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Control Valve

ZK 313

Original Installation Instructions

818542-04

Содержание ZK 313

Страница 1: ...Control Valve ZK 313 Original Installation Instructions 818542 04 ...

Страница 2: ...16 Storing the equipment 16 Transporting the 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 Rinse the equipment 24 Disassembling the equipment 26 Assembling the equipment 38 Servicing the equipment and installing spare parts 50 Troubleshoo...

Страница 3: ...tallation 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 installatio...

Страница 4: ...plosion hazard Explosion 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...

Страница 5: ... and hot or pressurized fluid may escape Make sure that the equipment is only operated within the admissible service range and limits For more information on limits and pressure temperature ratings see name plate and the section Technical Data The equipment may be damaged if the connection of the equipment with the pipe is not stable enough or the equipment is not sufficiently supported Hot or pre...

Страница 6: ...pertinent on site rules and regulations for preventing fire and explosions as well as industrial safety regulations working on pressure equipment making pipe connections working with dangerous hot or pressurized fluids lifting and transporting loads observing all notes and instructions in this installation operating manual and the applicable documents connecting the power supply of the actuator Pr...

Страница 7: ...ngle type The code letter D in the type designation indicates straight through and E indicates angle type Equipment of size DN 100 DN 150 is of the angle type features a hammer forged body and is indicated by the additional code character 0 in the type designation A special Z type hammer forged body is also available on request The equipment can be fitted with various types of actuators The actuat...

Страница 8: ...l be explicitly stated End connections The equipment is available with the following end connections Butt weld ends Socket weld ends Flanges The end connection is not specified in the type designation Equipment with socket weld ends and flanges are special design versions and not described in this IOM For more information on special design versions please contact the manufacturer ...

Страница 9: ...s No Designation 1 Mechanical connection for actuator in equipment with rotary actuator this is a spindle bearing shown here 2 Bonnet 3 Upper part No Designation 4 Body 5 Flow direction arrow on both sides 6 Name plate ...

Страница 10: ...10 The yoke is fitted with the following items No Designation 7 Spindle 8 Coupling 9 Stem installed in upper part No Designation 10 Indicator for scale markings on coupling 11 Scale ...

Страница 11: ...11 The stuffing box seal consists of the following items No Designation 12 Screwed union 13 Retaining ring No Designation 14 Support disk 15 Gland packing ...

Страница 12: ...ollowing items are fitted inside the equipment No Designation 9 Stem 16 Upper part 17 Upper main gasket 18 Pressure element 19 Lower main gasket No Designation 20 Ring 21 Throttle 22 Seat bushing 23 Valve plug ...

Страница 13: ...13 Equipment with spindle bearing features a bonnet that is provided with a grease nipple No Designation 24 Grease nipple only on actuator with handwheel or electric rotary actuator ...

Страница 14: ...lowing information The sign X in the Ex label signifies that operation at an excessive surface temperature caused by the medium must be avoided The equipment itself does not generate additional surface temperatures Once installed static electricity may arise between the equipment and the connected system During use in potentially explosive atmospheres the discharge or prevention of possible electr...

Страница 15: ...ressure is reduced in stages and the flow is split up into many partial flows This decreases the noise level during operation and extends the service life of the equipment thanks to reduced wear The equipment is fitted with an externally actuated stem During the opening process the stem controls the fluid flow by successively opening a series of flash chambers When the stem is in the closed positi...

Страница 16: ... sure that the equipment is dry and free from any fluid residues The equipment must be protected 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 g...

Страница 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...

Страница 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...

Страница 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...

Страница 20: ...em and how to mount the mechanical connection see page 38 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 Rinse the equipment on page 24 CA...

Страница 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...

Страница 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...

Страница 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...

Страница 24: ...from page 26onwards Replace the component part with an original spare part from the manufacturer For details on how to order spare parts refer to the parts list The two main gaskets of the equipment must be replaced in any case Re assemble the equipment as described from page 38 onwards Rinse the equipment Rinse the equipment in order to remove any dirt particles or fluid residues inside the equip...

Страница 25: ... clothing that is suitable for the fluid and if necessary wear protective gear For more information on suitable protective clothing and safety gear refer to the safety data sheet 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 equipm...

Страница 26: ...e Tool kit for removing internals for valves of type ZK 313 To order the tool kit please state the following stock code number 368220 The document no 4 ZK 428 comes with the tool kit It describes the content and application of the kit in detail If you need more information on the tool kit please refer to the manufacturer Preparing the equipment for disassembly DANGER Personnel working on pipes are...

Страница 27: ...iciently sturdy material Attach the noose strap to the lifting points or a flange The space required for disassembling and re assembling the equipment depends on the optional extras and the type of actuator For more information on the required service space see the attached drawings Attention The equipment or component parts may be damaged if it is disassembled or re assembled in the wrong order A...

Страница 28: ... Remove the two halves of the coupling 8 and the pointer 10 for the scale marking You can now remove the mechanical connection for the actuator For equipment with an electrical rotating motor you must remove the spindle bearing and spindle Loosen the nuts 32 Remove the fixing studs 30 and the locking washers 31 ...

Страница 29: ...om the equipment Unscrew the spindle out of the bearing if necessary Removing the bonnet The attachment of the bonnet to the body depends on the type of actuator Valves with pneumatic actuator feature a groove nut with which the bonnet is fixed All other types of actuator use grub screws for attaching the bonnet to the valve body The following two sections describe the mounting options in more det...

Страница 30: ...y from the standard bonnet the following drawing shows the actuator The actuator must be removed before the bonnet can be dismounted Do not dismount the yoke before all actuator parts including the coupling have been removed For this purpose proceed as described in section Removing actuator parts on page 27 beschrieben Unscrew the screw in adapter 38 from the stem 1 Unscrew the groove nut 36 2 Lif...

Страница 31: ...on 12 until you can move the stem 2 Slowly pull the stem 9 upwards until it hits the stop 3 and hold the stem in this position Lift the upper part 16 off the stud bolts 40 4 Protect the dismantled parts from damage and dirt The tool kit for removing the internals can only be used if the stud bolts 40 are attached to the body and the hexagon nuts 39 are screwed on Screw the hexagon nuts 39 handtigh...

Страница 32: ...moved together with the seat bushing Upper main gasket 17 Pressure bearing element Lower main gasket 19 Ring 20 Throttle unit 21 Seat bushing 22 For the sake of simplicity the following drawing does not show the nuts on the stud bolts The tool kit contains different extraction devices for the various equipment types Choose the extraction device according to the specification in the document Tool k...

Страница 33: ...action device is now firmly clamped in the seat bushing You can now take the internals out of the body by means of the extraction device Attention Damage may occur if the yoke slips off during dismounting Make sure that the yoke with the seating faces is correctly positioned on the stud bolts and nuts Put the yoke 43 onto the stud bolts 40 1 Make sure that the seating faces 44 at the yoke rest on ...

Страница 34: ...gh the bore in the yoke 43 2 Screw together the spindle and the extraction device 41 3 Screw the hexagon nut 46 handtight onto the spindle 4 To lift the seat bushing and the other internals off the body slowly fasten the hexagon nut ...

Страница 35: ...ention 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 correctly positioned and not skewed Take the screwed union 12 out of the upper part Take the retaining ring 13 out of the screwed union Take the support disk 14 out of the screwed u...

Страница 36: ...er should be approx 3 4 mm The width of hook tip should be approx 2 mm To clamp the stem you need a clamping device with clamping jaws with rubber coating For more details please contact the manufacturer CAUTION Operating personnel may get injured if the disc springs are decompressed in an uncontrolled manner Always wear sturdy work gloves and safety goggles when working on the stem and plug Detac...

Страница 37: ...se a suitable device to hold the plug in this position Use a screwdriver to lever the retaining ring 26 out of the groove in the stem 9 Put the point of the wire hook under the retaining ring Lift the hook to take the retaining ring out of gap between the stem 9 and the plug 23 ...

Страница 38: ...ff the stem Lift the stem out of the clamping device Take the disc springs 25 out of the plug Assembling the equipment Work prior to re installation CAUTION Sharp edges on component parts can cause cuts Wear industrial gloves when servicing equipment parts Clean all component parts before re installing them Make sure that the sealing surfaces of the stem and seat are correctly surfaced in relation...

Страница 39: ...position they were when the plug 23 was removed 1 Insert the plug with the disc springs into the stem 2 CAUTION Operating personnel may get injured if the disc springs are decompressed in an uncontrolled manner Always wear sturdy work gloves and safety goggles when working on the stem and plug Detach or attach the stem and plug only if the stem is held in position by means of a sturdy clamping dev...

Страница 40: ...ing or lifting the equipment and or component parts Make sure that the equipment cannot topple over Make sure that nobody is standing below the lifted equipment Attention Equipment may not work properly or get damaged if parts are tilted or skewed when installed Use suitable lifting gear to mount the component parts Do not tilt or skew the component parts during installation During installation ma...

Страница 41: ...Put the throttle unit 21 on the pressure element 5 Place the upper main gasket 17 on the throttle unit 6 You can also assemble the insert outside of the valve body and then use the extraction tool kit to fit it in the valve body Mount the insert in the specified order Fit the extraction tool to the body as described in section Removing inner parts from page 32 onwards Mount the assembled insert in...

Страница 42: ...raphite rings depends on the size of the equipment The exact number is indicated in the parts list For more detailed information please contact the manufacturer 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 stu...

Страница 43: ... 12 loosely into the upper part Put the packing ring 15 into the screwed union Put the support disk 14 into the screwed union Put the retaining ring 13 into the groove of the screwed union Tighten the screwed union 12 hand tight ...

Страница 44: ...rt 16 with the stem onto the stud bolts 40 in the body 1 When inserting the stem with plug in the insert ensure that it is not canted and that it does not hit any part Screw the hexagon nuts 39 on and tighten them until they are handtight 2 Tighten the hexagon nuts in diagonally opposite pairs to a torque of 300 Nm Tighten the screwed union 12 3 The torque required for tightening the screwed union...

Страница 45: ...nnet to the valve body The following two sections describe the mounting options in more detail DANGER Risk of bruises if the equipment or component parts fall down Use suitable lifting gear when moving or lifting the equipment and or component parts Make sure that the equipment cannot topple over Make sure that nobody is standing below the lifted equipment Mounting the bonnet Put the bonnet 2 onto...

Страница 46: ...indle protrudes too much Screw the 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 Tighten the screwed union to the following torque The torque depends on the type of actuator Handwheel operation and rotary actuator ZK 313 11 50 Nm Electric rotary actuator ZK 313 12 200 Nm In equipment wi...

Страница 47: ...g shows the equipment without the actuator Put the actuator onto the bonnet Insert the stud bolts 30 through the spindle bearing and the bonnet in the actuator Fix the stud bolts with washers 31 and nuts 32 Tighten the nuts to the specified torque ...

Страница 48: ...the stem and coupling a little and slightly tighten the lower bolts Insert the scale marking 10 in the coupling The scale marking 10 must be situated next to the scale in the cap recess To align the coupling rotate it and the stem Attention Equipment may not work properly or get damaged if screws nuts or bolts are tightened with the wrong torques Tighten the screwed union to the following torque S...

Страница 49: ...ng below the lifted equipment Put the distance ring 37 over the upper part 1 Place the actuator with yoke 2 onto the distance ring 2 Put the groove nut 36 onto the upper part To attach the yoke to the upper part fasten the groove nut 3 Screw the screw in adapter 38 onto the stem 4 Tighten the locknuts hand tight to the screw in adapter Attention Equipment may not work properly or get damaged if pa...

Страница 50: ...quipment as described from page 26onwards Remove the defective 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 installi...

Страница 51: ...em lift 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 stuffing box screw Make sure that ...

Страница 52: ...mental 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 equip...

Страница 53: ...nts provided by the actuator 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 qua...

Страница 54: ...sposal Materials Component EN ASME Body 1 0460 A105 1 5415 1 7383 A182F22 1 4903 A182F91 Upper part of body 1 0460 A105 1 4903 A182F91 Threaded bolt 1 7709 1 4980 A193B16 Nuts 1 7709 1 4980 A194 7 Technical data Dimensions and weights For information on dimensions and weights please see data sheet For information on dimensions and weights of the actuator please refer to the documents provided by t...

Страница 55: ...55 Fluid flowrate and differential pressure Flowrates cold water A Differential pressure B Flowrate ...

Страница 56: ...56 KVS value CV value 1 1 1 2 2 1 5 1 7 3 2 3 2 7 4 3 6 4 2 5 5 5 6 4 6 8 9 4 7 11 12 7 8 13 15 0 9 20 23 1 ...

Страница 57: ...harge to atmospheric pressure For higher back pressure take a correction factor into account The ascertained flowrate is reduced by the correction factor B Flowrate KVS value CV value 1 1 1 2 2 1 5 1 7 3 2 3 2 7 4 3 6 4 2 5 5 5 6 4 6 8 9 4 7 11 12 7 8 13 15 0 9 20 23 1 ...

Страница 58: ... 365 Maximum pressure You can find precise information on the pressure and temperature ratings of your equipment on the name plate and in the data sheet Manufacturer s Declaration You can find details on the conformity assessment in accordance with European Directives in our Declaration of Conformity or our Declaration of Incorporation To request the valid Declaration of Conformity or Declaration ...

Страница 59: ...59 ...

Страница 60: ...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 818542 04 07 2017 kx_mm 808600 05 GESTRA AG Bremen Printed in Germany ...

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