare parts set

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DN AG BG B0 C CG DG ISO 5211 gearbox type handwheel weight (kg)

APO 609 series 108

80 214,5 161 136 48 43,5 28,5 160 F05 QSS-200 S W160/12 11,7

100 253,5 211 169 54 52,5 34 160 F07 QSS-400 S W160/12 19,6

150 280 211 196 57 52,5 34 200 F07 QSS-400 S W200/12 25,7

6 1 Armatur CONAXE ASTM B381 F2 ASTM FHAT103R - 3.1

5 1 gearbox - - - - -

4 1 handwheel st.steel 316 - - - -

3 4 screw A4-70 ISO3506-1 AD2000 W2 -

2 4 washer A4 DIN 125 - - -

1 1 tag plate st.steel 316 - - - -

Pos. pcs. Name Material Standard VDS ESK EN10204

Miscellaneous requirements

Pressure rating CL 150

Item VSK reference

General V706

Testing V712

Marking V718

Operator V720

Medium design pressure Barg: 19,6 19,6 19,2 17,7 15,8 14,8 6,9

At temperature °C -46 38 50 100 150 177 204

- PED 97/23/EC cat. I modul H- design criteria EN593 / ASME 16.34 / API 609 cat. B- bi-directional tight shut off- anti blow out device- design pressure PS = 20bar = 2,0MPa- pressure / temperatur rating in acc. to ISO 7005, TR2000 and API 609 cat. B- leakage test acc. to EN12266-P10, P11, P12, API 598 soft seated- shell test pressure P10, P11 = 30bar- seat test pressure P12 = 22bar H²0, P12 = 6bar air- marking in acc. to EN 19 (MSS-SP25)- face to face dimension in acc. to API 609 cat. B and EN558 series 108- actuator flange in acc. to ISO 5211- anti static device in acc. to EN 12266/F21, AP 609- fire safe approved to ISO 10497

VDS: FHAT103R

Installation with shaft in horizontal,vertical or overhead position

Gearbox Setup inc. to factory standardW20-00-W0009-00 configuration A Gear box with handwheel and position indicator in stainless steelenclosed and weather-proof, grease and venting fittings,adjustable open / close end-stopsbolting in stainless steel

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Bemerk.MaterialNorm- / Zeichn.Nr.NameStk.Pos.

DN150ASTM B381 F2012C-150-2020-GK-Ti-90 Anflanschgehäuse CONAXE11

DN150ASTM B381 F2020C-150-20xx-GK-Ti-90 Klappenteller CONAXE12

DN150 PS20ASTM B265 Gr.2030C-150-20xx-xx-Ti-90 Halteflansch CONAXE13

DN150 PS20RTFE 15123041C-150-20xx-F1-00-90 Firesafedichtung CONAXE14

F07ASTM B381 F2050U-F07-50xx-WD-Ti-90 Welle 15

F07ASTM B381 F2060U-F07-50xx-xx-Ti-90 Achse 16

F07 PS50ASTM B348 Ti-Gr.2070S-F07-50xx-xx-00-90 Kammerungsring 47

F071.4571 / 316 Ti080S-F07-50xx-xx-00-90 Druckstück 28

1.4571 / 316 Ti A22 DIN7993Sprengring 29

F071.4571 / 316 Ti090S-F07-50xx-xx-00-90 Stopfbuchsbrille 210

F07/F071.4571 / 316 Ti100S-F07-xxxx-xx-00-90 Kombi-Brücke 111

1.4571 / 316 Ti KLN2702Typenschild 112

Ti Gr. 2 HelicoilEnergizer 113

F07Grafit 32x22x5 KLN2701Packungsring geflochten414

F07Grafit 32x22x5 KLN2701Packungsring radial gewickelt615

A4-70 M8x40 DIN938Stiftschraube 417

ASTM F468 Gr.Ti 5 M6x16 EN ISO 4026Gewindestift 218

ASTM F468 Gr.Ti 5 M6x12 DIN7991Senkschraube 819

A4 / 316 Ti M8 EN ISO 4032Sechskantmutter 420

SS316 16x8,2x0,9 DIN 2093Tellerfeder 1621

F07-25ASTM B348076S-F07-XX25-GB-Ti-90 Grundlagerbuchse F07 C&Q222

F07-37.5ASTM B348076S-F07-XX375GB-Ti-90 Grundlagerbuchse F07 C&Q223

A4 / 316 Ti A8,4 DIN 125Scheibe 824

A4 / 316 Ti 2.6x4 DIN 1476Kerbnagel 225

DN150 PS20ASTM B265 Gr.2041C-150-20xx-F2-Ti-90 Firesafering CONAXE126

A4-70 / 316 Ti M8x16 EN ISO 4762Zylinderschraube 427

PTFE KLN2703PTFE Einlageband Conaxe428

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Schichtung der Tellerfedern

VDS: FHAT103RwT5012

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Bemerk.MaterialNorm- / Zeichn.Nr.NameStk.Pos.

DN100ASTM B381 F2012C-100-2020-GK-Ti-90 Anflanschgehäuse CONAXE11

DN100ASTM B381 F2020C-100-20xx-GK-Ti-90 Klappenteller CONAXE12

DN100 PS20ASTM B265 Gr.2030C-100-20xx-xx-Ti-90 Halteflansch CONAXE13

DN100 PS20RTFE 15123041C-100-20xx-F1-00-90 Firesafedichtung CONAXE14

F07ASTM B381 F2050U-F07-50xx-WD-Ti-90 Welle 15

F07ASTM B381 F2060U-F07-50xx-xx-Ti-90 Achse 16

F07 PS50ASTM B348 Ti-Gr.2070S-F07-50xx-xx-00-90 Kammerungsring 47

F071.4571 / 316 Ti080S-F07-50xx-xx-00-90 Druckstück 28

1.4571 / 316 Ti A22 DIN7993Sprengring 29

F071.4571 / 316 Ti090S-F07-50xx-xx-00-90 Stopfbuchsbrille 210

F07/F071.4571 / 316 Ti100S-F07-xxxx-xx-00-90 Kombi-Brücke 111

1.4571 / 316 Ti KLN2702Typenschild 112

ASTM B863 Ti-Gr.2 HelicoilEnergizer 113

F07-25ASTM B348076S-F07-XX25-GB-Ti-90 Grundlagerbuchse F07 C&Q514

F07Grafit 32x22x5 KLN2701Packungsring geflochten415

F07Grafit 32x22x5 KLN2701Packungsring radial gewickelt616

A4-70 M8x40 DIN938Stiftschraube 417

A4-70 / 316 Ti M8x16 EN ISO 4762Zylinderschraube 418

ASTM F468 Gr.Ti 5 M6x16 EN ISO 4026Gewindestift 219

ASTM F468 Gr.Ti 5 M5x10 DIN7991Senkschraube 820

A4 / 316 Ti M8 EN ISO 4032Sechskantmutter 421

SS316 16x8,2x0,9 DIN 2093Tellerfeder 1622

A4 / 316 Ti A8,4 DIN 125Scheibe 824

A4 / 316 Ti 2.6x4 DIN 1476Kerbnagel 225

DN100 PS20ASTM B265 Gr.2041C-100-20xx-F2-Ti-90 Firesafering CONAXE126

PTFE KLN2703PTFE Einlageband Conaxe527

B . 012C-100-2020-BG-Ti-91drw#

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VDS: FHAT103RwT5012

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Bevorzugte Durchflussrichtung

5

6

19

19

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3.1 Certificate DN1003.1 Certificate DN150Certificate of conformanceIOM for Butterfly ValvesDrawing FHAT103RDrawing FHAT103R with part listDrawing FHAT103R DN100 with part list