operating manual non-return valve flowmag (type 12020 / 12021)

Operating manual Non-return valve FLOWmag (type 12020 / 12021)

BA 012020.01 EN

Operating manual Non-Return Valve FLOWmag 12020 / 12021

BA_012020.01_EN Albert Handtmann Armaturenfabrik GmbH & Co. KG 2015-09-07 2 / 14

Table of Contents Page Page

1. General 3 Valve Types 7

Proper Application 3 Technical Data 9 Incorrect Application 3 Performance Data 9

The User's Duty to Exercise Diligence 3 5. Assembly and Disassembly 10 2. Safety Information 4 Safety and Assembly Instructions 10

Symbols 4 Single Assemblies, Spare Parts 12

Safety Instructions 4 6. Maintenance 14 3. Delivery and Performance, Storage 4 Maintenance Instructions 14 4. Function and Operation 6 Troubleshooting 14

Valve Description 6 Spare Parts 14 Valve Operation 6

Safekeeping and Completeness

• The operating manual is part of the valve delivery package and must be available to authorised personnel at all times.

• It is impermissible to delete chapters from this manual. If the operating manual or pages thereof are missing, they must be replaced immediately.

Updating Service

This documentation is not subject to the updating service of Albert Handtmann Armaturenfabrik GmbH & Co. KG. Amendments to this document may be carried out without prior notification.

Copyright

This documentation contains copyrighted information. It should only be used in connection with the valve application.

Manufacturer

Albert Handtmann Armaturenfabrik GmbH & Co. KG Arthur-Handtmann-Str. 11; D-88400 Biberach, Germany Tel.: +49(0) 73 51/3 42-0; Fax: +49(0) 73 51/ 3 42-44 80 E-mail: [email protected]

Operating manual edition

C 01/2013



1. General This operating manual must be read and observed by everyone involved with the installation, commissioning, operation and maintenance of the non-return valve.

This operating manual applies to the following valve versions:

Types Equipment FLOWmag 12020 Magnetic non-return valve

with weld ends or threaded pipe connections FLOWmag 12021 Magnetic non-return valve in intermediate flange design

with weld ends

Proper Application

• The non-return valve is used in the food and beverage industry and the pharmaceutical and chemical industry.

• Non-return valves prevent return flow in the direction opposite flow or prevent connected pipe systems from flowing through. The valve is normally closed.

• The valve may be used for the intended purpose only. Pay close attention to the installation situation and/or flow direction, the specified pressure and temperature range and the flow media.

• Applicable and generally recognised safety rules as well as the operating manual instructions must be followed during assembly and disassembly, in operation and during maintenance.

Incorrect Application

The following are examples of incorrect application:

• Operating conditions other than those specified in the operating manual are present. • Liquid media different to that envisaged in the operating manual flow through the valve. • The safety information is disregarded during operation, assembly and maintenance.

• Independent modifications or changes to the valve are carried out that restrict safety or functionality.

• Valves are used although they are not functional.

The User's Duty to Exercise Diligence

The user must especially ensure that:

• The installation of the valves is carried out in accordance with the instructions. • The valves are operated according to their intended purpose and are in a fully functional state. • The statutory requirements for operation, assembly and maintenance are observed. • Only sufficiently qualified and authorised personnel maintain the valves.



2. Safety Information

2.1 Symbols

Risk of injuries!

Indicates an immediate hazardous situation!

• Non-observance may result in serious injury or death.

Caution – danger zone warning!

Indicates a potentially hazardous situation!

• Non-observance may result in minor to moderate injury

Functional impairment or material damage! Indicates a possible functional impairment or material damage:

Note

Important additional information, tips and recommendations.

2.2 Safety Instructions

Note The following safety information must be considered as an addition to the relevant applicable national accident prevention requirements and laws. Current standards of good engineering practice must be observed when planning the application and operation of the device. Please pay attention to the relevant rules and safety regulations in other countries.

Basic safety instructions to prevent injuries and to ensure correct functioning: • Transportation and storage are carried out correctly in accordance with the operating

manual. • Installation and maintenance tasks as well as operating actions should

only be carried out by appropriately authorised and qualified personnel with suitable tools.

• The device should only be installed and operated when in efficient working order and in accordance with the operating manual.



Risk of injuries!

• The valve must be switched off in the case of noticeable malfunctions.

• The area of the line where the valve is located must be locked within the system.

• Disassembling the valve from the piping system without relieving the system pressure first may result in burns, scalding or chemical burns.

• If the valve in a system is operated with acidic or alkaline media, your hands and fingers may suffer chemical burns when disassembling the valve.

• If the valve in a piping system is operated with hot media, the surface temperature of the valve can also reach this value.

• There is a risk of crushing due to moving parts.

o Faults must be eliminated immediately.

o Unintentional commissioning must be prevented.

o Make sure that the piping system pressure has been relieved.

o Make sure that the piping system has been flushed and emptied.

o Make sure that the piping system has cooled to a value below 50°C.

o Never reach into the switching section of the valve.

3. Delivery and Performance, Storage

• Check the information on the delivery note for correctness and check the delivery for completeness. Later complaints will not be accepted.

• Conduct a visual inspection for transport damage. The forwarding agent must be informed of any visible damages immediately (comment on the waybill).

• Claims due to transport damage not visible right away must be made to the forwarding agent within a week. • Store the delivery in dry rooms and, if possible, in the original packaging to protect it against external factors.



4. Function and Operation

4.1 Valve Description

These non-return valves are for low-bacteria/sterile processes in the beverage and food industry as well as in the chemical-pharmaceutical sector The non-return valve is equipped with a permanent magnet. Because the pressure spring was eliminated, other components installed in the product area are also eliminated, which makes cleaning and sterilising considerably easier. The valve types 12020 / 12021 are characterised by: • open flow, gentle product handling • flow with almost no pressure loss

• secure closing, no backflow • hygienically designed shutter and product area • patented, magnetic functional principle

4.2 Valve Operation

The conventional pressure spring has been replaced with an external magnetic field. If the flow of liquid is interrupted, the shutter is pushed against the valve seat, thus preventing backflow. If the liquid pressure exceeds the force of the magnetic field, the valve opens. The liquid can then flow through the product area unhindered.

Risk of injuries!

See Chapter 2.2 - Safety Information

Note Installation position of the valve or draining of the pipeline and flow direction in the valve.

Non-return valves should be cleaned within a defined time period (cleaning schedule). Generally this is done during pipe cleaning / flow.

Note Only use cleaning agents which are appropriate for stainless steel and the seals. Please refer to the safety data sheets of the cleaning agents.



4.4 Valve Types

FLOWmag 12020

Housing

The non-return valve consists of 4 main parts and has a weld end on both sides. Different weld-on connections are available. The preferred installation position is vertical. Valve design

1 2 3 4

Flange Housing Shutter Flange

Dimensions

012020 DN a [mm]

b [mm]

c ∅ [mm]

a* [mm]

10 51 41 13 55 15 60 54 19 65

25 80 72 29 85

40 100 90 41 105

3

2

4

1

a

b

c

a*



FLOWmag 12021 Housing in intermediate flange design

The non-return valve consists of a two-part housing and 2 flanges on the ends. The housing with all functional parts can be removed from the end flanges for maintenance work. Valve design

1 2 3 4 5

Housing part 1 Housing part 2 Flanges Shutter Magnetic half-rings

Dimensions

012021 DN a [mm]

b [mm]

c ∅

50 112 94 53

65 122 117 70

80 144 134 85

100 156 155 104

c b

a

1 2

3 4

5

3



4.5 Technical Data

Surface (Ra) ≤ 0.8 µm Nominal sizes (DN) 10, 15, 20, 25, 40 Nominal sizes ZF (DN) 50, 65, 80, 100 Nominal sizes (OD) 1“, 1 ½“, 2“, 2 ½“, 3“, 4“

Production / CIP

Flow media Liquids and gases, (non toxic, less aggressive) CIP media

Commercially available alkaline and acidic solutions

Operating pressure 0 - 10 bar

4.6 Performance Data

Product range

Materials Stainless steel 1.4404, DUPLEX Seals EPDM, FDA proof

Other parts

Materials Stainless steel 1.4307 Surface Precision-turned

Opening pressure

0.05 - 0.1 bar Temperature CIP / SIP 0 - 95°C / 140°C

line pressure (bar)

Flow

cap

acity

(m3 /h

)



5. Assembly and Disassembly

5.1 Safety and Assembly Instructions

Risk of injuries!

Permanent magnet • All electronic objects can be damaged by the magnetic field or their function can be

impaired. This also applies to medical/electrical devices, for example heart pace makers,

hearing aids, etc. • To exclude possible risks, the valves should only be maintained by personnel who are

instructed in devices of this type.

Risk of injuries!

See Chapter 2.2 - Safety Information

Caution – danger zone warning! (also see Chapter 2)

Please pay attention to the following prior to installation and commissioning: • Check the valve for visible external and internal damage. • Check the valve housing inside for residues. • Check the current system status (pressure, temperature, medium).

Please pay attention to the following if malfunctions occur and prior to disassembly: • The valve must be switched off in the case of malfunction. • Check the current system status (pressure, temperature, medium).

Caution – functional impairment or material damage!

Installation instructions: • Valves for welding in must be previously disassembled or the magnet and

seals must be removed. The housing cannot be welded in with a magnet installed! • Weld the housing into the piping system free of tension with sufficient free space. • Remove welding residue from the piping system. • The welding work (TIG, welding gas) should only be carried out by qualified welders (EN

287-1).




Assembly instructions: • Do not damage the valve insert, sliding surfaces or sealing surfaces.

Only use suitable tools and tensioning devices. • Only use suitable and approved spare parts from the manufacturer. • Slightly grease seals and insert them evenly into the groove.

(Only use grease approved for the field of food processing) • Bolts, slightly grease threads. Tighten parts evenly. • Carry out a manual functional check – activate the shutter.


Permanent magnet: • Do not remove the magnet unless it is absolutely necessary. • A safety clearance must be observed between the magnet and all electrical/electronic

objects and parts of equipment. It is possible these objects could be damaged or their functionality could be impaired.

• If the magnet is damaged by an impact or shock small broken pieces with sharp edges may form.



5.2 Disassembly / Assembly

FLOWmag 12020

O-ring seal

Flange

Housing

Screws

A B

Remove screws, take front flange off of housing, remove/replace O-ring seal

C D

Remove seal ring, magnetic half rings can be removed (normally not necessary)

Seal ring

Magnetic half-rings

Shutter part 1

Shutter part 2

Housing

Remove screws, take rear flange off of housing, remove/replace O-ring seal

O-ring seal

Flange

Housing

Screws

O-ring seal

Remove shutter from housing and screw on, remove/replace O-ring seal

1 Screws 2 Screws 3 Shutter part 1 4 Shutter part 2 5 Housing 6 Flange (valve inlet) 7 Flange (valve outlet) 8 Magnetic half-rings 9 Seal 10 O-ring seal 11 O-ring seal 12 O-ring seal



FLOWmag 12021

Flange

Housing

Screws

A B

Remove screws

E

Remove front and rear flange from housing O-ring seals accessible

Remove shutter from housing and screw on, O-ring seal accessible

C D

Separate housing parts Remove sealing ring and magnetic half rings (normally not necessary)

Shutter

Sealing ring

Housing part 1

Remove screws Housing can be disassembled O-ring seals accessible

Flange

Flange

Housing

Flange

Housing part 2

Screws

Magnetic half-rings Housing part 1

Housing part 2

Shutter part 2

Shutter part 1

O-ring seals

F



6. Servicing

6.1 Maintenance Instructions


Inspection and maintenance intervals: • Visual inspections must be carried out continuously every 4 weeks. • To ensure that the valve is ready for operation and functionally reliable, it should be

checked every year within the scope of the general internal maintenance procedure. >> Maintenance intervals must be set by the user • After maintenance, always remove protective devices and reconnect the feed and drain

lines to the valve. • Ensure that a function test is always performed on the valve

following maintenance work.

6.2 Troubleshooting

Malfunction Possible causes Measures

Leak (external)

• O-ring seals between flange and housing damaged

• Screws have come loose • Process pressure too high

• Replace seals

• Test tightening torque • Check pressure

Leak/backflow (internal)

• O-ring seal between taper and shutter damaged

• Seal area damaged

• Shutter blocked

• Replace seals

• Check seating area and taper for mechanical damage

• Manual functional check, remove shutter

Noise generation • Uneven flow/cavitation • Check process conditions, change installation position

6.3 Spare Parts

Seal / Position DN 10 DN 15 DN 20 DN 25 DN 40

Seal set for: 012020. 00010 00015 00020 00025 00040

Seal / Position DN 50 DN 65 DN 80 DN 100

Seal set for: 012021. 00050 00065 00080 00100

Seal replacement - please note the following points: • Use a suitable tool (dig hook) to remove the seals • The gasket grooves should be cleaned thoroughly before installing the new seals. • Slightly grease the seals (only use grease approved for the field of food processing) • Insert seals evenly into the gasket grooves

operating manual non-return valve flowmag (type 12020 / 12021)

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