Comeval Uniwat vf791 series Installation guide

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES, UNIWAT® VF791 - Ed.20/07

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

INSTALLATION, OPERATING

AND MAINTENANCE MANUAL

DOUBLE ECCENTRIC BUTTERFLY VALVES

1. GENERAL INFORMATION ON THE MANUAL .............2

2. NOTES ON POSSIBLE DANGERS................................2

2.1 Signicance of symbols .............................................2

2.2 Explanatory notes on safety information.....................2

3. PRESERVATION, STORAGE, HANDLING AND

TRANSPORT ......................................................................2

4. DESCRIPTION................................................................2

4.1 General Description / Operating principles .................2

4.2 Area of Application......................................................2

4.3 Technical data - remarks ............................................3

4.4 Marking/nameplate .....................................................3

4.5 CE marking. Intended use acc. to PED ......................3

5. INSTALLATION ..............................................................3

5.1 General remarks on installation ..................................3

5.2 Assembling additional modules ..................................4

5.3 Requirements at the place of installation....................4

6. COMMISSIONING & OPERATION.................................4

7. CARE AND MAINTENANCE..........................................5

8. TROUBLESHOOTING....................................................6

9. TROUBLESHOOTING TABLE.......................................6

10. DISMANTLING THE VALVE ........................................7

11. GOODS RETURN & DISPOSAL..................................7

12. WARRANTY / GUARANTEE........................................7

13. PARTS LIST..................................................................8

14. ANNEXES.....................................................................8

14.1 Declaration of Conformity .........................................8

14.2 Data Sheet................................................................8

Contents

Series UNIWAT® VF791

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES, UNIWAT® VF791 - Ed.20/07

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

1. GENERAL INFORMATION ON THE MANUAL

- This Manual provides information on safely using the product, being binding for preservation, storage, handling, transport,

installation, commissioning, operation, maintenance, repair and disposal, and must be thoroughly observed at any step.

- Please contact the supplier or the manufacturer in case of issues which cannot be solved by reference to this Manual.

- Any deviation from this Manual and sound engineering practice or modication on the product shall be notied to manu-

facturer for advice or approval.

- In addition, regional safety requirements must be always applied and observed at any step.

- All the work related to the product must be carried out, supervised and inspected by specialist personnel. It is the owner’s

responsibility to dene areas of responsibility and competence and to ensure the proper monitoring.

- This Manual is in accordance with Directive 2014/68/EU on Pressure Equipment (PED) and Machinery Directive 2006/42/EC.

- For ATEX applications, please refer to ATEX Specic instructions.

- The manufacturer reserves the right to make technical modications at any time.

2. NOTES ON POSSIBLE DANGERS

2.1 Signicance of symbols

ATTENTION!

. . . Warning of general danger.

2.2 Explanatory notes on safety information

In this Manual dangers, risks and items of safety information are highlighted to attract special attention.

Information marked with the symbol above describes practices, which if fail to comply with, 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.

The rest of information not specically emphasized in this Manual, along with Data Sheet and product marking, must also

be observed and complied with for safely using the product.

3. PRESERVATION, STORAGE, HANDLING AND TRANSPORT

ATTENTION!

- Use proper packing for transportation.

- Keep storage protection before installation.

- Keep the valves in a slightly open position and with the sealing unstressed.

- Valves are protected with epoxy paint protection. In order to prevent damage, corrosion or rust on the surface, avoid ex-

treme temperatures (keep at 5ºC to 50ºC), avoid high environmental humidity or corrosive environment. Keep the valves

away from direct sunlight, dust, ames or rain. Protect rubbers also against UV light. Do not pile up excessive weight. In

case of severe bumping inspect the material for any damage and replace if necessary.

4. DESCRIPTION

4.1 General Description / Operating principles

Buttery valves VF791 are quarter turn rotary valves, with preferred ow direction. The closure is carried out by turning the

handwheel or actuator clockwise, that rotates a stem 90º in conjunction with the disc with elastomeric seal, placed in the

interior of the valve body. See visual position indicator of gear or actuator to check position of the valve. The rst o󰀨set mo-

ves back the disc rotation axis from the disc sealing surfaces. This allows having a continuous sealing surface on the disc.

The second o󰀨set moves away the disc rotation axis from the center-line of the valve body which reduces the interference

at closing. Consult the manufacturer if a change of the actuation device is required.

Valve diagram with parts can be seen at the last page of the Manual.

Page 2

- Protect against external force (impacts, vibrations, etc.).

- Allow only skilled personnel; suitable handling and lifting equipment must be

used. See Data Sheet for weights or consult manufacturer.

- Always use suitable protection equipment, and minimize the use of human

body force at any step to avoid injuries.

- During handling make sure that operating device is well attached to the valve

or removed to avoid danger of detachment. Product parts such as hand levers,

handwheels or actuators must not be used to take up external forces that they

are not designed for: e.g. do not use them as climbing aids, or as connecting points for lifting gear, etc. Valves have

lugs to ease their lifting.

- There is a risk of body member (hand, nger, arm…) crushed against any other solid element (wall, pipe, oor, etc.)

during handling. Take this into account and handle with care.

- There is a risk of body member trapped between valve body and disc during operation of the valve. Make sure no

operation / supply to actuator disconnected if access to the interior of the valve.

- There is a risk of body member injury in case there is any exposed moving part between valve and actuator (special

arrangements). Take appropriate measures and set warning notes when required.

- Check correct position of nameplate and handle with care to avoid personnel cuttings.

Lug

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES, UNIWAT® VF791 - Ed.20/07

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

4.2 Area of Application

The valves are used to stop the ow, and they have also a certain throttling capacity by placing the disc in intermediate

positions. They are mainly used in water systems (distribution, watering, water treatment plants, etc.).

4.3 Technical data - remarks

For data such as main features, duties/limits of use, dimensions, etc. refer to also Data Sheet.

4.4 Marking/nameplate

Nameplate description of the valve:

4.5 CE marking. Intended use acc. to PED

5. INSTALLATION

5.1 General remarks on installation

The following points should be taken into account in addition to the general principles governing installation work:

ATTENTION!

- Before installation, make sure previous chapters are thoroughly followed.

- Ensure safe access and working conditions for proper performance.

- Only operate the valve while observing all the safety measures.

- Remove ange covers or any other remaining packing/storage protection if present.

- Lay pipelines such that damaging transverse, bending and torsional forces are avoided.

- Protect valves from dirt during construction work. The interior of the valve and the pipeline must be free of

foreign particles.

- Protect the valve soft parts from heating caused by welding works at the plant during commissioning.

- Avoid mechanical damage to the seat area and disc.

- Mount the valve in preferred direction, with the “Flow Arrow” marking pointing to the lower pressure side so that

the shaft side of the disc will be upstream when the valve is in closed position.

- Recommended installation orientation is with valve shaft horizontal.This will minimize any problems associated

with solid particles present in the process that otherwise could deposit in the lower bearing.

- The valve should be installed in the closed position to ensure that the laminated seal in the disc is not damaged

during installation. Particular care should be taken with those valves equipped with “Fail-open” actuators.

- If the pipe is lined, conrm that the disc does not contact the lining during the opening stroke.

Page 3

Mark Description

CE-Marking

Manufacturer logo

www.comeval.es Website of manufacturer

UNIWAT® Brand

VF791RGGE Valve code

Y.VV Manufacturing year (Y.16 = 2016)

ZZZZZ-N Batch / Serial no.

Liquids of group 2* compatible with materials of

construction, acc. to Directive 2014/68/EU, Annex II

table 9 up to category I

PS DN

100 150 200 250 300 350 400 500 600-1200

Out of scope

Neutral gases of group 2*, acc. to Directive 2014/68/EU, Annex II table 7 up to category I

PS DN

≤300 350-1200

Mark Description

Tab. Applicable tables acc. to

PED 2014/68/EU Annex II

PSmax Max. pressure

PN Nominal pressure, max.

pressure in bar

TS Min. / max. temperature

BODY Body material

DISC Disc material

(JS1030, CF8M…)

SEAL Disc sealing material

(EPDM, NBR...)

DN Nominal Diameter

* Classication of uids group 2 acc. to Directive 2014/68/EU, Article 13.

Check valve selection, material compatibility, pressure and tempe-

rature limits and other essential parameters. Ensure proper safety

devices/measures are implemented to prevent exceeding intended

use of the product. Contact the manufacturer for advice in case of

pressure tests exceeding the intended use. Refer to Data Sheet

and consult the manufacturer for further information.

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES, UNIWAT® VF791 - Ed.20/07

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

5.2 Assembling additional modules

Optional accessories (limit switches, extensions, etc.) that are supplied with valves must be tted as required for their

functions as shown in the system plan.

5.3 Requirements at the place of installation

- Aggressive environmental conditions may reduce the life span of the product. Consider special construction/protective

measures in such a case.

- Consider the interaction between the system and the equipment. Foresee elements to absorb vibrations, pipe dilata-

tions, guides, anchoring and proper support according to the weight of the components. Max. recommended velocities as

follows: PN6: 2,5 m/s; PN10: 3 m/s; PN16: 4 m/s.

- The system and operation protocol should be conceived in such a way to avoid high velocities and cavitation. Prevent

pulsing ow or water hammers, which are very harmful for valves and the rest of the components.

- Flooding of the product is not recommended.

- Allow enough space for valve installation, operation and maintenance.

- It is recommended to install a proper sized mesh strainer upstream the valve in order to protect seating surfaces from

abrasion or erosion that could lead to seat leakage.

- Planners / construction companies or the owner are responsible for positioning and installing products.

6. COMMISSIONING & OPERATION

Page 4

ATTENTION!

- When using the valve as an end seal, the employers’ liability insurance association of the gas and waterworks

species the use of a safety precaution such as a plug-in disc, blind ange, etc. With a medium jet that freely exists,

you must secure the exit area.

- When installing the valve, there is a crushing hazard between valve and pipe system. Mind the hands to avoid it.

- Make sure that counteranges are compatible with the standard of the valve anges. When matching up anges,

avoid gradients, rotation and pipe misalignment that could cause pipe and valve stress and leakage once installed.

Flanges should t smoothly. Select the proper ange face gaskets according to duty and centre them on the ange

face properly. Do not force the counteranges and do not try to tighten the bolts when a gap exists between valve

and pipe or if misalignment is observed. Add anti-seize compound on the threads. Tighten in a crosswise, moderate

and uniform manner. During start-up tighten again if leakage is noticed or replace gasket if necessary.

NOTE: Cap screws will be necessary for the top and bottom alignment tapped holes. The studs should be used in

the through-holes.

- When the valve is operated, there is a crushing hazard between the disc and the body. Ensure the valve is not

under operation in case hands are introduced inside the valve.

- ACTUATORS: If the valve requires pneumatic, electric or hydraulic actuator, separate actuator Manual shall be also

followed. To avoid unnecessary stress and risk of valve break, consider the weight and the relative position of ac-

tuator to evaluate its support. Make sure that the actuator is suitable for service particular requirements, valve adap-

tability, function needed, adequate torque for the valve, adequate speed, need for limit switches, etc. Contact our

Technical Department for advice. In case of actuator mounted, disconnect the energy supply before starting work.

ATTENTION!

- Before commissioning the valve, check the material, pressure, temperature, ow direction and other essential para-

meters. Always use the product within the scope of intended service and operating duties.

- Before commissioning, make sure previous chapters are thoroughly followed.

- Regional safety instructions should be adhered to.

- It is essential to ush the pipe system thoroughly to eliminate all the particles and impurities which could remain in

the pipes and particularly welding residue, chips, tool remains, etc. that could damage the equipment during start-up.

Ensure that during cleaning of the pipe system, any chemicals used and temperature are compatible with the valve

construction.

- Temperatures above 50ºC or below 0ºC may cause personnel injuries if valves are touched.

- Leakage of media through valve stem, between counteranges or at closing (end of pipeline) may also cause scal-

ding, health harm, pollution, re or damage to other parts of the installation depending on the media.

Use suitable protection equipment when approaching the valve, ensure that the corresponding warning signs are

displayed on the valve or surrounding area, and/or isolate the equipment in case of danger.

- Do not pressurize if the valve does not have operating device. Buttery valves are not self-locking.

- Before commissioning a new plant or restarting it after repairs or modication, always ensure that:

- All work has been completed correctly.

- The valve is in the correct position for its function.

- Safety devices/measures have been implemented.

- Valve operation, lling, warming-up and starting-up shall be gradual so as to avoid any inadmissible stress.

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES, UNIWAT® VF791 - Ed.20/07

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

- Ensure valve surface is in good condition and retouch coating protection when needed.

- Check for tightness in valve connections and stem sealing. If leakage in valve connections, retighten ange bolts cros-

swise and gradually if necessary until leakage elimination. If leakage persists, correct alignment and centring of the valve

should be checked, and surfaces should be thoroughly cleaned. If contact surfaces are irreversibly damaged replace

them. If valve leaks through the stem please contact us for advice.

- Once the valve installed, make an initial opening and closing operation to check its proper operability, without additional

tools.

- We recommend control operation in the range of 15º to 75º disc open angle only. Leaving the disc near to closed posi-

tion can lead to premature wear.

- In case of risk of media freezing inside the valve, take due measures to avoid it.

For worm gear adjustment:

7. CARE AND MAINTENANCE

The operator must dene maintenance and maintenance-intervals to meet requirements.

- Check for body, seat and connections tightness, and valve smooth operation without additional tools.

Page 5

ATTENTION!

- In the event of infrequent use, operate the valve as frequently as possible to avoid deposits of dirt and valve

blocking.

- Before disassembling the valve, note chapters 3, 10 & 12.

- When using the valve as an end seal, the employers’ liability insurance association species the use of a

safety precaution such as a plug-in disc, blind ange, Before starting maintenance work on an end valve with a

free stem end, you must mount a blind ange.

- Only carry out maintenance work in the pipework when the valve has been secured from operation (in case of

actuator, ensure it has been disconnected from the mains supply and secured from reactivation).

- When the valve is operated, there is a crushing hazard between the disc and the seat area. Ensure the valve

is not under operation in case hands are introduced inside the valve.

- Check the valve surface inside and outside and retouch coating protection when needed. If advanced corro-

sion or erosion is observed, double check service and valve features and replace the valve properly.

- A buttery valve is not self-locking, so that the operating device (lever, gear or actuator) should only be disas-

sembled after pressure release.

ATTENTION!

- Worm gear has two allen screws to adjust the end positions. The one at left side is to adjust the open position.

The one at right side is to adjust the closed position. By loosening the screw you allow further turning of the valve.

Valves delivered with assembled worm gear are already adjusted at factory. A bad adjustment of these screws

could lead to valve wrong function.

Adjusting screw

at close

Adjusting screw at open

Blocking

screw

Blocking screw

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES, UNIWAT® VF791 - Ed.20/07

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

- When being replaced, the disc sealing (18) and the o-rings should always be slightly greased.

- Replacement of the disc sealing:

Due to the double-eccentric bearing the disc sealing can be replaced without disassembly of the disc. Valves up to

DN1000 must either be completely dismantled from the pipeline or at least disconnected from the pipeline on one side to

replace the disc sealing.

• Open the disc (14) until the disc sealing (18) emerges from the body (28).

• Unfasten the retainer screws (30).

• Remove retainer (17) and disc sealing.

• Clean the disc in the sealing zone.

• Check the seat ring in the body (19) for damage or deposits.

• Insert the new disc sealing into the groove of the disc and slightly grease it.

• Insert the hexagonal screws and fasten them crosswise, moderately and uniformly, checking that the disc sealing

is not protuding excessively.

- Replacement of the O-rings in the bearings: Please consult us.

After any maintenance work please refer to chapters 5 and 6 for installation / commissioning.

Recommended Spare parts:

Use only original spare parts.

It is advisable to keep disc sealings and o-rings as spare parts. Other spare parts available are stem and disc. Type and

number of each spare part to be stored according to many factors: service level, valves quantity, etc. In many cases a

good choice is to keep complete valves as spare part.

8. 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 this Manual.

9. TROUBLESHOOTING TABLE

Technical support always available through our website www.comeval.es or your local distributor.

Page 6

ATTENTION!

- Read the complete Manual before carrying out installation and repair work.

- Read chapter 6 before recommissioning.

FAULT POSSIBLE CAUSE CORRECTING MEASURES

No ow

Not enough ow

Flange covers or protection not removed Clear valve entrances

Valve closed or almost closed Check valve position

Piping clogged Check piping system

Valve is impossible

or di󰀩cult to open

or close

Service conditions (e.g. medium, temperature)

may be outside the specied limits

Replace the valve

Consult the supplier or manufacturer

Power failure Check the power supply

Actuator fault Overhaul the actuator or replace it

Wrong direction of rotation Turn in the correct direction

(anticlockwise for opening)

Solid matter is blocking the valve disc Rinse or clean the valve

The parallel key on the stem has sheered o󰀨 Determine the cause and

replace the parallel key

Liquid has solidied between the bearings If possible, ush the bearings and the stem via

the ushing connections

Valve is leaking

at closing

The disc is not completely closed Put the disc into the closed position

Dirt trapped at closing Move the disc and ush the valve in the open

position

Mechanical stop of the worm gear at closing

not well adjusted. Adjust it according to chapter 6

The disc sealing or seat is damaged Replace the disc sealing or repair the seat

Stem leakage

Stem seals or stem damaged or worn down Revise and replace if needed

Excessive pressure or temperature,

uid not compatible Revise working conditions

Body or anges

break

Assembly bolts with counteranges has been

wrongly tightened or counteranges are

misaligned or with too much gap.

Weight not properly supported

Revise installation and tightening

according to this Manual

Working parameters beyond allowable limits Replace by suitable valve

ATTENTION!

- It is essential that the safety regulations are observed when identifying faults.

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

©COMEVAL VALVE SYSTEMS Technical Dept. Ref. IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES, UNIWAT® VF791 - Ed.20/07

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

10. DISMANTLING THE VALVE

11. GOODS RETURN & DISPOSAL

- For any returned goods, the issuing company must provide information in written on any hazards and the precaution in

case of potentially polluting or harmful residues, or any mechanical damage that could present a health, safety or environ-

mental risk, as enforced by EU Health, Safety and Environment Law, including the Safety Data Sheet of the substances

identied as potentially hazardous.

- Valves are recyclable and not expected hazard to the environment, with the exception of soft parts (PTFE and rubber

compounds) that should be disposed separately only by approved procedure, and no incineration is permitted.

12. WARRANTY / GUARANTEE

- The extent and period of warranty cover are specied in the “General Sales Terms” of COMEVAL VALVE SYSTEMS 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 conrmed application.

- No warranty claims are accepted for any damage caused as the result of incorrect handling or disregard of this Manual,

Data Sheet and relevant regulations.

- This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid

down by specications or other agreements.

- Justied 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.

- Our guarantee coverage does not cover for any commissioning, maintenance or installation of the product or external parts.

- Our guarantee does not cover products proved to have been tampered with or faulted by material wear and tear.

- The Purchaser is responsible for checking that the incoming product is received in good condition and conforms to the

ordered specications. In case of damage caused during transit it is necessary to immediately complain to the carrier within

24 hours. After this time carriers could not assume the derived costs. In case of any deviation in relation to order speci-

cations, please contact us.

Page 7

COMEVAL VALVE SYSTEMS, S.L. y CIA., Soc. Comanditaria

Les Rotes, 15 46540 El Puig (Valencia) España

Phone +34 961 479 011 ·Fax +34 961 472 799

E-mail [email protected] - www.comeval.es

ATTENTION!

The following points must be observed:

- Pressureless pipe system.

- Medium must be cool.

- Plant must be drained.

- Note chapter 3 for proper handling and lifting.

- Additionally, in case of toxic, corrosive, ammable or caustic media:

- Purge pipe system carefully.

- Use proper protection equipment to avoid health harm.

- Adopt proper actions to avoid pollution of the environment.

IOM - DOUBLE ECCENTRIC BUTTERFLY VALVES

UNIWAT® VF791

Comeval Valve Systems reserves the right to alter any technical data contained in this Manual without prior notice. Regularly updated data on www.comeval.es

13. PARTS LIST

Page 8

Nº PART

1Gear box

2Key

3 Connection

4 Gland

5O-ring

6 O-ring

7Space washer

8O-ring

9O-ring