Definox VDCI-MC PFA User manual

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 1/35 February 2013
VDCI-MC MIXPROOF VALVES
PFA – SP – SP-C – PMO-C
www.definox.com

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 2/35 February 2013
TABLE OF CONTENTS
1 CHANGE MANAGEMENT 3
2 SAFETY 4
2.1 IMPORTANT INFORMATION 4
2.2 GENERAL INFORMATION 4
3 INTRODUCTION 5
3.1 DISASSEMBLING THE VALVE: (Extracting the isolation sub-assembly from the body of the valve 5
3.2 DISASSEMBLING THE PNEUMATIC ACTUATOR: (Changing the internal seals) 5
4 DISASSEMBLING THE VALVE 6
4.1 DISMANTLING THE SIGNALLING BOX 6
4.2 BODY AND ISOLATION 7
4.3 DISASSEMBLING THE VDCI-MC PFA BREAKAWAY ACTUATOR: (to change the seals if required) 8
4.4 DISASSEMBLING LOWER PLUGS VDCI-MC MIXPROOF VALVES 9
4.5 DISASSEMBLING UPPER PLUG VDCI-MC PFA SP SP-C and PMO-C MIXPROOF VALVES 10
4.6 DISASSEMBLING THE MAIN PNEUMATIC ACTUATOR 11
4.7 DISASSEMBLING THE LANTERN SUB-ASSEMBLY 12
4.8 DISASSEMBLING THE SHAFT/PISTON SUB-ASSEMBLY 13
5 REASSEMBLING VDCI-MC MIXPROOF VALVES 14
5.1 REPLACING FAULTY COMPONENTS OR SEALS ON THE PLUGS 14
5.1.1 REPLACING PFA SEALS ON VDCI-MC PFA PLUGS 14
5.1.2 REPLACING SEALS ON VDCI-MC SP SP-C & PMO-C PLUGS 15
5.1.3 REASSEMBLING THE VDCI-MC SHAFT/PISTON ASSEMBLY 18
5.1.4 REASSEMBLING THE VDCI-MC LANTERN ASSEMBLY 19
5.1.5 REASSEMBLING THE VDCI-MC ACUATOR ASSEMBLY 20
6 VDCI-MC PARTS 21
6.1 PARTS FOR THE VDCI-MC PFA BREAKAWAY ACTUATOR SUB-ASSEMBLY: (seal kits page 30) To fit or remove [29] and [30], refer to the
maintenance notice IT-TDFX-187 for box ACS. 21
6.2 PARTS FOR THE VDCI-MC ACTUATOR: (seal kits page 31) 22
6.3 PARTS FOR PLUG SUB-ASSEMBLY VDCI-MC PFA: (seal kits page 30) 23
6.4 PARTS FOR PLUG SUB-ASSEMBLY VDCI-MC SP: (seal kits page 32) 24
6.5PARTS FOR PLUG SUB-ASSEMBLY VDCI- MC PMO-C: (seal kits page 32-33) 25
6.6PARTS FOR BODY SUB-ASSEMBLY VDCI MC-PFA and SP SP-C : (seal kits page: 31)26
6.7PARTS FOR DECTECTION OPTION PLUG OPEN VDCI-MC 27
6.8TABLE OF PARTS FOR VDCI-MC PFA SP SP-C & PMO-C MIXPROOF VALVES 28
6.9REFERENCES OF SEAL KITS FOR VDCI-MC MIXPROOF VALVES 30
6.9.1PFA seal kits for VDCI-MC PFA plugs 30
6.9.2EPDM FDA seal kits for VDCI-MC PFA plugs 30
6.9.3FKM FDA seal kits for VDCI-MC PFA plugs 30
6.9.4NBR seal kits for VDCI-MC PFA breakaway sub-assembly 30
6.9.5EPDM FDA seal kits for VDCI-MC PFA / SP / SP-C / PMO-C bodies 31
6.9.6FKM seal kits for VDCI-MC PFA / SP / SP-C / PMO-C bodies 31
6.9.7NBR seal kits for VDCI-MC PFA / SP / SP-C / PMO-C main actuators 31
6.9.8EPDM FDA seal kits for VDCI-MC SP / SP-C / PMO-C plugs 32
6.9.9FKM FDA seal kits for VDCI-MC SP / SP-C / PMO-C plugs 32
6.9.10EPDM FDA seal kits for VDCI-MC PMO-C plugs 32
6.9.11FKM FDA seal kits for VDCI-MC PMO-C plugs 33
6.9.12List of toolkits for VDCI-MC mixproof valves 34

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 3/35 February 2013
1 CHANGE MANAGEMENT
For VDCI-MC-PFA DN63-80 actuators.
Use of pin 7142193(2) with cam 7142205(1) for all actuators from 01/05 to 04/05.
From 05/05 use of pin 7142220(1) with cam 7142222(1).
CHANGES INDEX DATE PAGE(S) INITIALS
New version. 1 May 2005 / T. PICOT
Lantern index changed. 2 October 2005 / T. PICOT
Safety information added. 3 January 2006 / T. PICOT
Seal fitting modified [49]. 4 February 2006 16 T. PICOT
Lubricant type + information added. 5 June 2006 5 T. PICOT
VDCI-PFA rail table added. 6 December 2006 27 T. PICOT
Safety information added on page: 5 + layout changed. SP PMO
Option of upper plug [48b] added on page: 16, lower plug [49]
modified on page: 17, sealing system on lantern detection added
on page: 26.
7 January 2008 5/16/21/26/27/28/31 T. PICOT
Update evolution PPJ. 8 December 2009 T. PICOT
Add PMO-C version – switch M8 replaces M5. 9 August 2011 9/15/25/27/29/31-33 G.BEGAUD
Modification VDCI-MC PMO-C version and SP. 10 March 2012 9/15/25/27/29/31-33 T. PICOT
Seal 7006124 replace 7380826. 11 June 2012 29/31 T.PICOT
Update evolution VDCI-MC PMO-C 12 July 2012 10/15/25/26/29/32/33 T.PICOT
Add toolkit items 13 August 2012 33 G.BEGAUD
Modification Rep :48 14 September2012 28/32/33 T.PICOT
Add version VDCI-MC SP-C rep [51b] + [54b] 15 February 2013 / T.PICOT

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 4/35 February 2013
2 SAFETY
2.1 IMPORTANT INFORMATION
Always read the maintenance notice before manipulating the valve
Failure to observe these instructions can result in serious bodily injury or loss of life.
This can also result in less serious injuries or damage to the equipment.
Electricity can result in serious bodily injury or loss of life.
This can also result in less serious injuries or damage to the equipment.
2.2 GENERAL INFORMATION
The following advice is given to ensure optimum use of the equipment.
•The tasks must be performed in the order specified.
NOTE !
DANGER !
CAUTION
DANGER !
CAUTION !

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 5/35 February 2013
MAINTENANCE NOTICE VDCI-MC Mixproof valves (PFA SP PMO-C)
3 INTRODUCTION
IMPORTANT: Before carrying out any maintenance work, check with the supervisor that
the installation is stopped and drained (pipes empty and depressurised, pumps stopped,
tanks shut off or empty).
The disassembly process for mixproof valves is divided into two distinct steps.
3.1
DISASSEMBLING THE VALVE: (Extracting the isolation sub-assembly from the body of the
valve
This operation enables access to the isolation seals (Changing the seals) and the
removal of the pneumatic actuator.
This is a straightforward procedure and can be performed on-site as it does not present
any particular problems.
This is the case in the majority of maintenance operations on this type of valve.
3.2 DISASSEMBLING THE PNEUMATIC ACTUATOR: (Changing the internal seals)
IMPORTANT: This operation must be performed using a special tool ensuring that the
necessary precautions are taken. (IMPORTANT: stressed spring)
NOTE: After carrying out any maintenance work on DEFINOX products it is essential
that you check the correct function of the equipment concerned: tightness, pressure, etc…
IMPORTANT: In the lower section of the valve, NEVER BLOCK or RESTRICT the flow
from the LEAKAGE CHAMBER.
IMPORTANT: Ensure that the lubricants used are compatible with elastomer seals.
CAUTION
NOTE !
CAUTION
CAUTION
VDCI
-
MC PFA
VDCI-MC SP SP-C & PMO-C

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 6/35 February 2013
4 DISASSEMBLING THE VALVE
Before starting the disassembly procedure, if the valve is fitted with a signalling box
it may be necessary to detach the signalling unit from the actuator.
4.1 DISMANTLING THE SIGNALLING BOX
Dismantling without disconnection
IMPORTANT: Before starting any work on the box, it is important to ensure that
the air supply is closed and that the circuit is purged.
Dismantling with disconnection
IMPORTANT: Before starting any work on the box, it is important to ensure that
the mains supply is switched off, that the air supply is closed and that the circuit is
purged.
Turn the cover [1] anti-clockwise to align and release the contacts from the
connector [2], then remove the connector.
Disconnect the air pipes from the box.
Unscrew the stuffing box assembly [3], locate and disconnect the wires on
the terminal [4], then remove the supply cable.
Refit the cover [1] and turn it fully anti-clockwise to detach the connector [2] from
the base [5], then remove the box.
Unscrew the two CHC screws [6] and remove the base [5] from the valve actuator.
(Take care not to lose the torque seal [7] located on the actuator
when disassembling the box).
To fit and remove box ACS, refer to maintenance notice IT-TDFX-187.
CAUTION !
CAUTION !

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 7/35 February 2013
4.2 BODY AND ISOLATION
•Supply air to the main pneumatic actuator to relieve the upper clamp collar of the shear
force from the spring.
•If a signalling box is installed on the valve, use the box’s air circuit to manoeuvre the
valve into an open position.
IMPORTANT: (Do not place your hands inside the lantern whilst manipulating
the actuator, risk of serious injury). See diagram below.
•Disassemble the cam fastening screw [29] and the sensing cam [30].
•Disassemble the upper clamp collar [56].
•Interrupt the air supply to the actuator (the valve returns to a closed position).
•Remove the plug/pneumatic actuator assembly [A] from the VDCI body [65] or [69].
•Disassemble the lower clamp collar [56] and remove the protector [54].
CAUTION
NO
YES
))(
(
69
A
54
65
56
56
30 29
54b

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 8/35 February 2013
4.3 DISASSEMBLING THE VDCI-MC PFA BREAKAWAY ACTUATOR:
(to change the seals if required)
•Disassemble the fastening screws [33] from the cover [32].
•Remove the breakaway piston [56] from the cover.
•Remove the torque seals [31] [28] [35] [36].
See seal kit for VDCI-MC-PFA breakaway actuator.
35
56
28 36
32
33
31

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 9/35 February 2013
4.4 DISASSEMBLING LOWER PLUGS VDCI-MC MIXPROOF VALVES
•Using a plug valve wrench [A] on the lower plug side [43], [51], or [86] and the holding
wrench [B] on the plates on the actuator shaft side [1], unscrew the lower plug sub-
assembly of the pneumatic actuator [53].
•(see diagram below)
LOWER PLUG TOOLS
Diameter DN 38 - 50 DN 63 - 80 DN 104 - 150
Plug valve wrench A N° 7141979 N° 7142224 N° 7142225
Holding wrench B N° 7142226
•Using the plug valve wrench [A] on the plug side and the support plates on the actuator
shaft side [1] (in a vice with protective clamping jaws or with an open-end wrench).
•Unscrew the valve [51] [51] or [86] from the from the lower plug assembly shaft [45].
(See diagram below, only for VDCI-MC SP and PMO-C mixproof valves).
•Remove the torque seals [50] [49] and [48] (to change the seals if necessary).
A
B
43 51
1
53
PFA SP SP-C PMO-C
86
51
45
49
50
86
85
48
48
V
DCI-MC SP
V
DCI-MC PMO-C
51b

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 10/35 February 2013
4.5 DISASSEMBLING UPPER PLUG VDCI-MC PFA SP SP-C and PMO-C MIXPROOF VALVES
•Unscrew the indexing screw [68].
•Unscrew the two fastening screws [60].
•Remove the clamp collar [61] from the lantern [11].
•Next, remove the upper plug [37] or [44].
•Remove the PPJ [83] from the lantern [11]
•Remove the seals [13] [58] and [59] as well as the ring [12] (if a replacement is required, see
parts reference at the end of this notice).
11
68
37
60
61
89

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 11/35 February 2013
4.6 DISASSEMBLING THE MAIN PNEUMATIC ACTUATOR
•Disassemble the air pipes [16] and [17] from the upper plug supply.
•Position the actuator sub-assembly [53] on the press (see diagram below).
•Ensure that the course of the press is adjusted to dimensions [A] and [B].
•Use a tube [C] to prevent damage to the upper part of the actuator lantern [53].
•Press the springs to release the snap-ring [18].
•Remove the snap-ring [18] from its housing using a screwdriver, then release
the pressure.
•Remove the sub-assembly for the lantern/shaft/piston [11] [10] [6] [9] shaft/main
actuator [1] [5] [3] springs [23] [26] from the actuator body [2].
Diameter DN 38 - 50 DN 63 - 80 DN 104 - 150
Maximum compression A
(mm) 202 242 307
Minimum expansion B
(mm) 350 360 515
Ø Tube (mm) C Interior Ø: 78 minimum Interior Ø: 115 minimum Interior Ø: 152 minimum
2
22
1
23
5
7
9
10
18
11
53
18
17
16
C

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 12/35 February 2013
4.7 DISASSEMBLING THE LANTERN SUB-ASSEMBLY
•Hold the clamp pin [10] with a drift punch [B] and the drift punch guide [C] held in a vice.
•Unscrew the breakaway piston nut [7] using a plug valve wrench [A].
•Release the nut [7], the breakaway piston [9] and the clamp pin [10] on the lantern
assembly [11].
Diameter DN 38 - 80 DN 104 - 150
Plug valve wrench nut A N° 7141988 N° 7141989
Drift punch B Maximum Ø 5 mm
Drift punch guide C N° 7142262
7
9
11
10
A
B
C

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 13/35 February 2013
4.8 DISASSEMBLING THE SHAFT/PISTON SUB-ASSEMBLY
•Release the set screw [4] on the nut [3].
•Unscrew the main piston [5] screw [3] using a plug valve wrench [A] and the holding
wrench [B].
•Release the main piston [5] screw [3] and remove the valve actuator shaft [A].
SHAFT/PISTON DISASSEMBLY TOOLS
Diameter DN 38 - 150
Plug valve wrench nut A N° 7141988
Holding wrench B N° 7142226
3
5
1
B
A
4

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 14/35 February 2013
5 REASSEMBLING VDCI-MC MIXPROOF VALVES
5.1 REPLACING FAULTY COMPONENTS OR SEALS ON THE PLUGS
5.1.1 REPLACING PFA SEALS ON VDCI-MC PFA PLUGS
IMPORTANT: It is essential that you disassemble the lower plug before replacing
the PFA seal located on the upper plug.
•Isolate the defective PFA seal using a cutter taking care not to mark the bearing surface of
the plug (protect the stainless steel surface using the edge of a steel rule or a plastic off-cut).
•Place the new seals in an oven at 165°C (+/-3%) for 30 minutes.
IMPORTANT: Do not exceed a maximum of 200°C. If the temperature is too low,
there is a risk that the seal will deform or tear during installation.
•For the PFA seal [40] on the upper plug [43], insert the seal between the recess and
the plug bridge, zone [A] (see diagram below).
•Insert the PFA seal quickly from one side of the groove, then progressively push it into
its housing.
IMPORTANT: Be sure to position the bevelled side of the PFA seal correctly on
the plugs (see diagram below).
•Remove the torque seals [38] and [42] as well as the ring [41] (if a replacement is required,
see parts reference at the end of this notice).
CAUTION
CAUTION
CAUTION
A
43
40
37
41
38
39
42
LOWER PLUGUPPER PLUG

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 15/35 February 2013
5.1.2 REPLACING SEALS ON VDCI-MC SP SP-C & PMO-C PLUGS
IMPORTANT: It is essential that you disassemble the lower plug before replacing
the seals located on the upper plug.
•Before replacing faulty seals (see list of seals and kits at the end of the notice) grease
the seals with a suitable lubricant.
•For the process seals [47] or [42] in contact with the product use a food grade silicone
grease (of the type Molykote111).
•For the external seals [48] on the upper plug [44] or [84], on intermediate plug [85] and
lower plug [86] which are mounted dry.
•For external seals [48bis] for harsh operating conditions refer to the next page.
•It is essential that the seals [48] are not twisted when mounting.
•Be sure to distribute the volume of the seal into the groove to provide a uniform contact
surface around its entire rim.
•Remove the torque seal [47] or [42] and the ring [46] or [41]. (if a replacement is required, see
parts reference at the end of this notice).
CAUTION
V
DCI-MC SP VDCI-MC PMO-C
44
46
48
48
48bis
48
48
48 42 41
84
86
85
47
87
88

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 16/35 February 2013
•Assembling external seals [48bis] for harsh operating conditions.
78 80 79
48bis
44
81
82

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 17/35 February 2013
•Before replacing faulty seals on the lower plug (see list of seals and kits at the end of
the notice).
•Grease the seal [50] (with Molykote111 type grease).
•Grease (type Molokyte111) the bridge [51] or [77] on the bearing surface of the seal [49]
(to aid installation of the seal).
•Fit the seal [49] dry, taking note of the concentricity of the seal on the plug.
•Tighten the assembly using the plug valve wrench [A] on the valve side [51] or [86] and
the support plates on the actuator shaft side [45] (in a vice with protective clamping jaws
or with an open-end wrench).
•Tighten the plug [51] on the shaft [45] until a meal/metal contact is achieved.
Diameter DN 38 - 50 DN 63 - 80 DN 104 - 150
Plug valve wrench A N° 7141979 N° 7142224 N° 7142225
51
45
A
50
49

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 18/35 February 2013
5.1.3 REASSEMBLING THE VDCI-MC SHAFT/PISTON ASSEMBLY
•Remove the torque seals [24] [22] (if a replacement is required, see parts reference at the end of
this notice) and grease the seals with grease (of the type 4025 H1 by QUINPLEX).
•Remove the rings [25] and [21] (if a replacement is required, see parts reference at the end of this
notice). Ref.:[21] Assembled only on DN63 to 150.
•After replacing the seals and rings, reassemble the shaft [1] in the main piston [5].
•Tighten the nut [3] using a plug valve wrench nut [A] and the holding wrench [B].
•Then lock the set screw [4].
B
A
4
3
22
21
5
1
24
25

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 19/35 February 2013
5.1.4 REASSEMBLING THE VDCI-MC LANTERN ASSEMBLY
•Remove the torque seals [24] [22] (if a replacement is required, see parts reference at the end of
this notice) and grease the seals with grease (of the type 4025 H1 by QUINPLEX).
•Remove the rings [15] and [7] (if a replacement is required, see parts reference at the end of this
notice).
•After replacing the seals and rings, position the protector [A] on the thread of the clamp
pin [10].
•Insert the clamp pin [10] in the lantern [11] and the breakaway piston [9].
•Remove the protector [A] to tighten the nut [6] on the thread of the clamp pin [10].
Use a drift punch [C] and the plug valve wrench [B] to tighten the assembly.
(see table below)
Diameter DN 38 - 50 DN 63 - 80 DN 104 - 150
Valve protector A N° 7141886 N° 7141887 N° 7141888
Plug valve wrench B N° 7141988 N° 7141989
Drift punch C Maximum Ø 5 mm
B
C
6
15
9 20
19
11
14
A
7 8
10

MAINTENANCE NOTICE
IT-TDFX-164 Number 15 Page 20/35 February 2013
5.1.5 REASSEMBLING THE VDCI-MC ACUATOR ASSEMBLY
•Tighten the guides [A] and [B] on the shaft [1] (see table and diagram below).
•Position the spring [26] on the body [2], reassemble the shaft/piston assembly on
the spring [26], position in the spring assembly [23] and thread the lantern assembly
on the guide [A] (see diagram below).
•Mount the assembly on the press to position the snap-ring correctly [18]
(for press courses see page 11, idem for disassembly).
•Reassemble the connectors [16] and [17] on the lantern [11]
(check the alignment of the connectors, see diagram below).
VALVE ACTUATOR ASSEMBLY TOOLS
Diameter DN 38 - 50 DN 63 - 80 DN 104 - 150
Clamp pin guide A N° 7141889 N° 7141890 N° 7141891
Actuator body guide B N° 7142227 N° 7142228 N° 7141885
1617
18
11
A
1
23
26
B
2
When reassembling, align the air connection holes.