Gefa DG1 User manual

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ARMATURENTECHNIK
Original instructions
Germaniastraße 28 • D-44379 Dortmund
Tel.: +49 (0)231 / 61 00 9-0 • Fax: +49 (0)231 / 61 00 9-80
Internet: www.gefa.com • E-Mail: [email protected]
Version 0 • DocID 104070923

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Table of contents
1 Imprint ............................................................................................................................................................. 4
2 Safety instruction ........................................................................................................................................... 5
2.1 Used information and warning signs ........................................................................................................ 5
2.2 Intended Use............................................................................................................................................ 6
2.3 User.......................................................................................................................................................... 6
2.4 Improper use ............................................................................................................................................ 6
2.5 Due diligence of the operator ................................................................................................................... 6
2.6 Product safety .......................................................................................................................................... 7
2.7 Product-specific dangers.......................................................................................................................... 7
2.8 Outflowing media ..................................................................................................................................... 7
2.9 Failure of actuator operating power ......................................................................................................... 7
2.10 Mounting of actuators...............................................................................................................................7
3 Scope of supply.............................................................................................................................................. 8
3.1 Exploded view drawing DN8-50 ............................................................................................................... 8
3.2 Components ............................................................................................................................................. 8
3.3 Exploded view drawing DN65-100 ........................................................................................................... 9
3.4 Components ............................................................................................................................................. 9
4 Transport and storage ................................................................................................................................. 10
5 Assembly and commissioning.................................................................................................................... 11
5.1 Installation conditions.............................................................................................................................12
5.2 Installation position................................................................................................................................. 12
5.3 Initial operation.......................................................................................................................................13
5.4 Mounting instructions ............................................................................................................................. 14
5.5 Impermissible operation ......................................................................................................................... 14
6 Operation ...................................................................................................................................................... 15
7 Maintenance and repair ............................................................................................................................... 16
7.1 Maintenance........................................................................................................................................... 16
7.2 Tightening/replacing the stuffing box packing ........................................................................................ 17
7.3 Replacing the seat ................................................................................................................................. 18
8 Decommissioning and disposal ................................................................................................................. 19
8.1 Decommissioning ................................................................................................................................... 19
8.2 Removing of the valve............................................................................................................................ 19
8.3 Disposal ................................................................................................................................................. 19
9 Technical data and materials ..................................................................................................................... 20
9.1 Dimension sheet DN8-50 - full bore - threaded end and butt weld end, short ....................................... 20
9.2 Dimension sheet DN65-100 - full bore - threaded end and short butt weld end .................................... 21
9.3 Dimension sheet DN15-65 - reduced bore - threaded end and short butt weld end.............................. 22
9.4 Dimension sheet DN80-150 - reduced bore - threaded end and short butt weld end............................ 23
9.5 Dimension sheet DN8-100 - full and red. Bore - threaded end and short butt weld end with AP series
actuator .................................................................................................................................................. 24
9.6 Dimension sheet DN8-50 - full bore - long butt weld end....................................................................... 25
9.7 Dimension sheet DN8-50 - full bore - orbital end ................................................................................... 26
9.8 Dimension sheet DN65-100 - full bore - orbital end ............................................................................... 27
9.9 Dimension sheet DN10-50 - full bore - V-flange PN10-40 ..................................................................... 28
9.10 Dimension sheet DN65-100 - full bore - V-flange PN10-40 ................................................................... 29
9.11 Dimension sheet DN8-50 full / DN15-65 reduced bore with T-hand lever ............................................. 30
9.12 Dimension sheet, actuator connection DIN 3337 / ISO 5211................................................................. 31
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9.13 Materials DN8-50 full bore / DN15-65 reduced bore.............................................................................. 32
9.14 Materials DN65-100 full bore / DN80-150 reduced bore........................................................................ 33
9.15 Pressure-temperature diagram DN8-100............................................................................................... 34
9.15.1 Pressure-temperature diagram DN8-25...................................................................................... 34
9.15.2 Pressure-temperature diagram DN32-50.................................................................................... 35
9.15.3 Pressure-temperature diagram DN65-100.................................................................................. 36
10 How to proceed in case of malfunctions ...................................................................................................37
11 Annex ............................................................................................................................................................ 38
11.1 Structure of control elements ................................................................................................................. 38
11.1.1 Structure of the hand lever.......................................................................................................... 39
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1 Imprint
Read the operating instructions thoroughly before installing your valve. Failure to follow these instructions or the
warning and safety labels could result in serious injury or property damage. These operating instructions must
be available to all users at all times. GEFA Processtechnik GmbH is not liable for unauthorized changes of the
device or for improper use.
All rights reserved GEFA Processtechnik GmbH
GEFA Processtechnik GmbH
Germaniastraße 28
44379 Dortmund, Germany
Tel: [phone]
Fax: [phone]
E-Mail: [email protected]

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2 Safety instruction
This chapter contains basic instructions for the safe handling of this valve.
Observe all instructions for transport, storage, installation, commissioning, maintenance and decommissioning
as well as disposal. In explosive arenas, the relevant standards, the specifications of the manufacturer and the
risk assessment must be observed
Failure to observe safety instructions may result in personal injury and / or property damage.
The safety instructions in this documentation are uniform and marked with an icon on the left side of the note. A
signal word above the text indicates the hazard level. The color of the hazard word additionally signals the haz-
ard level.
The warning notice also includes:
>Nature and origin of danger.
>Possible consequences of the danger.
>Measures to avoid the danger.
If more than one hazard level occurs, the safety notice for the highest level is used.
Nature and origin of danger.
Possible consequences of the danger.
Measures to avoid the danger.
Signal words for warnings
The signal word identifies the severity of the hazard that occurs if it is not avoided.
DANGER means: Serious personal injury threatens immediately.
WARNING means: Serious personal injury may be imminent.
CAUTION means: Light / medium personal injury threatens immediately.
NOTICE means: property damage threatens directly or possibly.
2.1 Used information and warning signs
The warning sign represents a source of danger. Warning signs are located
>At the device near the source of danger.
>In the operating instructions before the activity is described, which can be a hazard.
The following information and warning signs are used in this operating manual:
Safety Notice General
Wear safety gloves
Wear safety shoes
Observe and obey all local safety regulations, safety precautions and operating instructions. These apply in ad-
dition to or in addition to the safety instructions stated and shown in this manual. If contradictory identifications
occur, speak with the responsible authority. All PPE (personal protective equipment) must be provided by the
user of the valve.
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2.2 Intended Use
The valve is used exclusively for shutting off, throttling and regulating media flows under the Consideration of
the data given on the valve and technical details given in this manual Data, diagrams, applications described
and only in connection with the components, which are recommended by GEFA Processtechnik GmbH, ap-
proved and mentioned in this documentation. The faultless and safe operation of the device requires proper
transport, proper storage and installation as well as careful operation and maintenance. This documentation is
part of the device and must be available at all times. Observe all safety regulations which are listed in this docu-
mentation. The valve may only be operated in such a way that no fatigue stress occurs. Max. 500 load changes
at Δp = PS or max. 500 / (Δp / PS) ³ permissible partial load changes (see DIN EN 13445-3 section 5.4.2). The
valve may only be operated in this way within the scope of the DGRL. The suitability of the product wetted parts
used and their chemical resistance must be clarified before commissioning the system. The usual flow rates for
this valve must not be exceeded. Changes or modifications to the device are not permitted. The improper use
leads to the exclusion of any liability claims.
2.3 User
All work on the unit may only be performed by qualified personnel and together with this documentation. Quali-
fied persons within the meaning of this documentation are those who are authorized to assemble, commission
and mark devices, systems and connections in accordance with the standards of safety technology.
2.4 Improper use
Do not mount the valve if:
>Parts are obviously damaged.
>There is not enough free space to ensure easy operation of the hand levers, handwheels and manual emer-
gency shifts.
or the fitting as:
>Support member of the pipe guide is used.
>Riser is used.
>This includes the actuators such as hand levers, gear operator, actuator, feedback and control systems.
2.5 Due diligence of the operator
It is the duty of care of the operator to plan and control all actions that ensure safety in the workplace.
In particular, the operator must ensure that:
>the valve is only used as intended.
>the valve is only operated in a perfect, fully functional condition.
>the safety regulations relevant to the installation site and generally applicable technical rules for the installa-
tion location must be observed.
>the permissible materials of the wetted parts are suitable for the media, pressures and temperatures used.
The operator must also ensure that the responsible personnel:
>has the necessary qualifications to work with the valve.
>has read and understood the operation instructions before working with the valve and follows the described
instructions.
>can clearly identify all safety signs required for the work.
>All necessary protective equipment is provided and must be worn.

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2.6 Product safety
The valves of GEFA Processtechnik GmbH correspond to the state of the art and the prescribed safety rules,
but nervertheless hazards can occur in connection with valves. The valve may only be operated in proper condi-
tion, in the intended area and under consideration of all associated documentation. Any change to the valve
may only be made after approval by the manufacturer. The basic requirement for trouble-free operation is
proper connection of the electrical, hydraulic and pneumatic lines.
WARNING Improper use / excessive stress of the valve
The use of material incompatible media or operating outside the approved specification, exceeding
the manufacturer's approved pressure and temperature limits, the use of the valve as a climbing
aid, including all actuators (hand lever, gearbox, drive, feedback and control systems), and from
the outside acting loads and shear forces due to additional stresses can lead to failure of the pres-
sure-bearing parts and bursting of the valve.
2.7 Product-specific dangers
WARNING Dangers relating to a valve
The flow medium, the control pressure, the temperature and moving parts can potentially pose a
hazard. These potential hazards must be prevented by appropriate activities by the operator.
It is not permissible to reach into the valve at any time. In general, there is a risk of injury to moving
parts.
2.8 Outflowing media
WARNING Outflowing media
If harmful or environmentally hazardous media leak out (e.g. leaks or disassembly of the valve),
they must be collected in such a way that there are no hazards to persons or the environment. Ob-
serve all applicable local regulations that apply to the disposal of the respective medium and the
valve.
2.9 Failure of actuator operating power
WARNING Failure of actuator operating power
In case of failure of actuator operating power, the valve could go into a state of insecurity for its in-
tended use.
Choose your valve in such a way that if the actuator operating power fails, the valve can change
into a safe operating state for its intended use.
2.10 Mounting of actuators
Observe the following notes for mounting of a valve actuator.
CAUTION Ventilation of pneumatic components
a) During venting operations on pneumatic components, increased noise may occur.
ðPrevent this by suitable measures (silencer).
NOTICE Mounting of actuators
Actuators must be installed in alignment with the valve stem. Tensions can lead to increased wear
or leakage of the stem seal.
The weight of a built-up actuator must not load the stem of the valve on one side. Therefore actuat-
ors must be intercepted if necessary - without fixation.
Pneumatic or hydraulic actuators must be operated at the agreed design pressure. Pay attention to
the maximum permissible operating pressure.
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3 Scope of supply
3.1 Exploded view drawing DN8-50
3.2 Components
Pos. Designation
1 Ball valve
1.1 Center section
1.1.1 Body
1.1.2 Ball
1.1.3 Seat
1.1.4 Stem
1.1.5 Body seal
1.1.6 Stem seal
1.1.6.1 Disc spring washer
1.1.6.2 Washer
1.1.6.3 Gland
1.1.6.4 (1) Thrust washer
1.1.6.4 (2) Thrust washer
1.1.6.5 Stem packing
1.1.6.6 Primary sealing
1.1.7 Flat hexagon nut
1.1.8 Safety cap
1.1.9 Locking clip
1.2 End cap
1.3 Hexagon screw
1.4 Hexagon nut
2 Hand lever
2.1 Hand lever
2.2 Cylinder screw
2.3 Cylinder screw
2.4 Hexagon screw
2.5 Washer
2.6 Hexagon nut

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3.3 Exploded view drawing DN65-100
3.4 Components
Pos. Designation
1 Ball valve
1.1 Center section
1.1.1 Body
1.1.2 Ball
1.1.3 Seat
1.1.4 Stem
1.1.5 Body seal
1.1.6 Stem seal
1.1.6.1 Disc spring washer
1.1.6.2 Washer
1.1.6.3 Gland
1.1.6.4 Washer
1.1.6.5 Stem packing
1.1.6.6 Primary sealing
1.1.6.7 Washer
1.1.7 Centering ring
1.1.8 Packing gland
1.1.9 Hexagon screw
1.2 End cap
1.3 Hexagon screw
1.4 Hexagon nut
2 Hand lever
2.1 T-piece
2.2 Stop plate
2.3 Pipe
2.4 Cylinder screw
2.5 Cylinder screw
2.6 Hexagon screw
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4 Transport and storage
WARNING Transport of the valve
Failure to comply with the transport instructions can result in significant personal injury(even death)
and property damage.
NOTICE Transport
The transport may only be carried out by qualified and authorized personnel with suitable protect-
ive equipment.
In order to guarantee a faultless function, pay attention to the following during transport and storage:
>The valve must be transported and stored dry and clean.
>During transport and intermediate storage the high performance butterfly valve should not be outside a tem-
perature range of -15°C and +30°C.
>In humid rooms, a drying material or heating must be used to avoid condensation
>If the valves are painted (coated) on the outside, this coating must remain without damage, otherwise the
faulty spots must be repaired immediately!
>The factory-adjusted basic setting (position of the disc at delivery) must not be changed.
The transport packaging protects the valve against soiling and damage, therefore it is important:
>do not remove the packaging until the valve is going to be installed.
To prevent damage and life-threatening injuries when transporting the valve:
>Impact and vibrations must be avoided.
>Only use suitable and approved load handling equipment and slings.
>When selecting the load suspension and slinging equipment, take the weight of the valve into account.
>The transportation routes must be blocked and marked, that no unauthorized person can enter the danger
zone.
>Do not suspend large valve on the gearbox or flange! Protect the shut-off element and flange sealing sur-
faces against any damage!
>For valves that are delivered without actuation, the shut-off element is not secured against adjustment. It
must be transported in such a way that it can not be opened from the closed position by external influences
(eg vibration).