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GESTRA ZK 213, Original Installation Instructions

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GESTRA ZK 213 Original Installation Instructions Download Page 3

 

 

 

   

3 

Foreword 

This installation & operating manual (IOM) will help 
you use the control valve ZK 213 and its variants 
(referred to as "equipment" in this document) safely 
and efficiently for its intended purpose. 

  

This installation & operating manual is intended for 
anyone commissioning, using, operating, servicing, 
cleaning or disposing of this equipment and, in 
particular, for professional after-sales service 
technicians, qualified personnel and authorised and 
trained staff. 
All of these persons must read and understand the 
content of this installation & operating manual. 
Following the instructions given in this installation & 
operating manual helps avoiding danger and 
increases the reliability and service life of the 
equipment. Please note that in addition to the 
instructions given in this installation & operating 
manual you must also observe all locally applicable 
rules and regulations concerning the prevention of 
accidents as well as approved safety guidelines for 
good professional practice. 

  

Availability 

Keep this installation & operating manual together 
with the plant documentation for future reference. 
Make sure that this installation & operating manual 
is available to the operator.  
The installation & operating manual is part of the 
equipment. Please hand over this installation & 
operating manual when selling the equipment or 
passing it on. 

  

Keep the applicable documents specified on page 7 
together with this installation & operating manual 
for future reference. 

  

Formatting features in the 

document 

Certain text elements of this installation & operating 
manual feature a specific typographic design. You 
can easily distinguish the following text elements: 
Standard text 

Cross-reference

 

  

 

Listing 

 

Sub-items in listings 

 

Steps for action. 

  

 

Here you will find additional useful 
information and tips serving to assist you 
in using the equipment to its fullest 
potential. 

  

Summary of Contents for ZK 213

Page 1: ...Control valve ZK 213 Original Installation Instructions 818449 03 ...

Page 2: ...equipment 17 Mounting and connecting the equipment 18 Preparing installation 18 Connecting the equipment 19 Checking the function 20 Operating the equipment 21 After operation 21 Maintaining the equipment 23 Purging the equipment 24 Disassembling the equipment 26 Assembling the equipment 40 Servicing the equipment and installing spare parts 57 Troubleshooting 58 Putting the equipment out of operat...

Page 3: ...observe all locally applicable rules and regulations concerning the prevention of accidents as well as approved safety guidelines for good professional practice Availability Keep this installation operating manual together with the plant documentation for future reference Make sure that this installation operating manual is available to the operator The installation operating manual is part of the...

Page 4: ...osion risk if equipment is used that is not suitable for the environmental conditions When using the equipment in explosion risk areas make sure that The permissible surface temperature of the equipment for the place of installation must not be exceeded If electrically insulated equipment is installed appropriate measures must be taken to discharge any static electricity between pipe flanges The h...

Page 5: ...the place of installation If the stuffing box is leaking there is a risk of severe injuries caused by escaping hot fluid Use the equipment only if it is in proper working condition Replace any leaking stuffing box seal The equipment can be provided with different types of actuator e g with an electric or hydraulic actuator Depending on the type of power supply for the actuator there is a risk of s...

Page 6: ...n on suitable safety clothing and safety gear refer to the safety data sheet of the fluid in question Protective gear comprises the following items protective helmet work boots industrial leather gloves Wear some form of ear protection when standing close to the equipment 1 m or less during operation Typographic features of warning notes DANGER Notes with the heading DANGER warn against imminent d...

Page 7: ...ndicated by the following code numbers in the type designation 13 electrically operated linear actuator 14 spindle bearing for electrically operated rotary actuator or handwheel 20 pneumatically operated diaphragm actuator or piston actuator 40 Hydraulic cylinder As optional extra a pressure balance device may be connected to the insert Equipment with pressure balance has the suffix mD in its type...

Page 8: ...ignation 1 Mechanical connection for actuator in equipment with rotary actuator this is a spindle bearing shown here 2 Yoke 3 Name plate 4 Body No Designation 5 Direction arrow on both sides 6 Insert 7 Pressure balance device ...

Page 9: ...9 The yoke is fitted with the following items No Designation 8 Spindle 9 Scale 10 Scale marking on coupling No Designation 11 Coupling 12 Stem ...

Page 10: ...10 The stuffing box seal consists of the following items No Designation 13 Stuffing box flange 14 Stuffing box No Designation 15 Gland packing 16 Stuffing box ring ...

Page 11: ...11 The following items are fitted inside the equipment No Designation 6 Insert here with pressure balance 12 Stem 17 Upper main gasket No Designation 18 Sleeve 19 Lower main gasket 20 Collar bush ...

Page 12: ...12 No Designation 12 Stem 17 Upper main gasket 21 Pressure piece 22 Threaded ring 23 Retaining ring No Designation 24 Valve plug 25 Thrust ring 26 Sleeves 27 Seat bushing ...

Page 13: ...13 The following items are available as optional extra No Designation 7 Pressure balance device 28 Position indicator ...

Page 14: ...tic electricity may arise between the equipment and the connected system During use in potentially explosive atmospheres the discharge or prevention of possible electrostatic charging is the responsibility of the manufacturer or owner of the system If there is a possibility that medium might escape e g via actuating devices or leaks in screwed couplings the manufacturer or owner of the system must...

Page 15: ...pening process the stem controls the fluid flow by successively opening a series of flash chambers When the stem is in the closed position the fluid flow is completely stopped and bubble tight closure is ensured The tandem seat consists of a primary and a secondary seat for double shut off When the equipment is closed the stem 12 and plug 24 are in the lowest position During the opening process fi...

Page 16: ...by its packaging The packaging must protect the equipment from moisture and mechanical damage The equipment must be stored in a horizontal position Make sure that the stem of the equipment is moved at least every two months in order to avoid that the packing rings get stuck CAUTION There is a risk of getting crushed by the spindle Wear sturdy leather gloves when working on the spindle or stem Make...

Page 17: ...ent strength for the equipment including the actuator For more information on the weight of the equipment see the attached documents For more information on the weight of the actuator see the documents provided by the actuator manufacturer For more information on lifting points and the centres of mass see the attached documents Carefully clean the equipment before transportation Meet the requireme...

Page 18: ...er Preparing installation Remove the transport packaging Check the equipment for transport damage If you detect any transport damage please contact the manufacturer When supplied by the factory the connections may be sealed off with sealing plugs Remove sealing plugs before mounting the equipment Keep the sealing plugs and the packing for further use DANGER Personnel working on pipes are exposed t...

Page 19: ...osition and the actuator mounted on top Other installation positions are possible Contact the manufacturer if you want to mount the equipment in a different position of installation Mount the equipment in the desired installation position Make sure that the equipment is supported by the pipes If the supports can only be attached directly to the equipment ask the manufacturer for more information o...

Page 20: ...mechanical connection see section Assembling the equipment from page 40 onwards Connect the actuator properly to its power supply Checking the function Make sure that the equipment is safely mounted and that all connections are made correctly To remove residues from the pipes and the equipment after installation purge the pipes with the fluid to be used For more information see chapter Purging the...

Page 21: ...th caused by harmful substances in or on the equipment Only qualified personnel are allowed to perform work on contaminated equipment Always wear the protective clothing prescribed for contaminated areas when working on the equipment Make sure that the equipment is completely decontaminated before carrying out any service work Follow the pertinent instructions for handling the hazardous substances...

Page 22: ... sure that the equipment cannot be switched on inadvertently Attention Damage to the equipment due to improper maintenance work Make sure that only qualified personnel performs maintenance work A qualified person must be acquainted with and experienced in the following Working on pressure equipment Lifting loads Assembling and disassembling the equipment The qualified personnel must observe and fo...

Page 23: ...orrectly when the stem is in closed position by measuring the temperature Replace leaky or worn components Spindle bearing Grease with the recommended grease see next section and a lint free cloth Lubricating nipples on spindle bearing equipment with rotating motor Apply the recommended grease see next section 12 months Secure actuator fastening Check that screws and bolts are secure Tighten loose...

Page 24: ...ling the equipment from page 40 onwards Purging the equipment Rinse the equipment in order to remove any dirt particles or fluid residues inside the equipment DANGER Personnel working on pipes are exposed to safety risks and may suffer severe injuries poisoning or even loss of life Make sure that no hot or hazardous fluid is in the equipment or the pipes Make sure that the pipes upstream and downs...

Page 25: ...heet of the fluid in question Attention Equipment may be damaged by unsuitable cleaning fluid Rinse the pipe with the same fluid that is used during normal operation Make sure that the cleaning fluid does not damage the equipment material if you use a different fluid for cleaning than the normal operating fluid Make sure that the cleaning fluid does not come into contact with the fluid used during...

Page 26: ...uipment for disassembly DANGER Personnel working on pipes are exposed to safety risks and may suffer severe injuries poisoning or even loss of life Make sure that no hot or hazardous fluid is in the equipment or the pipes Make sure that the pipes upstream and downstream of the equipment are depressurised Make sure that the installation is switched off and protected against unauthorised or unintend...

Page 27: ... actuator For more information on the weight of the equipment see the attached documents For more information on the weight of the actuator see the documents provided by the actuator manufacturer Connect the lifting gear to the equipment or part that you want to lift For this purpose use a noose strap of sufficiently sturdy material Attach the noose strap to the lifting points or a flange The spac...

Page 28: ...e bearing You do not have to remove the spindle from the bearing to do this To remove the spindle bearing 1 and spindle 8 you must first detach the coupling To do so proceed as follows Loosen the hexagon nut 30 on the coupling anti rotation device Remove the hexagon head bolt 29 Some equipment is fitted with a position indicator The position indicator comes with a separate installation operating m...

Page 29: ...he two hexagon head bolts 35 The following drawing shows the equipment with actuator bearing for an electric rotary actuator Here the mechanical connection for the actuator is designed as a spindle bearing 1 The spindle 8 is connected with the spindle bearing and can be remove together with it Remove the mechanical connection for the actuator from the equipment Unscrew the spindle out of the beari...

Page 30: ... insert from equipment without pressure balance The procedure for equipment with pressure balance is described on page 32 To remove the packing rings proceed as follows Attention Excessive loosening can damage the stuffing box packing Loosen the nuts of the stuffing box bolts only until the resistance felt ceases Loosen the four nuts 38 of the stuffing box flange 13 until the resistance felt cease...

Page 31: ... strong lifting gear to the stuffing box flange 13 Lift the insert 6 off the equipment Take the stem 12 out of the equipment Take the upper main gasket 17 out of the equipment For details on how to disassemble the stuffing box packing see page 36 ...

Page 32: ...he packing rings proceed as follows Attention Excessive loosening can damage the stuffing box packing Loosen the nuts of the stuffing box bolts only until the resistance felt ceases Loosen the four nuts of the stuffing box flange 13 until the resistance felt ceases Loosen the bolts 39 of the pressure balance device until the resistance felt ceases ...

Page 33: ...ch two threaded rods with one nut each Attention The equipment may be damaged if the bearing capacity of the removal support is not sufficient Make sure that all parts of the removal support are capable of withstanding the loads and forces encountered during the removal process The weight of the parts to be removed depends on the equipment type For information on the weight of the parts to be remo...

Page 34: ...the equipment is tilted while being lifted with the removal support the resulting misalignment can damage the equipment Tighten the nuts of the removal support evenly To remove the thrust ring 25 from the body tighten the two nuts of the removal support evenly Tighten the nuts until the thrust ring is completely lifted off the body Use a suitable lifting device to remove the thrust ring Pull the t...

Page 35: ...turer The required dimensions of the removal support and the position of the threaded holes depend on the equipment type Contact the manufacturer for a detailed specification The removal support described in this section is only a recommendation Contact the manufacturer if you want to use a different kind of removal support Place the support frame with the two rods above the upper edge of the body...

Page 36: ...ush Disassembling the stuffing box in equipment without pressure balance The procedure for equipment with pressure balance is described on page 37 You only have to disassemble the stuffing box packing if you want to replace or service it In any other case the stuffing box can remain attached to the insert in order to avoid damage to the packing rings Attention The packing rings may get damaged Mak...

Page 37: ...tuffing box packing if you want to replace or service it In any other case the stuffing box can remain attached to the insert in order to avoid damage to the packing rings Attention The packing rings may get damaged Make sure you do not damage the packing rings during installation and removal When installing and removing the packing rings never use force Make sure that the packing rings are correc...

Page 38: ...ement You can now take the pressure balance device out of the insert For this purpose proceed as follows Remove the bolts 39 of the pressure balance device Loosen the stuffing box screw 46 of the pressure balance device Remove the balance ring 47 Take the packing rings 48 out of the stuffing box Take the ring 49 off the bore Remove any dirt deposits in the bore of the stuffing box ...

Page 39: ...ng and the retaining ring are accessible through the gap between the plug and the stem Use a claw tool to remove the threaded ring The size of the claw tool depends on the equipment type For more details on the dimensions contact the manufacturer To remove the plug proceed as follows Press the valve plug 24 into the stem 12 and hold it there The disc springs are compressed The pressure on the reta...

Page 40: ...ays insert new main gaskets when assembling the equipment Check all gaskets seals and packing rings before installing them Replace any damaged gasket seal or packing ring Check all component parts Replace the two main gaskets and any damaged components Attention Equipment may not work properly or get damaged if parts are tilted or skewed when installed Use suitable lifting gear to mount the compon...

Page 41: ...ion of the disc springs is shown and described in the supplied technical documents Insert the disc springs 55 into the hole in the valve plug 24 1 Put the pressure piece 21 onto the disc springs 2 Put the bore in the stem 12 onto the valve plug 24 ...

Page 42: ...oove in the threaded ring 22 To fix the threaded ring turn the claw tool clockwise Press the valve plug into the stem Fasten the threaded ring hand tight Insert the retaining ring 23 into the gap between the stem and the valve plug Let go of the valve plug The retaining ring now secures the threaded ring in place ...

Page 43: ... manufacturer install the collar bush Fitting the seat bushing Put a new lower main gasket 19 onto the collar bush 20 in the body Use a suitable lifting device to put the sleeve 26 onto the body Use a suitable lifting device to put the seat bushing 27 onto the body For the installation proceed in reverse order of the removing procedure ...

Page 44: ...when put into the body Use a suitable mounting support or lifting device To install the sleeve use the same mounting support 40 41 42 that was used for removing it Use a suitable lifting device to put the sleeve 18 into the body Use a suitable lifting device to put the thrust ring 25 into the body For the installation proceed in reverse order of the removing procedure ...

Page 45: ...et damaged if screws nuts or bolts are tightened with the wrong torques Apply the torques indicated in the parts list when tightening screws nuts and bolts To compress the lower main gasket install the insert and yoke and tighten them with the torques indicated in the parts list before mounting the upper main gasket Push the insert 6 over the stem and into the body ...

Page 46: ...lts handtight in diagonally opposite pairs The torques required for tightening the cap nuts and the stud bolts depend on the equipment type The tightening torques for your equipment are indicated in the parts list Tighten the cap nuts and the stud bolts with the specified torques The lower main gasket is now compressed To install the other component parts you have to remove the insert and the yoke...

Page 47: ...taching pressure balance element Put the sleeve 50 of the pressure balance device into the insert 6 Attention Malfunctions may occur if the packing rings are damaged Before installation discard and replace any damaged packing rings Make sure that the packing rings are correctly positioned and not damaged or skewed when fitted Put the packing rings 51 into the insert ...

Page 48: ...g rings are correctly positioned and not damaged or skewed when fitted Put the ring 49 into the bore Put the packing rings 48 into the bore Put the balance ring 47 into the bore Put the stuffing box screw 46 into the bore Put the bolt 39 into the bore Repeat these steps for the other stuffing boxes of the pressure balance device To mount the stuffing box packing do not tighten the bolts any more T...

Page 49: ...ws the equipment without pressure balance Attention Malfunctions may occur if the packing rings are fitted incorrectly Make sure that the packing rings of the stuffing box 15 are inserted in the following order one wiper ring made from graphite and CrNi pure graphite rings one wiper ring made from graphite and CrNi The number of pure graphite rings depends on the size of the equipment The exact nu...

Page 50: ... the equipment without a connection for sealing fluid In equipment with a connection for sealing fluid insert the grooved ring 59 instead of the pure graphite ring Attention Equipment may not work properly or get damaged if screws nuts or bolts are tightened with the wrong torques Apply the torques indicated in the parts list when tightening screws nuts and bolts The tightening torques for your eq...

Page 51: ...ue After mounting the stuffing box flange you can fasten the bolts of the stuffing box for the pressure balance with the indicated torque Attention Equipment may not work properly or get damaged if screws nuts or bolts are tightened with the wrong torques Apply the torques indicated in the parts list when tightening screws nuts and bolts The torques required for tightening the bolts depend on the ...

Page 52: ...s for your equipment are indicated in the parts list Apply MoS2 grease to the threads of the stud bolts 37 and the cap nuts 36 2 Pay careful attention to properly aligning the scale on the yoke support with the marking on the stem see drawings on page 55 Put the yoke 2 onto the stud bolts of the body Tighten the cap nuts and the stud bolts handtight in diagonally opposite pairs Tighten the cap nut...

Page 53: ...spindle further into the spindle bearing Attention Equipment may not work properly or get damaged if screws nuts or bolts are tightened with the wrong torques Apply the torques indicated in the parts list when tightening screws nuts and bolts The tightening torques for your equipment are indicated in the parts list In equipment with rotary actuator put the spindle bearing 1 with the spindle 8 scre...

Page 54: ... list when tightening screws nuts and bolts The tightening torques for your equipment are indicated in the parts list Insert the stud bolts 33 into the spindle bearing 1 and the yoke Fasten the nuts 34 with the specified tightening torque Install the actuator as described in the operating manual for the actuator Connect the actuator properly to its power supply ...

Page 55: ...the stem 12 and spindle 8 as shown The two outer edges of the coupling must be situated next to the cap support as shown Rotate the coupling to align it The marking on the coupling must be situated above the marking on the stem Make sure the largest possible gap of 10 mm maximum is left between the coupling and the stem If necessary turn the cap round so that the marking of the coupling is lined u...

Page 56: ...ted in the parts list when tightening screws nuts and bolts The tightening torques for your equipment are indicated in the parts list Use the four hexagon head bolts 32 to screw the two coupling halves together Fasten the hexagon nuts 31 on the hexagon head bolts handtight Tighten the hexagon nuts 30 and 31 with the specified torque Some equipment is fitted with a position indicator The position i...

Page 57: ...fective component part from the equipment Attention Equipment may leak if the gaskets are damaged Always insert new main gaskets when assembling the equipment Check all gaskets seals and packing rings before installing them Replace any damaged gasket seal or packing ring Mount the new component part Check all component parts before re installing them Replace the defective component parts Replace t...

Page 58: ...ift is affected by foreign matter The nozzles are dirty or clogged by foreign particles Rinse the installation If necessary disassemble the equipment and clean the component parts During operation loud noises are audible The nozzles are dirty or clogged by foreign particles The stuffing box is leaking The stuffing box has not been tightened enough Tighten the nuts to the recommended torque Make su...

Page 59: ...nmental damage may be caused by poisonous fluid residues Before disposing of the equipment make sure that it is clean and free of fluid residues For the disposal of all materials observe the pertinent legal regulations concerning waste disposal Remove all residues from the equipment For the disposal of all residues observe the pertinent legal regulations concerning waste disposal Removing the equi...

Page 60: ...ctuator manufacturer Switch the installation off and protect it against unauthorised or unintended re activation WARNING Risk of severe injuries or death if the actuator is not removed correctly Before working on the actuator cut off power supply to the actuator Follow all instructions and observe all notes given in the operating manual for the actuator Make sure that only qualified and trained pe...

Page 61: ...or the equipment Technical data Dimensions For information on the exact dimensions of the equipment see the dimensional drawing supplied with the equipment Weights For information on the exact weights of the equipment see the dimensional drawing supplied with the equipment Fluid flowrate and differential pressure For information on flowrate and differential pressure see name plate and or the suppl...

Page 62: ...ration of Incorporation To request the valid Declaration of Conformity or Declaration of Incorporation please contact GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon 49 421 3503 0 Telefax 49 421 3503 393 E Mail info de gestra com Web www gestra de This declaration is no longer valid if modifications are made to the equipment without consultation with us ...

Page 63: ...63 ...

Page 64: ...rld www gestra de GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon 49 421 3503 0 Telefax 49 421 3503 393 E Mail info de gestra com Web www gestra de 818449 03 07 2017 kx_mm 808557 03 GESTRA AG Bremen Printed in Germany ...

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