C.M.O FL Series Instructions for use


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 1
17/09/2014
INSTRUCTIONS AND
MAINTENANCE MANUAL
SERIES: FL
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
RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 2
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THEFLPENSTOCKCOMPLIESWITHTHEFOLLOWING:
MachineryDirective:DIR2006/42/EC(MACHINERY).
PressureEquipmentDirective:DIR97/23/EC(PED)ART.3,P.3.
PotentiallyExplosiveAtmospheresDirective(optional):DIR94/9/EC(ATEX)CAT.3ZONE2and22GD.
TheFLpenstockcomplieswiththeDirectiveonEquipmentandProtectiveSystemsforPotentially
ExplosiveAtmospheres.Inthesecasesthelogowillappearintheidentificationlabel.Thislabelshows
theexactclassificationofthezoneinwhichthepenstockcanbeused.Theuserisresponsibleforitsuse
inanyotherzone.
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HANDLING
Payspecialattentiontothefollowingpointswhenhandlingtheequipment:
SAFETYWARNING:Beforehandlingthepenstock,checkthatthecranetobeusediscapableof
bearingitsweight.
Donotliftthepenstockorholditbythearm.Liftingthepenstockbythearmcanleadtooperating
problemsasitisnotdesignedtowithstandthepenstock’sweight.
Whenliftingthepenstock,takecarenottodamagethesealingjoints,asthismayleadtoleakage
duringtheoperationofthepenstock.
Topreventdamage,especiallytotheanticorrosiveprotection,itisrecommendedtousesoftstrapsto
lifttheCMOretentionpenstocks.Thesestrapsmustbesecuredinthetoppartofthebody,usingthe
holesfittedtosecurethepenstockandwiththehelpofshackles.
Iftheequipmentispackedinwoodenboxes,thesemustbeprovidedwithclearlymarkedholding
areaswheretheslingswillbeplacedwhensecuringthem.Intheeventoftwoormorepenstocks
beingpackedtogether,separationandsecuringelementsmustbeprovidedbetweenthemtoprevent
possiblemovements,knocksandfrictionduringtransport.Whenstoringtwoormorepenstocksinthe
sameboxyoumustensuretheyarecorrectlysupportedtopreventdeformations.Inthecaseof
dispatchesbyseawerecommendtheuseofvacuumbagsinsidetheboxestoprotecttheequipment
fromcontactwithseawater.
Payspecialattentiontomaintainingthecorrectlevellingofthepenstocksduringloadingand
unloadingaswellasduringtransporttopreventdeformationsintheequipment.Forthispurposewe
recommendtheuseofmountsortrestles.
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INSTALLATION
Inordertoavoidpersonalinjuryandothertypesofdamage(tothefacilities,thepenstock,etc.),we
recommendfollowingtheseinstructions:
Thestaffresponsiblefortheinstallationoroperationoftheequipmentmustbequalifiedandtrained.
UsesuitablePersonalProtectiveEquipment(PPE)(gloves,safetyboots,goggles,etc).
Shutoffalllineswhichaffectthepenstockandputupawarningsigntoinformabouttheworkbeing
carriedout.
Completelyisolatethepenstockfromthewholeprocess.Emptytheconduitorline.
Drainallthefluidfromtheconduitorlinethroughthepenstock.
Usenon‐electricalhandtoolsduringinstallationandmaintenance,inaccordancewithEN13463‐1(15).
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ASSEMBLY


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 3
Beforeinstallation,inspectthepenstocktoensurenodamagehasoccurredduringtransportorstorage.
Ensurethatthepenstocksealingareaisclean,andcheckthattheflapswivelswithoutanydifficultyon
thelugsofthebody.
‐Ifthepenstockistobeinstalledonaflange,inspectthepipeandtheinstallationflange,ensuring
theyarecleanandtheflangeboreholesstandardcoincideswiththepenstockboreholesstandard.
‐Ifthepenstockistobewall‐mounted,inspectthewalltoensureitiscleanandflat.
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ASPECTSTOBECONSIDEREDDURINGASSEMBLY
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Whenmountingthepenstock,itisvitallyimportantthattheturning
pointoftheflap(bodylugs)are,whateverthetypeofattachmentor
typeofpenstock,intheupperpartofthepenstock,inordertoensure
thattheforceofgravityclosestheflap.
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TheFLpenstockisunidirectional,andisalwaysinstalledinsuchamannerthatthefluidwhichcomes
fromaconduitorlinefirstpassesthroughthebodyofthepenstockandthenpushesontheflap.
Physicallyitcannotbemountedinanyotherway,withthesingleassemblyoptionthereforeguaranteed
tobethecorrectone.
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Turningpoint
ConduitFlap
Body
fig.4


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 4
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Sinceeachofthesepenstocksisdesignedtocomplywiththeoperatingconditionsofeachinstallation,
thereareseveraloptionstoinstalltheFLpenstock.
Themostnotablearethetwomostcommonoptions:oneisboltedtoanexistingflangeandtheotheris
mountedonawallandsecuredwithanchors.
Eachoftheseoptionsisdescribedindetailbelow.
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Tomountthepenstockboltedtoaflange(fig.5),thesestepsshouldbefollowed:
‐Positionthepenstocksupportedontheflangeoftheinstallation,checkingthattheboreholes
coincidewiththepenstockbodyboreholes.
‐Afterensuringthattheboreholecoincides,removethepenstockfromtheflange.
‐Cleanthefaceoftheflangewherethepenstockistobemounted.
‐Positionasealtightjointontheflange,inordertoensuretherearenoleakagestotheoutside
wheretheflangeandthepenstockcometogether.Thesealtobeinstalledwillbeselectedinline
withtheworkingconditionsinsidetheline(temperature,pressure,typeoffluid,etc).
‐Checkthatthepenstock,theinsideofthebodyand,aboveall,thesealingareaareclean.
‐Cleanthefaceofthebodysupportedontheflange.
‐Positionthepenstocksupportedontheflange.
‐Positionthepenstocksotheturningpointoftheflap(bodylugs)remainsintheupperpartofthe
installation.
‐Ensurethatthesealtightjointbetweentheflangeandthepenstockiscorrectlypositioned.
‐Aftercorrectlypositioningboththesealtightjointandthepenstock,fastenthejoiningbolts.
Theseboltsandnutsmustbesuitablefortheoperatingconditions.
‐Oncealltheboltsareinplace,tightencrosswisewithalowinitialtorque.
‐Finally,completethefinaltorqueinaccordancewiththeapplicablestandard.
‐Aftercarryingoutallthesestepsandbeforefinishingtheassemblyprocess,checkthattheflap
swivelswithoutanydifficultyontheturningpoint.
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Installationpiping
fig.5
Turningpoint
Body
FlangeSealtightjoint


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 5


Inordertoinstallthepenstockmountedonawallandsecuredusingchemicalorexpansion
anchors(fig.6),thesestepsshouldbefollowed:
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‐Checkthatthewalliscompletelyflat,otherwisethebodymaybecomedeformedandproduce
irreparabledamagewhentighteningtheanchoring.
‐Placethepenstockonthewall,ensuringthepassageofthepenstockcoincideswiththewall
orifice.
‐Usingtheholesofthebodyofthepenstockasaguide,maketheboreholesnecessaryinthewall
forthechemicalorexpansionanchors.
‐Removethepenstockfromthewallwhereitistobelocatedandapplysealingpastesuchas
SIKAFLEX‐11FCorsimilarinordertopreventleakagesbetweenthebodyandthewall.
‐Returnthepenstocktoitslocationabovethesealingpasteandintroducethechemicalor
expansionanchors.Theseanchoringsshouldalsobesuitablefortheoperatingconditionsand
theirmeasurementsinaccordancewiththeapprovedplans.
‐Onceallthechemicalorexpansionanchorsareinplace,carryouttheinitialtighteningwithlow
torqueandcrosswise.
‐Oncealltheanchorsareslightlytightened,continuewithfinaltorqueincrosswisemode.Usea
flatruletocarryoutthistightening.Supporttheruleonthebodyandbegintotightenthe
anchors,andstoptighteningassoonasthebodybeginstoloseshape.Usetheflatruleto
preventexcessivetightening.
‐Thefinaltorquemustbecorrectwiththeapplicablestandard.
‐Aftercarryingoutallthesestepsandbeforefinishingtheassemblyprocess,checkthattheflap
swivelswithoutanydifficultyontheturningpoint.
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fig.6
Body
SIKAFLEX‐11FCcord
Wall


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 6

Thesearethemostcommonattachmentoptions,although,asmentionedonotheroccasions
throughoutthismanual,thedesignoftheseFLpenstocksisdefinedinaccordancewiththecustomer's
requirementsineachspecificproject.Inconsequence,ifyourequireadifferentattachmentoption,
contactCMO'stechnicalsalesdepartmentforabespokeprojectinlinewithyourneeds.

Thepenstockcanbeinstalledsecuredtoawallwithanchorsorboltedtoaflange;inallcasesthe
followingmustbetakenintoaccount:
Theequipmentmustbefirmlysecuredintheinstallation.
Asregardsscaffolding,laddersandotherauxiliaryelementstobeusedduringassembly,followthe
safetyrecommendationsindicatedinthisdossier.
Oncetheequipmenthasbeenassembled,makesurethattherearenoelementswhichcaninterfere
withtheflapmovement.
Theassemblyoftheequipmentmustbecoordinatedwiththesite’scontrolandsafetystaffandno
modificationsarepermittedintheequipment’sexternalindicationelements(limitswitches,
positioners,etc.).

ASSEMBLYPOSITIONS

Thistypeofpenstockscanbemountedonaverticalflange(fig.7)locatedattheendofahorizontal
pipe,ormountedonaverticalwall(fig.8)inwhichthereisasquare,roundorrectangularorifice.
Whateverthetypeofinstallation,thepositionofthepenstockisvertical.
ThisFLpenstockisaretentionpenstockwhichisdesignedforuseasendofline,meaningitisalways
assembledattheendofafacility.
Thesearethemostcommonattachmentoptions,although,asmentionedonotheroccasions
throughoutthismanual,thedesignoftheseFLpenstocksisdefinedinaccordancewiththecustomer's
requirementsineachspecificproject.Inconsequence,ifyourequireadifferentattachmentoption,
contactCMO'stechnicalsalesdepartmentforabespoke
projectinlinewithyourneeds.





















fig.8fig.7


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 7

Oncethepenstockhasbeeninstalled,checkthatallbolts,nutsandanchoringshavebeencorrectly
tightened.
AllCMOpenstocksaretestedatitsfacilities,althoughthepenstockmayhavebecomedamagedduring
transportorassembly.Onceinstalled,itisveryimportanttocheckthatthepenstockworkscorrectly,
makingsurethattheflapswivelsonitsturningpointwithoutanydifficulty,thatitsitsperfectlyonthe
sealwhenthepenstockisclosed,etc.

IfthepenstockhaselectricalaccessoriesoryouareinanATEXzone,earthconnectionsmustbemade
oncethepenstockisinplacebutbeforeoperatingit.
IfyouareinanATEXzone,checkthecontinuitybetweenthedifferentelementsofthepenstock(EN
12266‐2,annexB,pointsB.2.2.2.andB.2.3.1.).Checktheearthconnectionofthepenstock.



TheseFLpenstocksdonothaveanactuatorsystem,butratherareautomatic.Itisthefluidwhichopens
orclosesthepenstock.
Whenthefluidcomesfrominsidethepipetotheoutside,itpushesontheflapwhichswivelsonthe
turningpointandopensthepenstock.Thedegreeofopeningwillbeproportionaltothepressureofthe
fluid:thegreaterthepressure,themorethepenstockwillopen(fig.9).
Whenthefluidcomesfromtheextractortowardsthepiping,itpushestheflapagainstthebody,
pressingontheelastomersealinordertoachievesealtightintegrity.Thegreaterthefluidpressure,the
moretheflappressesagainstthebody,thusensuringsealtightintegrityatalltimes(fig.10).



ACTUATOR
fig.9fig.10
GateopenGateclosed


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 8



CMOwillnotbeliableifthepenstockssufferanydamageduetoimproperhandlingorwithoutproper
authorisation.ThepenstocksmustnotbemodifiedexceptunderexpressauthorisationfromCMO.
Thefollowinginstructionsshouldbefollowedinordertoavoidpersonalinjuryormaterialdamagewhen
carryingoutmaintenancetasks:

Thestaffresponsibleforthemaintenanceoroperationoftheequipmentmustbequalifiedand
trained.
UsesuitablePersonalProtectiveEquipment(PPE)(gloves,safetyboots,goggles,etc.).
Shutoffalllineswhichaffectthepenstockandputupawarningsigntoinformaboutthework
beingcarriedout.
Completelyisolatethepenstockfromthewholeprocess.Emptytheconduitorline.
Drainallthefluidfromtheconduitorlinethroughthepenstock.
Usenon‐electricalhandtoolsduringmaintenance,inaccordancewithEN13463‐1(15).

Theonlymaintenancerequiredinthistypeofpenstocksistochangetherubbersealingjoint.Itis
recommendedtocheckthesealregularlyevery6months,althoughtheworkinglifeofthesealswill
dependontheoperatingconditionsofthepenstock,suchas:pressure,temperature,numberof
operations,typeoffluidandothers.Thesejointsareboltedwithflanges;boththeflangesandthebolts
aremadeofstainlesssteel,andcanbereusedseveraltimes.
InanATEXzone,electrostaticchargesmaybepresentinsidethepenstock,whichcancauseariskof
explosion.Theuserwillberesponsibleforcarryingoutappropriateactionsinordertominimisethe
risks.
ThemaintenancestaffmustbeinformedabouttherisksofexplosionandATEXtrainingis
recommended.
Regularcleaningofthepenstocktopreventaccumulationofdust.
Avoidre‐paintingtheproductssupplied.

IMPORTANTSAFETYASPECTS

Inordertoworkinidealsafetyconditions,boththeelectricalandmagneticelementsmustbeidle.
Theelectricalcontrolcabinetsmustalsobeoutofservice.Themaintenancestaffmustbeuptodate
withthesafetyregulationsandworkcanonlystartunderordersfromthesite’ssafetystaff.
Thesafetyareasmustbeclearlymarked,avoidingtheuseofauxiliaryequipment(ladders,
scaffolding,etc.)inmovingparts,inordertoproducethemovementoftheflap.
Beforestartingmaintenanceworkonthepenstock,securetheflapinopenpositionusingmorethan
onesystem,thusensuringitwillstayinplaceintheeventoffailure.

Takingintoaccounttherecommendationsindicated,themaintenanceoperationscarriedoutinthis
typeofequipmentareshownbelow:






MAINTENANCE


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 9
REPLACINGTHESEALINGJOINT

1. Makesurethereisabsolutelynopressureorfluidinthefacility.
2. Placetheflap(2)incompletelyopenposition.
3. Securetheflap(2)inthispositionusingmorethanonesystem.
4. Unscrewandremovethescrews(8)fromtheflange(4)andtheseal(3).
5. Removetheflangeseal(4)andfinallythedeterioratedseal(3).
6. Cleanthesealhousing(3).
7. Fitanewsealingjoint(3)withthesamedimensionsastheoldone.
8. Returntheflange(4),checkingthatitiscorrectlyfittedandtheseal(3)hasnotbeendamagedin
theprocess.
9. Removethesystemstosecuretheflap(2)inopenposition,andcarefullypositionitinclosed
position.
10. Beforestartinguptheinstallation,checkthattheflap(2)swivelsfreelyonitsturningpoint;also
checkthattheflap(2)sitsperfectlyontheclosingseal(3)whenthepenstockisclosed.
Note:Thenumbersinbracketsrefertofig.11.






















Note:Duringtheassemblyofthenewsealingjoint,itisrecommendedtoapplypetroleumjellytothe
jointtofacilitatetheassemblyprocessandthecorrectoperationofthepenstock(donotuseoilor
grease);table1belowshowsdetailsofthepetroleumjellyusedbyCMO:









PETROLEUMJELLY
SayboltColour  ASTMD‐156 15
Meltingpoint(ºC) ASTMD‐12760
Viscosityat100ºC ASTMD‐4455
Penetration25ºCmm./10ASTMD‐937165
Siliconecontent None
PharmacopeaBP OK
table1
fig.11


RETENTION PENSTOCK FL SERIES 
C.M.O.
AmateguiAldea142,20400Txarama‐Tolosa(SPAIN) MAN‐FL.ES00
Tel.National:902.40.80.50Fax:902.40.80.51/Tel.International:34.943.67.33.99Fax:34.943.67.24.40
[email protected]http://www.cmo.es page 10
LUBRICATION
Theonlypointofthepenstockwhichrequireslubricationistheturningpoint,whichwerecommend
greasingabouttwiceayear.
AfterthemaintenanceandinanATEXzone,youmustchecktheelectricalcontinuitybetweenthepipe
andtherestofthevalve’scomponents,suchasthebody,flap,stem,etc.StandardEN12266‐2,AnnexB,
pointsB.2.2.2.andB.2.3.1.).

STORAGE

Toensurethepenstockisinoptimumconditionsofuseafterlongperiodsofstorage,werecommend
storingitinawell‐ventilatedplaceattemperaturesbelow30ºC.
Itisnotadvisable,but,ifstoredoutside,thepenstockmustbecoveredtoprotectitfromheatand
directsunlight,withgoodventilationtopreventhumidity.Thefollowingaspectsmustbeconsideredfor
storagepurposes:
Thestorageplacemustbedryandundercover.
Itisnotrecommendedtostoretheequipmentoutdoorswithdirectexposuretoadverseweather
conditions,suchasrain,wind,etc.Evenwhentheequipmentispackaged.
Thisrecommendationisevenmoreimportantinareaswithhighhumidityandsalineenvironments.
Windcancarrydustandparticleswhichcancomeintocontactwiththepenstock’smovingpartsand
thiscanleadtooperatingdifficulties.
Theequipmentmustbestoredonaflatsurfacetoavoidlossofshape.
Iftheequipmentisstoredwithoutsuitablepackagingitisimportanttokeepthepenstock’smoving
partsgreased,forthisreasonitisrecommendedtocarryoutregularchecksandlubrication.
Likewise,ifthereareanymachinedsurfaceswithoutsurfaceprotectionitisimportantforsomeform
ofprotectiontobeappliedtopreventtheappearanceofcorrosion.
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COMPONENTSLIST
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table2
POSDESCRIPTION
1BODY
2FLAP
3SEAL
4FLANGESEAL
5ARM
6SHAFT
7 BUSHING
8SCREWSANDBOLTS
fig.12