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11 Installation and operation

Prior to installation:

Ensure that valve body and diaphragm

material are appropriate and compatible

to handle the working medium.

Check the suitability prior to the

installation.

See chapter 6 "Technical data".

11.1 Installing the

diaphragm valve

WARNING

The equipment is subject to pressure!

Risk of severe injury or death!

Only work on depressurized plant.

WARNING

Corrosive chemicals!

Risk of caustic burns!

Wear appropriate protective

gear when installing.

CAUTION

Hot plant components!

Risk of burns!

Only work on plant that has

cooled down.

CAUTION

Never use the valve as a step or an aid

for climbing!

This entails the risk of slipping-off or

damaging the valve.

CAUTION

Do not exceed the maximum

permissible pressure!

Take precautionary measures to

avoid possible pressure surges

(water hammer).

Installation work must only be performed

by trained personnel.

Use appropriate protective gear as

specified in plant operator's guidelines.

Installation location:

CAUTION

Do not apply external force to the valve.

Choose the installation location so that

the valve cannot be used as a foothold

(climbing aid).

Lay the pipeline so that the valve body

is protected against transverse and

bending forces, and also vibrations and

tension.

Only mount the valve between

matching aligned pipes.

Direction of the working medium:

optional.

Mounting position of the diaphragm valve:

optional.

Installation:

1. Ensure the suitability of the valve for

each respective use. The valve must

be appropriate for the piping system

operating conditions (medium, medium

concentration, temperature and

pressure) and the prevailing ambient

conditions. Check the technical data of

the valve and the materials.

2. Shut off plant or plant component.

3. Secure against recommissioning.

4. Depressurize the plant or plant

component.

5. Completely drain the plant (or plant

component) and let it cool down until

the temperature is below the media

vaporization temperature and scalding

can be ruled out.

6. Correctly decontaminate, rinse and

ventilate the plant or plant component.

Installation - Butt weld spigots:

1. Adhere to good welding practices!

2. Disassemble the bonnet with the

diaphragm before welding the valve body

into the pipeline (see chapter 12.1).

3. Allow butt weld spigots to cool down.

4. Reassemble the valve body and the

bonnet with diaphragm (see chapter

12.4).

Содержание 653

Страница 1: ...653 654 653 654 Diaphragm Valve Metal Diaphragm sizes 8 100 GB INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS ...

Страница 2: ...to by the operator and by any additional installation personnel Contents 1 General information 2 2 General safety information 2 2 1 Information for service and operating personnel 2 2 2 Warning notes 3 2 3 Symbols used 3 3 Definition of terms 4 4 Intended area of use 4 5 Condition as supplied to customer 4 6 Technical data 4 7 Order data 6 8 Manufacturer s information 9 8 1 Transport 9 8 2 Deliver...

Страница 3: ...ications G Any servicing work and repairs not described in the installation operating and maintenance instructions must not be performed without consulting the manufacturer first DANGER Strictly observe the safety data sheets or the safety regulations that are valid for the media used In cases of uncertainty Consult the nearest GEMÜ sales office 2 2 Warning notes Wherever possible warning notes ar...

Страница 4: ...10 DN 40 PEEK Cap DN 50 DN 100 PES 653 handwheel PPS glass filled 654 handwheel A4 stainless steel Ambient conditions Max ambient temperature Standard 60 C Max ambient temperature Accessory MAG 35 C Temperature at mounting point for proximity switches see ambient temperature diagram below Working medium Corrosive inert gaseous and liquid media which have no negative impact on the physical and chem...

Страница 5: ... 26 2 30 0 40 29 3 30 9 30 9 30 9 30 2 29 5 32 8 50 50 46 5 48 4 48 4 48 4 51 7 50 6 55 2 80 65 77 0 68 5 68 5 96 0 80 111 0 80 0 87 0 111 0 100 100 194 0 173 0 188 0 214 0 Kv values determined acc to IEC 534 standard inlet pressure 6 bar Δp 1 bar stainless steel valve body and soft elastomer diaphragm MG diaphragm size Diaphragm temperature range C Diaphragm Liquid Media Steam Sterilisation Code ...

Страница 6: ... connections Clamps ASME BPE for pipe ASME BPE length ASME BPE 80 Clamps DIN 32676 series B for pipe EN ISO 1127 length EN 558 series 7 82 Clamps ASME BPE for pipe ASME BPE length EN 558 series 7 88 Clamps DIN 32676 series A for pipe DIN 11850 length EN 558 series 7 8A Clamps SMS 3017 for pipe SMS 3008 length EN 558 series 7 8E Aseptic clamps on request For overview of available valve bodies see d...

Страница 7: ...ster stroke limiter locking device to prevent opening and diaphragm size 10 50 K mounting for proximity switches M 8x1 With seal adjuster locking device to prevent opening and diaphragm size 80 100 mounting for proximity switches M 12x1 only in connection with bonnet version X only in T valve version Order example 653 50 D 60 40 13 0 4 D H 1503 Type 653 Nominal size 50 Body configuration code D Co...

Страница 8: ...l locking device Control function B without padlock L with padlock EDP No Designation Description 88264576 653MAGSV1 C1 AT Electromagnetic locking device 24 V DC normally closed M22x1 ATEX 88232776 653MAGSV1 C1 Electromagnetic locking device 24 V DC normally closed M22x1 IP 54 connector socket design A DIN EN 175301 803 88279388 653MAGSV2 C1 Electromagnetic locking device 24 V DC normally open M22...

Страница 9: ...e tools required for installation and assembly are not included in the scope of delivery Only the setting tool for the stroke limiter of GEMÜ 654 diaphragm size 80 100 is included see page 14 G Use appropriate functional and safe tools 9 Functional description The metal diaphragm valve is equipped with a stainless steel bonnet GEMÜ 653 has a handwheel in high temperature and chemically resistant p...

Страница 10: ...n location so that the valve cannot be used as a foothold climbing aid G Lay the pipeline so that the valve body is protected against transverse and bending forces and also vibrations and tension G Only mount the valve between matching aligned pipes Direction of the working medium optional Mounting position of the diaphragm valve optional Installation 1 Ensure the suitability of the valve for each...

Страница 11: ...of delivery Installation Flange connection 1 Pay attention to clean undamaged sealing surfaces on the mating flanges 2 Align flanges carefully before installing them 3 Centre the seals accurately 4 Connect the valve flange and the piping flange using appropriate sealing material and matching bolting Sealing material and bolts are not included in the scope of delivery 5 Use all flange holes 6 Only ...

Страница 12: ...le 15 Gently close the valve with handwheel 7 CLOSED position valve is tight G Screw in the seal adjuster nut 13 until it stops and secure with lock nut 6 SW19 open end wrench Setting the stroke limiter G Move the valve to the OPEN position by turning handwheel 7 upside down until the required flow rate is reached G Pull of handwheel 7 from the threaded spindle 15 G Screw stroke limiting sleeve 5 ...

Страница 13: ... seal adjuster c anticlockwise upwards until it stops Setting the stroke limiter G Move the bonnet to the desired OPEN position by turning the handwheel G Turn stroke limiter b clockwise downwards until it stops Important The seal adjuster must not turn during this process Completing the settings G Put protective cap a in place and align the flats by a light twisting movement G Press protective ca...

Страница 14: ...the male thread is visible c Releasing the seal adjuster G Turn seal adjuster c clockwise downwards until it stops Setting the seal adjuster G Move the bonnet to the desired CLOSED position by turning the handwheel c G Turn seal adjuster c anticlockwise upwards until it stops G Move the bonnet to the desired OPEN position by turning the handwheel b G Turn the stroke limiter clockwise downwards unt...

Страница 15: ...bonnet see Valve disassembly removing bonnet from body 1 Unscrew the diaphragm or pull it out diaphragm size 8 2 Clean all parts of the remains of product and contamination Do not scratch or damage parts during cleaning 3 Check all parts for potential damage 4 Replace damaged parts only use genuine parts from GEMÜ 12 3 Mounting the diaphragm 12 3 1 General information Important Mount the correct d...

Страница 16: ...m size 8 The compressor is fixed to the spindle Compressor and bonnet flange seen from below Diaphragm size 10 The compressor is loose Compressor and bonnet flange seen from below B D C D B C A A Pict 1 Pict 2 Anti twist system of the spindle at the compressor A double flat arrows picture 1 is fitted at the end of the bonnet spindle to protect the spindle against twisting When mounting the compres...

Страница 17: ...osition The position of A is offset by 45 to the position of C Place the compressor loosely on the bonnet spindle fit the recesses D into the guides C and A into B The compressor must be able to be moved freely between the guides Diaphragm size 100 The diaphragm is round Compressor and bonnet flange seen from below C D D C B B A A Place the compressor loosely on the bonnet spindle fit A into B and...

Страница 18: ...anufacturer and material in parallel to compressor weir Diaphragm sizes 10 100 Threaded pin type diaphragm Diaphragm boss Recess of compressor Diaphragm pin 1 Move bonnet A to the closed position 2 Place the compressor loosely on the bonnet spindle fit A into B and D into C see chapter 12 3 1 General information 3 Check if the compressor fits closely in the guides 4 Screw new diaphragm tightly int...

Страница 19: ...ockwise until its bolt holes are in correct alignment with the bolt holes of the bonnet 10 Press the diaphragm face tightly onto the backing diaphragm manually so that it returns to its original shape and fits closely on the backing diaphragm 12 4 Bonnet mounting on the valve body 1 Move bonnet A to the closed position 2 Open bonnet A approx 20 3 Position bonnet A with the mounted diaphragm 2 on t...

Страница 20: ...ked solenoid order data MAG Normally closed version locking pin extended in 24 V DC see type key The locking device is also available with ATEX approval 13 2 Special version with mechanical locking device A special version of GEMÜ 653 654 is available with a mechanical locking device With additional functions B K F types of locking device the locking device can be mechanically locked or unlocked o...

Страница 21: ...e K Mounting of locking device to prevent opening proximity switch possible F Mounting of locking device to prevent closing proximity switch possible 13 3 Special version for mounting of proximity switches Only use proximity switches that can be mounted flush A special version of GEMÜ 653 654 is available for mounting of proximity switches additional function A see type key Proximity switches can ...

Страница 22: ...roximity switch 6 until it touches damping cam 3 G Turn back proximity switch 6 by 1 2 to 3 4 turns G Secure this position by fixing it with nut X Setting the proximity switch for the CLOSED position G Remove lower screw 5 see delivery condition on previous page from bonnet G Move the bonnet to the closed position G At least 2 3 of the damping cam 3 must be visible Otherwise please proceed as foll...

Страница 23: ...y latest after the first sterilisation process 15 Inspection and servicing WARNING The equipment is subject to pressure Risk of severe injury or death G Only work on depressurized plant CAUTION Hot plant components Risk of burns G Only work on plant that has cooled down CAUTION G Servicing and maintenance work may only be performed by trained personnel G GEMÜ shall assume no liability whatsoever f...

Страница 24: ...turn If not completed GEMÜ cannot process credits or repair work but will dispose of the goods at the operator s expense Note for returns Legal regulations for the protection of the environment and personnel require that the completed and signed goods return declaration is included with the dispatch documents Returned goods can be processed only when this declaration is completed 19 Information No...

Страница 25: ...ctly set Reset seal adjuster see chapter 11 3 With special version F MAG LOC locking device closed Unlock locking device Valve leaks between bonnet and valve body Shut off diaphragm incorrectly mounted Remove bonnet check diaphragm mounting replace if necessary Bolting between valve body and bonnet loose Retighten bolting between valve body and bonnet Shut off diaphragm faulty Check shut off diaph...

Страница 26: ... 653 654 21 Sectional drawing and spare parts A 2 1 18 Leak detection hole 19 20 19 Item Name Order description 1 Valve body K600 2 Diaphragm 600 M 18 Bolt 653 S30 654 S30 19 Washer 20 Nut A Bonnet 9653 9654 ...

Страница 27: ...ctive 97 23 EC Description of the equipment product type Diaphragm Valve GEMÜ 653 GEMÜ 654 Notified body TÜV Rheinland Berlin Brandenburg Number 0035 Certificate no 01 202 926 Q 02 0036 Conformity assessment procedure Module H Valves DN 25 comply with section 3 paragraph 3 of the Pressure Equipment Directive 97 23 EC They are not identified with a CE label as per Pressure Equipment Directive 97 23...

Страница 28: ...bau GmbH Co KG Fritz Müller Str 6 8 D 74653 Ingelfingen Criesbach Telefon 49 0 7940 123 0 Telefax 49 0 7940 123 224 info gemue de www gemu group com Subject to alteration 11 2013 88297247 VALVES MEASUREMENT AND CONTROL SYSTEMS ...

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