DUKER 3004 User manual

Issue 02 Düker GmbH, www.dueker.de 1
Operation instructions
Gate Valve
Type 3004 with blow-off pipes and
welding studs for steel pipes
for gas
Item no. of the operation instructions: 764835, issue 02, 9 pages, 2017
Specifications subject to change without notice
for hand wheel and stem extension set

Issue 02 Düker GmbH, www.dueker.de 2
1. Intended use
2. Safety precautions
2.1 General safety instructions
2.2 User safety instructions
2.3 Special risks
3. Transport and storage
4. Installation into the pipeline
4.1 Venting function
5. Operation
6. Service and maintenance
7. Drawing and parts list
8. Diagnostics and trouble shooting

Issue 02 Düker GmbH, www.dueker.de 3
1. Intended Use
After the installation into a pipe system, shut-off valves are only intended for stopping or allowing media to
pass within the range of the permitted operating conditions (temperature and pressure limit "PN" labeling on
the valve, unless stated otherwise).
Gate valves are used exclusively for open/closed operation in pipe systems.
We will not assume any responsibility for consequential damage caused by
unauthorised modification of the valve and the accessories supplied
improper operating or operating conditions
acts of God
2. Safety Precautions
2.1 General safety instructions
The same safety regulations apply for valves as for the pipe system in which they are installed. The
following instructions only include additional safety instructions to be observed for valves.
When using this valve, the generally recognized rules of good practice (standards, DVGW regulations,
VDI guidelines or other regulations valid at the place of installation) must be observed.
The valve must be professionally installed into the pipeline.

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2.2 User safety instructions
The operator of the valve must ensure that the valve is only used in accordance with the intended use. This
is not the responsibility of the manufacturer. The valve may only be operated by properly qualified and
trained staff. The operating manual and the corresponding safety instructions must be read and understood.
It is prohibited to use any valves with a nominal pressure ("PN") and maximum admissible
operating temperature insufficient for the operating conditions.
The approved range is indicated on the valve.
Warning: Temperatures below 10 °C and above 40° C during work on the pipeline parts involve
the risk of injury. Protective measures must be taken accordingly.
Operating media must correspond to the specification of the valve. The manufacturer does not
assume any liability for damage resulting from corrosion caused by aggressive media. Neglect
of these regulations may result in imminent danger to life and health, and may cause damage to
the pipeline.
2.3 Special risks
Be sure to free the pipeline from any pressure and risk prior to disassembly, maintenance and
repair of the valve. During disassembly the medium may leak, therefore the pipeline and the valve
must be completely emptied.
The energy supply must be switched off.

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3. Transport and storage
All valves must be carefully transported and stored.
The valves are fully enamelled or powder-coated. The coatings are shock-sensitive and must be
protected against impact stress.
The gaskets are sensitive to light: Unpackaged valves may only be exposed to bright daylight or
ultraviolet light for a very short time. This is why the openings are sealed with protective caps.
Valves must be stored in darkened rooms, in their original packaging with the protective caps.
In the event of storage over an extended period of time, the storage location should be frost-
protected, cool, dry, dark and free of dust. Alternatively, the valve may also be packed in order
to fulfill these conditions.
The valve should be stored on a pallet or similar support and only transported with suitable tools such as
wide straps to its designated point of installation. Do not use chains!
4. Installation into the pipeline
The Gate valve with the specified DIN length may only be welded into the pipeline in the "metal arc hand
welding process" (electrical welding). The welding studs comply with EN 12627.
All legal requirements, standards and specifications according to DVS
e.g. ISO 3834-1 "Quality requirements for fusion welding" shall be observed.
For the installation of valves into pipe systems, the same instructions apply as for the connection of pipe
system components. The following work steps must be observed:
Transport the valve to the point of installation in its protective packaging.
Remove all packaging materials from the valve.
Check valve for transportation damage. Damaged valves must not be installed.
Check coating for damages. The coating may be mended with a repair kit.
It needs to be ensured that nominal pressure and connecting dimensions of the valve are in
correspondence with the operating conditions. See marking on the valve.
Remove dirt and hard foreign matter from valve and pipelines prior to installation.
A functional test must be carried out prior to installation: The valve must shut and open properly.
The connections of the pipeline must be adjusted concentric to the valve.

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The valve must installed in a horizontal pipeline, with the stem in vertical position.
The valve should have adequate floor support.
Both welding studs must not be shortened.
Make sure that the surfaces in the welding area are bare metal, free from zinc and dry.
To prevent a strong heating of the sealing wedge, the valve must be fully open.
In no case, the stem may be used as the opposite pole, but only the pipe to be welded.
The valve must be welded in free of tension
The valve should only be closed when the housing is no more than lukewarm.
Check the weld seam during the pressure test of the pipeline.
Adjust the length of the blow-off pipes to the covering height.
Then insert the blow-off pipes into the free pipe ends of the valve and weld them on. Observe the
welding instructions.
When using detergents and disinfectants it must be ensured that these products do not attack the
materials and gaskets of the valve.
During the pressure test of the pipe system with the installed valve, the following test pressures may
not be surpassed:
Valve opened: The test pressure must not exceed 1.5 x PN (see type plate).
Valve shut: The test pressure must not exceed 1.1 x PN (see type plate).
The valve must be protected from dirt which can derive from work (e.g. painting, masonry and concrete
work) in the area of the valve.
4.1 Venting function
To vent the system, unscrew the plug on the ball valve.
When the gas line is filled, the ball valves are opened and the air in the pipeline can escape. When this air
has been removed, the ball valve is closed, the plugs screwed back on and the system is ready for
operation.
When repairing the gas line, the corresponding part of the pipeline system is shut off.
The gas is vented through the venting tubes. The system is then purged with nitrogen.
This ensues that the remaining gas residues are thoroughly removed. Safe working is possible on the gas
line. The venting is as described above.

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5. Operation
The valve is shut by turning it clockwise and is opened by turning it in the opposite direction. Manual power
suffices to operate the valves. Use of extensions to increase actuating torque is not permissible, since this
will cause damage to the valve.
Operating torques
The stated operating torques are the max. permissible torques for full differential pressure at the actuating
stem, these are described in EN 1074-2.
nominal diameter
DN
max.
operating torque
as per EN 1074-2
MOT Nm
no. of turns for
closing
stem square
mm
80
80
16
17
100
100
20
19
150
150
30
19
200
200
34
24
250
250
42
27
300
300
51
27
6. Service and Maintenance
The valves do not require regular maintenance work. However, when a pipeline section is inspected, the
valve may not show any leakage to the outside.
The valve should be checked for tightness and proper function at least once per year.

Issue 02 Düker GmbH, www.dueker.de 8
7. Drawing and parts list
Lengths
Pos
Description
1
body
2
bonnet
3
cap nut
4
clamp piece
5
stem nut
6
stem
7
o-ring
8
o-ring
9
snap ring
10
wedge
11
head gasket
12
cylinder screw
13
adapter piece
14
o-ring
15
ball valve
16
pipe clamp
DN
L
D
80
660
88,9
100
680
114,3
150
730
168,3
200
780
219,1
250
1050
273,0
300
1084
323,9

Issue 02 Düker GmbH, www.dueker.de 9
8. Diagnostics and trouble shooting
Problem
Possible cause
Remedial action
Gate valve does not close
Foreign particle on sealing face
Remove foreign particle
Heavy deposits on the sliding surface
Clean sliding surface
Gate valve does not open
Foreign particle is jamming sealing
wedge
Remove foreign particle
Leakage at the stem or seat gasket:
Check whether the valve is completely shut.
If so: Verify whether the valve has been shut with the full torque.
If leakage on the valve continues: Open and shut the valve several times while under pressure.
If the leakage on the valve continues: Repair necessary.
We would like to point out that we do not assume any liability for damages or disruption of
operations resulting from non- observance of the operating manual.
The distribution and reproduction of these Operating Instructions, utilization and communication of their contents to
others is authorized exclusively for the purpose of ensuring the correct installation and operation of the Düker product
treated in the document. For all other purposes, distribution, reproduction and utilization of the contents, also in
excerpts, is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the
grant of a patent, utility model or design.