rsgvl installation operation & maintenance manual€¦ · gate valve dn80 -dn300 4 qad#im1080, rev...

LITE PATTERN RESILIENT SEAT GATE VALVE DN80 - DN300

1 QAD#IM1080, Rev B, 23.11.20

www.challengervalves.com.au

RSGVL

Installation

Operation &

Maintenance

Manual


2 QAD#IM1080, Rev B, 23.11.20

Index

1. Introduction

1.1 General Application 3

1.2 Technical Data 3

1.3 Approvals / Reports 3

1.4 Features 4

1.5 Operation 4

1.6 Design Constraints 4

2. Installation, Operation and Maintenance

2.1 Preparation 5

2.2 Installation 5

2.3 Maintenance 5

2.4 Replacing the Bonnet Gasket 6

2.5 Replacing the Stem Seals 6

2.6 Replacing the Stem Seals Under Pressure 6

3. Warranty 7


3 QAD#IM1080, Rev B, 23.11.20

1 Introduction 1.1 General Application Resilient seated gate valves are the perfect solution for isolating pipeline systems. Complete with inside screw and non-rising spindle design, the RSGV gate valve is suitable for use in potable or waste water applications. - Operated by a hand wheel for above ground applications. - Operated by a removable key for buried applications. Use limits: Not permitted for high unbalanced heads, flow control or throttling.

1.2 Technical Data

Design and Manufacturing Standard: AS 2638.2 Size Range: DN80 ~ DN300 Allowable operating pressure: 1600 kPa

Maximum operating temperature: 0-40◦C (AS2638.2—AS4020)

0-65◦C (General Application)

End Connections: Flanged to AS 4087 Figure B5 (Table C)

Face to face standard: AS 2638.2

Test standard: AS 2638.2

Coating: AS4158 Akzo Nobel Resicoat R4, HJF10R: Blue RAL5017GL

Maximum Velocity: 5m/s

1.3 Approvals / Reports

Standardsmark SAI Global SMKP20472 WaterMark SAI Global WMK20472 Potable Water Testing (AS4020) Beijing Building Materials Testing Academy JS2016WS0268 WSAA PA06-09


4 QAD#IM1080, Rev B, 23.11.20

1.5 Operation

The RSGVL gate valve is designed and manufactured to close to completely, block flow, or open fully to allow maximum flow in

pipelines. It is suitable for use with potable water, raw water and low solids sewage up to 40°C (AS4020) or 65°C (General Applications)

Minimum liquid temperature must be above freezing.

1.6 Design Constraints

Please consider the following points when selecting your valve:

Consideration should be given at the design stage as to where valves will be located to give access for operation, adjustment,

maintenance and repair.

If a valve is installed less than 6 diameters downstream of an elbow or tee etc., it will experience very high-localised velocities

that are far in excess of the average velocity. This high velocity will result in excessive turbulence within the valve and

variations in performance may be experienced, therefore installation in this area should be avoided.

Valves must be provided with adequate support. The valve and adjoining pipe work must be supported to avoid the imposition

of pipeline strains on the body which may impair its performance.

Heavy valves may need independent support or anchorage.

Valve can be installed in the vertical and horizontal orientations, it is not recommended to install the valve upside down.

Prevent water freezing in the valve, failure to do so may damage the valve.

1.4 Features

Ideal for use on potable water and sewerage applications.

Designed, tested and certified in accordance with AS2638.2.

Valve sizing conforms to the Australian requirements of the water supply

code.

The body and bonnet are made of high grade ductile iron to AS1831.

The floating wedge nut is self adapting ensuring alignment with the stem

and disc. Its aluminium bronze material is self lubricating providing

optimum compatibility with the stainless steel shaft and allowing reduced

operating torques.

The ductile iron wedge is fully encapsulated by EPDM rubber preventing

creep, corrosion and forming a drop tight seal.

Valves can be supplied in clockwise or anti-clockwise closing directions.

Fusion bonded epoxy coating to AS4158 internally and externally providing

longer life and excellent corrosion protection.

Bonnet allows for easy access for cleaning and maintenance without having

to remove from pipeline.

Lifting lugs (DN150 and above) and support feet for easy handling.

Stem seals can be replaced without having to remove the valve from the

pipeline, this can also be completed while the pipeline is still under

pressure.

Full port design avoids pressure loss, clogging and the ingress of debris.


5 QAD#IM1080, Rev B, 23.11.20

2. Installation, Operation and Maintenance.

2.1 Preparation before installation of gate valve

Valves should be protected during transportation. Collision and falling should be avoided during transportation and installation.

It is strictly prohibited to lift from any point other than the provided lifting lugs.

Due to RSGV comprising rubber components, they are not to be stored exposed outdoors or exposed in sunshine for long

periods of time.

If the valve is installed in a pit, enough space shall be kept to accommodate the working personnel.

The pipelines shall be designed with supporting fixtures such as support frames. It is strictly prohibited for the valve to support

the pipeline weight or external weight.

Prior to connecting the valve with the pipeline, the flange shall be welded to the pipe. It is strictly prohibited to clamp the valve

during the flange welding.

Foreign materials shall be cleared from the pipelines. It is strictly prohibited to leave weld slag, stones or other foreign

materials in the pipeline which could damage the valve.

Prior to installation of the valve, prepare handling tools, spanners and other necessary tools, gaskets, bolts (or studs), nuts and

washers. Bolts and nuts shall meet the pipeline design requirements. It is strictly prohibited to use fasteners without

sufficient strength.

2.2 Installation of gate valve

When installing the gate valves, ensure that the seat and the flange faces are clean.

When valves are provided with lifting lugs, plates or eye nuts, these must be used to lift the

valve.

To ensure adequate sealing it is important to select the correct type of gasket for the medium

concerned, gaskets with the correct flange size must be used.

Place valve between pipe flanges and insert the bolts.

Tighten bolts loosely. If a gap is visible between the flange and the valve do not continue to

fasten the items together. This will cause excessive strain on the valve castings and may cause

failure.

Tighten bolts in a diagonal sequence to ensure flanges are pulled up parallel. As per bolting

sequence shown right (Figure 1).

Finally, tighten bolts to correct torque levels as recommended per WSA 109.

Ensure the pipeline is free from any debris prior to commissioning the valve.

2.3 Maintenance of gate valve

The valve is to be maintained periodically.

No lubrication is required as the medium lubricates all required parts.

Make sure all bonnet and flange bolts are tight at all times, More regular inspections are required when installed in high

vibration applications.

1

2

11

8

3

10

5

12

7

4

9

6

Figure 1. Bolting Sequence


6 QAD#IM1080, Rev B, 23.11.20

2.4 Replacing the Bonnet Gasket.

- Make sure no pressure is in the pipeline

- Remove bonnet fasteners

- Remove bonnet

- Remove and replace bonnet gasket

- Replace bonnet

- Refit fasteners and tighten.

2.5 Replacing the Stem Seals.

Under no line pressure:

1. Close the valve and release all line pressure from the pipeline.

2. Remove the anti dust cover (part 7) and limit ring (part 8) there is a layer

of wax between the two items that must be removed.

3. Unscrew (turn anti clockwise) the hex drive that is now exposed using a

socket and extension arm, this will remove the stem bearing (part 6)

4. Remove and replace the 3 O-rings (part 9 = 1 external and part 10 = 2

internal)

Ensure the new o rings are lubricated with a suitable Watermark or

equivalent approved o ring lubricant.

5. Remove any old thread locker, clean the bearing then apply a medium

thread locker to the threads. Screw the bearing into the bonnet clockwise

until tight and re apply the limit ring.

6. Melt wax over limit ring and slide over dust cover.

2.6 Replacing the Stem Seals Under Pressure.

- Rotate the stem (part 5) so the wedge (part 2) is in the fully open position

until the wedge nut (part 3) is tight against the down bearing (part 11)

- Follow steps 2 - 6 on above replacing stem seals instructions.

- WARNING - Never operate the valve to the closed position when replacing

the stem O-rings while under pressure.

1

2

3

4

5

6 8

14

9

15

10

12

7

11

13


7 QAD#IM1080, Rev B, 23.11.20

3. Warranty

This warranty covers faults in the products construction, material and assembly.

Products which are within 12 months from the date of purchase and are found to be defective after inspection by a

Challenger authorised representative in construction, material or assembly will be repaired or exchanged with an

equivalent product free of charge (at the discretion of Challenger)

Warranty Conditions:

1. The installation of the product is in accordance with the instructions provided.

2. Proof of purchase (including date of purchase) is provided.

3. The product has not been used in an unsuitable or improper manner.

4. The product has not been affected by inadequate or lack of maintenance.

5. The product has not been affected by unsuitable media, chemical or electrical influences.

6. Application does not exceed the max allowable temperature of 60 degrees Celsius or continuous 40 degrees Celsius.

7. Pressure does not exceed 16 Bar (1600Kpa)

8. Installation is subject to the requirements of the applicable regulatory authority.

rsgvl installation operation & maintenance manual€¦ · gate valve dn80 -dn300 4 qad#im1080, rev...

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