ARI Stevi 422 Series User manual

Rev. 0040307000 0410 englisch
Series 422 Series 462
1.0 General information on operating
instructions ..................................................... 2
2.0 Notes on possible dangers............................ 2
2.1 Significance of symbols ..........................................2
2.2 Explanatory notes on safety information .................2
3.0 Storage and transport ................................... 2
4.0 Description...................................................... 3
4.1 Scope of applications ..............................................3
4.2 Operating principles ................................................3
4.3 Diagram ..................................................................4
4.3.1 Plug design ........................................................4
4.4 Technical data .........................................................5
4.5 Marking ...................................................................5
5.0 Installation....................................................... 5
5.1 General notes on installation...................................5
5.2 Requirements at the place of installation ................6
5.3 Installation instructions concerning actuators .........6
6.0 Putting the valve into operation.................... 7
7.0 Care and maintenance................................... 8
7.1 Replacement of stem sealings ............................... 8
7.1.1 Stuffing box packing design ............................... 8
7.1.2 Bellows seal design ........................................... 9
7.2 Replacement of internal parts ............................. 10
7.2.1 Replacement of plug and stem ....................... 10
7.2.2 Replacement of seals of
pressure balanced plugs ................................ 10
7.2.3 Replacement of the seat ring............................11
7.3 Tightening torques.................................................11
7.3.1 Tightening torques for nuts ..............................11
7.3.2 Tightening torques for seat rings .....................11
8.0 Troubleshooting ............................................11
9.0 Troubleshooting table ................................ 12
10.0 Dismantling the valve or the top part ...... 13
11.0 Warranty / Guarantee ................................. 13
12.0 EC declaration of conformity.................... 14
Contents
Operating and installation instructions
Straight through control valves - STEVI®422 / 462

Page 2 Rev. 0040307000 0410
Operating and installation instructions
Straight through control valves - STEVI®422 / 462
1.0 General information on operating instructions
These operating instructions provide information on mounting and maintaining the fittings.
Please contact the supplier or the manufacturer in case of problems which cannot be
solved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.
The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and maintenance instructions as well as technical data (in the operating instructions,
product documentation and on the device itself) must also be complied with to the fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
3.0 Storage and transport
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
ATTENTION !
. . . Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.

Rev. 0040307000 0410 Page 3
Operating and installation instructions
Straight through control valves - STEVI®422 / 462
4.0 Description
4.1 Scope of applications
Valves are used for „controlling the flow of liquids, gases and vapours in chemical and other
processing plants and for plant engineering“.
The information complies to the Pressure Equipment Directive 97/23/EC.
It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
ARI control valves are especially suitable for actuation by pneumatic or electrical actuators.
Three plug types are available to suit the various applications:
parabolic plug (standard pattern)
perforated plug
pressure balanced plug
The flow through control valves is always against the closing direction.
In the case of control valves with perforated plugs, gases and vapours flow against the
closing directions, but liquids flow through in the closing direction. If a pneumatic actuator is
to be used on a straight-way valve with a perforated plug with the fluid moving in the closing
direction, a higher closing force will be needed. This is to prevent vibration as the plug
approaches the closed position.
If the forces generated by the actuators are too low, arrangements should be made to
relieve the pressure as far as this is compatible with service conditions.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed
these requirements, e.g. aggressive or abrasive media, the operator should
state the higher requirements when ordering.
- Valves made from grey cast iron are not authorised for use in systems subject
to TRD 110.

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Operating and installation instructions
Straight through control valves - STEVI®422 / 462
4.3 Diagram
4.3.1 Plug design
Fig. 1: Series 422 Fig. 2: Series 462
Fig. 3: Perforated plug
(Pressure balanced plug
refer to Fig. 11)

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Operating and installation instructions
Straight through control valves - STEVI®422 / 462
4.4 Technical data
for
- Principal dimensions
- Pressure-temperature-ratings, etc. refer to data sheet.
4.5 Marking
5.0 Installation
5.1 General notes on installation
The following items should be taken into account besides the general principles governing
installation work:
- Planners / construction companies or operators are responsible for positioning and
installing products.
- The valves are designed for application, not influenced from weather.
- For application outside or in adverse environments like corrosion-promoting conditions (sea water,
chemical vapours, etc.), special constructions or protective measures are recommended.
Fig. 4
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Connecting bolts for pipe flanges should be mounted preferably from the
counter flange side (hexagon nuts from the valve side).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
Refer to data sheet for weights.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Strainers or filters should be installed before the valves.
CE-marking
Serial-No.
Year of manufacture clear speech
Notified body
Manufacturer
Nominal pressure
Nominal diameter
Type-Number
(1. and 2. position)
Stem sealing
Material of
internal parts
Kvs-value
Flow
Plug
design
characteristic
Customer-specific
information

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Operating and installation instructions
Straight through control valves - STEVI®422 / 462
5.2 Requirements at the place of installation
The place of installation should be easily accessible and provide ample space for
maintenance and removing the actuator. Stop valves should be installed before and after
the control valve to enable maintenance working without draining the piping system. The
valve should preferably installed vertically with the actuator at the top. Inclined or horizontal
installation without supports is permissible only with light actuators.
For this installation position, the two distance columns (or joke) have to be above each
other in the vertical plane.
Permissible servo weights for valves with unsupported horizontal stems:
55 kg for DN200-250
The pipes must be lagged to protect the actuators from excessive heat. Sufficient space
must be left for the maintenance of the stem packing.
To ensure that the servo controlled valves function correctly, the pipe run should be straight
for at least 2 x n.d. upstream and 6 x n.d. downstream of the valve.
5.3 Installation instructions concerning actuators
Normally, servo controlled valves are supplied complete with actuator fitted.
It is not permitted to mantle / dismantle actuators with valves operating and service
conditions (temperature and pressure). The actuators must be assemble as describe in the
operating instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seating at closing pressure.
When retrofitting actuators, the maximum permissible force for valve actuation must be
taken into account:
Fig. 5: Pipeline vertically Fig. 6: Pipeline horizontally
ATTENTION !
Care must be taken with the bellow type valves when actuators are mounted or
removed. (Hold the valve-stem against turning with an open-end wrench!)
Fig. 422 Fig. 462
59kN for DN 200-250 37kN for DN 200-250

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Operating and installation instructions
Straight through control valves - STEVI®422 / 462
6.0 Putting the valve into operation
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or
modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.

Page 8 Rev. 0040307000 0410
Operating and installation instructions
Straight through control valves - STEVI®422 / 462
7.0 Care and maintenance
Maintenance and maintenance intervals have to be defined by the operator according to
the service conditions.
7.1 Replacement of stem sealings
7.1.1 Stuffing box packing design
The stuffing box packing (pos. 17) requires maintenance.
If leaks develop, immediately tighten the hexagon nuts (pos. 22) gradually until the packing
(pos. 17) stops leaking.
The service life of stuffing box packings (pos. 17) can be increased by checking regularly
leakage.
If leaks can no longer be stopped by tightening the nuts (pos. 22), a new packing ring (pos.
17) must be inserted into the gland.
Replacement of stuffing box packing:
- Remove actuator. (Refer to operating instructions for actuator!)
- Insert the new packing ring (pos. 17) as shown in Fig. 8
Damaged stems must also be replaced (refer to item 7.2 for instructions) since a new ring
pack will soon start leaking again if the stem is damaged.
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
Fig. 7: Stuffing box packing
Fig. 8: split packing ring
If a split packing ring is used, cut with
a chamfer as shown in Fig. 8.

Rev. 0040307000 0410 Page 9
Operating and installation instructions
Straight through control valves - STEVI®422 / 462
7.1.2 Bellows seal design
If the stem leaks, the bellows seal is defective. The leak can initially be stopped by
tightening the sleeve nut (pos. 25.16).
Stem and bellows (pos. 25.3) can only be replaced together.
Replacement of bellows seal:
- Remove actuator.
(Refer to operating instructions for actuator!)
- Loose nuts (pos. 7).
- Detach bellows assembly (pos. 25) incl. stuffing box
housing (pos. 12).
- Slacken screw joint (pos. 25.17) resp. sleeve nut (pos.
25.16) by about one turn.
- Loose nuts (pos. 29).
- Lift bellows housing (pos. 22.1).
- Drive spring pin (pos. 16) out with a drift.
- Unscrew stem adapter (pos. 15) with plug (pos. 8).
- Loose nuts (pos. 25.8).
- Detach mounting bonnet (pos. 25.2) or stuffing box
housing (pos. 25.2).
- Extract stem-/bellows unit (pos. 25.3) from the bellows
housing (pos. 25.1).
- Bolt new parts together and drill them.
- Replace 2 gaskets (pos. 25.6) and 1 gasket (pos. 5).
- Assemble in reverse order.
- Secure with nuts (pos. 7, 25.8 and 29) and tighten them
crosswise.
(For tightening torques refer to item 7.3.1)
- Tighten the screw joint (pos. 22.17) resp. the sleeve nut (pos. 22.16) gradually up to
tightness of the stuffing box packing (pos. 22.10).
ATTENTION !
Refer to item 10.0 and 11.0 before
dismantling the valve.
ATTENTION !
- Ensure that the torsion lock is
correctly positioned when inserting
new stem/bellows unit. Introduce the
grooved pin (pos. 25.9) into the
torsion lock groove.
Make sure it runs smoothly! Fig. 9: Series 462

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Operating and installation instructions
Straight through control valves - STEVI®422 / 462
7.2 Replacement of internal parts
7.2.1 Replacement of plug and stem
- Remove actuator.
(Refer to operating instructions for actuator!)
Series 422
- Loose nuts (pos. 7).
- Detach stuffing box housing (pos. 12).
- Slacken nuts (pos. 22) by 2 or 3 turns.
- Extract plug (pos. 8) and stem (pos. 10).
- Drive pin (pos. 9) out with a drift.
- Unscrew plug (pos. 3).
- Bolt new parts together and drill them.
- Replace gasket (pos. 5).
- Assemble in reverse order.
- Secure with nuts (pos. 7) and tighten them
crosswise.
(For tightening torques refer to item 7.3.1)
Series 422
For replacement of plug and stem with bellows sealing (Series 462) refer to item 7.1.2.
7.2.2 Replacement of seals of pressure balanced plugs
- Remove actuator.
(Refer to operating instructions for actuator!)
- Remove plug as described in item 7.2.1.
- Prise worn piston seal (pos. 32) out of groove in
plug with suitable tool (e.g. screwdriver).
- Insert new piston seal (pos. 32), taking care that it
is in the correct position (refer to Fig. 11).
- Replace guide ring (pos. 31).
- Clean sliding surface of guide bush (pos. 30);
smooth with fine abrasive if necessary.
- Replace 2 gaskets (pos. 5).
- Assemble in reverse order.
- Secure with nuts (pos. 10) and tighten them
crosswise.
(For tightening torques refer to item 7.3.1)
ATTENTION !
Refer to item 10.0 and 11.0 before
dismantling the valve.
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
Fig. 10: Series 422
Fig. 11: Pressure balanced plug

Rev. 0040307000 0410 Page 11
Operating and installation instructions
Straight through control valves - STEVI®422 / 462
7.2.3 Replacement of the seat ring
- Remove actuator. (Refer to operating instructions for actuator!)
- Loose nuts (pos. 11).
- Detach valve top part.
- Unscrew seat ring (pos. 2) with a special wrench (can be obtained from the manufacturer).
- Clean thread and sealing taper in body (pos. 1) and apply with suitable lubricant.
- Replace respectively recondition seat ring (pos. 2).
- Install seat ring (pos. 2). (For tightening torques refer to item 7.3.2.)
- Replace gasket (pos. 5).
- Assemble valve top part.
- Secure with nuts (pos. 11) and tighten them crosswise.
(For tightening torques refer to item 7.3.1.)
7.3 Tightening torques
7.3.1 Tightening torques for nuts
7.3.2 Tightening torques for seat rings
! Refer to operating instructions for actuator concerned for
installing actuators !
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
If malfunctions cannot be eliminate with the help of the following table
“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
M 16 = 80 - 120 Nm
M 20 = 150 - 200 Nm
M 24 = 340 - 410 Nm
DN 200 = 3300 Nm
DN 250 = 3850 Nm
-
ATTENTION !
It is essential that the safety regulations are observed when identifying faults.

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Operating and installation instructions
Straight through control valves - STEVI®422 / 462
9.0 Troubleshooting table
ATTENTION !
- read item 10.0 and 11.0 prior to dismantling and repair work!
- read item 6.0 before restarting the plant !
Fault Possible cause Corrective measures
No flow Valve closed Open valve (using actuator)
Flange covers not removed Remove flange covers
Little flow Valve not sufficiently open Open valve (using actuator)
Dirt sieve clogged Clean / replace sieve
Piping system clogged Check piping system
Kvs value of valve unsuitable Fit valve with higher Kvs value
Valve stem moves in jerks. Stuffing box sealing too tight
(for valves with graphite packings)
Slacken stuffing box gland or hex. nut
(pos. 22) slightly,
valve must nor start leaking!
Valve plug slightly seized owing to
solid dirt particles
Clean internals, smooth rough spots
Valve stem or plug cannot be
moved.
Seating and plug clogged with dirt;
especially with V-port and perforated
plugs
Clean seating and plug with suitable
solvent
Valve plug seized in seating or guide
owing to deposits or dirt in medium
Replace plug and seating; use parts
made from different material if neces-
sary
Valve stem leaking. Stuffing box gland too slack in valves
with stuffing box packings
Tighten or repack stuffing box gland or
nuts (pos. 22); refer to item 7.1.1
Bellows defective in valves with bellow
seal
Replace bellows unit; refer to item
7.1.2
Leakage too high when
valve is closed.
Sealing surfaces of plug eroded or
worn
Replace plug - refer to item v
Sealing edge of seating damages or
worn
Replace seating; refer to item 7.2.1,
fit dirt sieve if necessary
Piston sealing ring worn
(pressure-relieved valves)
Replace sealing ring
Seating and/or plug dirty. Clean internals of valve, fit dirt sieve if
necessary
Pneumatic actuator not completely
vented; spring force not fully effective
Vent actuator air chamber completely
Actuator not powerful enough Install more powerful actuator;
check service data

Rev. 0040307000 0410 Page 13
Operating and installation instructions
Straight through control valves - STEVI®422 / 462
10.0 Dismantling the valve or the top part
11.0 Warranty / Guarantee
The extent and period of warranty cover are specified in the "Standard Terms and
Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of
departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under
conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist
appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.
Technology for the Future.
GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone [phone] Telefax ([phone] or 159
Internet: http://www.ari-armaturen.com E-mail: [email protected]
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic
media.

Page 14 Rev. 0040307000 0410
Operating and installation instructions
Straight through control valves - STEVI®422 / 462
12.0 EC declaration of conformity
ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, D-33756 Schloß Holte-Stukenbrock
EC declaration of conformity
as defined by
the Pressure Equipment Directive 97/23/EC
Herewith we declare,
that according to the above mentioned Pressure Equipment Directive (PED) the below listed prod-
ucts comply and have been approved according to table 6, annex II, module H or module H1 (with
safety function: also EC type test according to module B+D) through Lloyd´s Register Quality Assur-
ance GmbH (BS-No. 0525), Am Sandtorkai 41, D-20457 Hamburg.
Schloß Holte-Stukenbrock, 11.01.2010
Module H, Certificate-No: 50003/1
Straight through stop and control valves
Type 405, 460, 440, 441, 445, 446, 470, 471, 422, 462, 425, 426, 480
Applied standard:
DIN EN 60534 part 1
VDI/VDE 3844 sheet 1
DIN 3840
AD 2000 leaflet A4
- Cast iron with spheroidal graphite
- Cast steel
- Forged steel
Module H1, Certificate-No: 50003/2
Straight through control valves with safety function
Type 440, 441
Applied standard:
DIN EN 60534 part 1
VDI/VDE 3844 sheet 1
DIN 3840
AD 2000 leaflet A4
- Cast iron with spheroidal graphite
- Cast steel
- Forged steel
(Brechmann, Managing director)
...................................................

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Straight through control valves - STEVI®422 / 462

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Operating and installation instructions
Straight through control valves - STEVI®422 / 462