Hydroseal KAPLAN User manual

VALVE OPERATION MANUAL
KAPLAN BALL VALVES
• Never use pressurized gases with plastic piping systems.
• Ensure all testing is done using established and secure hydrostatic equipment.
Certain liquids may be prone to vaporization [o-gassing] which might cause presure uctuation.
Valves may be damaged.
• Do not apply excessive weight or mass on top of the valve.
• Avoid slurries, this might result in uneven ow.
• Avoid crystallized or gelled substrate, this might result in uneven ow.
• Always operate valves and piping systems within their designed engineering limits and reccomended conditions.
• Ensure adequate space is always kept around the valve for inspections and maintainence.
• Ensure the right materials, seats and valve types are used that have adequate chemical resistance to the substrate.
• Keep valves from being exposed to direct sunlight for long periods. UV rays might aect the composition.
• Ensure routine and periodic maintenance and inspection is done to avoid costly problems.
SECTION 1 - GENERAL OPERATING GUIDELINES
• When suspending valves use common sense, ensure adequate support and spacing is maintained.
• Thermoplastic may be damged with impacts and sharp objects. Avoid blunt and sharp trauma.
• Ensure cartons and packages are stored appropriately, excessive cartons being stacked might collapse.
• Avoid contact with paint, tar-sand, insecticides and pesticides, and highly corrosive agents.
• During assembly and handling do not carry valves by their handles.
• Keep valves from being exposed to direct sunlight for long periods. UV rays might aect the composition.
• Prior to assembly ensure a quick and eective visual check is done to ensure items are not defective.
SECTION 2 - TRANSPORTATION AND STORAGE
• Perform a visual check prior to installation.
• Wear adequate protective equipment when working with tools, solvents, power drills etc.
• If using U Clamps or anything similar during assembly make sure not to over-tighten.
• During installation of piping systems ensure adequate spacing and hoops are designed in the system.
• Ensure no unnecessary stresses are caused on the piping system such as tension, compression, impact etc.
• Visually check to determine the direction of ow of valves before installing.
• Before hydrostatic testing ensure that union nuts are rmly screwed into position. Take care not to over-tighten.
• If connecting to metallic systems ensure that no undue stress is caused to valves.
• Never use a pipe wrench on thermoplastic.
• For detailed solvent welding, threading and anging connections read Hydroseal Canada’s Technical Guide.
SECTION 3 - INSTALLATION
• Do not exert excessive force when opening or closing valves.
• If sand or other large particles are in the piping system ensure to ush these out before operation of valves.
• Ensure that valves are opened and closed only by trained people, never use tools to open/close valves.
• If valve provided is lubricant free ensure that water is owing before attempting to operate handles.
SECTION 4 - ASSEMBLY
EN.005
Valve Operation Manual
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AUTHORISED SOLE AUSTRALIAN DISTRIBUTOR
UNIVERSAL PIPING PTY LTD - PERTH
[email protected]

VALVE OPERATION MANUAL
KAPLAN BALL VALVES
• Perform regular and scheduled maintenance. Leakages and tightness of valves may happen due to
temperature changes over prolonged periods.
• Check for cracks, deformities on the outside.
• Check for uids on the outside.
• Check tightness of union nuts.
• Verify the handle mechanism operates smoothly.
SECTION 8 - MAINTENANCE
• Perform a visual check prior to installation.
• Wear adequate protective equipment when working with tools, solvents, power drills etc.
• Do not attempt maintenance or replacement is there is still any pressure running through the piping system.
• Never use a pipe wrench on thermoplastic.
• Ensure all uid is completely drained from the piping system.
• Loosen union nuts before extraction of valve from line.
• If replacing parts such as seals, seats, balls etc then consult the manufacturer for any specic details.
SECTION 6 - DISASSEMBLY
• Refer to detailed actuator installation guide in Hydroseal Canada’s Technical Guide.
SECTION 7 - AUTOMATION
CLOCKWISE > to close CLOSED > should be perpendicular to the pipe
COUNTER CLOCKWISE > to open OPEN > should be parallel to the pipe
SECTION 5 - HANDLE POSITION
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Valve Operation Manual
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SECTION 9 - TROUBLESHOOTING
PROBLEM CAUSES SOLUTION
Leakage observed
when valve is closed
Union nuts may have loosened. Tighten the valve.
Seats may be scratched or eroded. Replace seat or entire valve.
Valve may have object within the body. Clear blockage.
Ball mechanism may be scratched, cracked or eroded. Replace ball or entire valve.
Leakage observed Unions nuts may have loosened. Tighten the valve.
O ring(s) may be scratched or eroded. Replace O rings or entire valve.
Handle not turning smoothly Valve may have object within the body. Clear blockage.
Deformity in valve or parts of valve. Replace valve.
Handle fails to engage Stem may be broken or cracked. Replace stem or entire valve.
The mechanism between stem and ball is broken. Replace stem and ball, or entire valve.
AUTHORISED SOLE AUSTRALIAN DISTRIBUTOR
UNIVERSAL PIPING PTY LTD - PERTH
[email protected]

SECTION 10 - TECHNICAL
VALVE OPERATION MANUAL
KAPLAN BALL VALVES
EN.005
Valve Operation Manual
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Øde
H1
ØD1 ØD
L1
L
I
Ød
W
1
2
3
4
5
6
789
11 101213
1-1/2" DN40
FLOW
OPERATING TEMPERATURE/PRESSURE
PP PVC
WORKING PRESSURE (kPa)
WORKING PRESSURE (PSI)
1600
1400
1200
1000
800
600
200
400
0
60 80 100 120 140 160 180 200 220 240 260 280
20 30 40 50 60 70 80 90 100 110 120 130
200
180
150
120
90
60
30
0
TEMPERATURE ºC
TEMPERATURE ºF
CPVC
JOINT END:
THREADED (PT.NPT.BSPF)
SOCKET (ASTM.DIN.JIS)
WORKING PRESSURE:
200 PSI
PART NOMINAL
SIZE
SOCKET,
THREAD TYPE UNIT OF MEASURE: MM ASTM DIN JIS
DN D D1 d H1 L L1 de l de l de l W
KPES.0050 1/2" DN 15 46.00 32.00 13.00 49.00 116.00 62.00 21.34 22.60 20.00 17.00 22.00 22.60 45.00
KPES.0075 3/4" DN 20 56.00 38.00 19.00 60.00 133.00 72.00 26.67 25.50 25.00 19.50 26.00 25.50 52.00
KPES.0100 1" DN 25 66.00 45.00 25.00 69.00 150.00 80.00 33.40 28.60 32.00 23.00 32.00 28.60 58.00
KPES.0125 1 1/4" DN 32 82.00 55.00 31.00 76.00 168.00 87.00 42.16 31.90 40.00 27.00 38.00 31.90 66.00
KPES.0150 1 1/2" DN 40 98.00 67.00 40.00 91.00 173.00 94.00 48.26 35.10 50.00 32.00 48.00 35.10 69.00
KPES.0200 2" DN 50 120.00 81.00 50.00 110.00 206.00 112.00 60.32 38.20 63.00 37.50 60.00 38.20 81.00
KPES.0250 2 1/2" DN 65 120.00 89.00 50.00 110.00 211.00 112.00 73.02 41.40 75.00 41.50 76.00 41.40 81.00
KPES.0300 3" DN 80 162.00 108.00 75.00 140.00 262.00 147.00 88.90 48.00 90.00 51.00 89.00 51.00 118.00
KPES.0400 4" DN 100 220.00 134.00 100.00 185.00 311.00 177.00 114.30 57.50 110.00 61.00 114.00 61.00 140.00
Pressure Loss
Calculation Formula
∆P = Pressure Drop
Q = Flow in GPM
Cv = Flow Coefficient
∆P = [ ]2
Q
Cv
CV FACTORS
SIZE FACTOR SIZE FACTOR
1/4" - 1 1/2" 90
3/8” - 2" 140
1/2" 8 2 1/2" 330
3/4" 15 3" 480
1" 29 4" 600
1 1/4" 75 6” -
CONSTRUCTION
NO PARTS PCS MATERIALS
1 HANDLE CAP 1 ABS
2 HANDLE 1 ABS
3 STEM 1 PVC, CPVC, PP
4 O-RING 2 EPDM, VITON
5 NUT 2 PVC, CPVC, PP
6 CONNECTOR 2 PVC, CPVC, PP
7 INSERT 1 PVC, CPVC, PP
8 BODY 1 PVC, CPVC, PP
9 O-RING 1 EPDM, VITON
10 O-RING 2 EPDM, VITON
11 BALL 1 PVC, CPVC, PP
12 SEAT 2 PTFE
13 O-RING 2 EPDM, VITON
SELECTION CHART
Lever Handle Operator and Gear Box Operator
SIZE MATERIAL CONNECTION SEALS PRESSURE RATING
1/2” ~ 4”
PVC
CPVC
PP
SOCKET or
THREAD EPDM or VITON 200 PSI @ 70F Non-Shock
AUTHORISED SOLE AUSTRALIAN DISTRIBUTOR
UNIVERSAL PIPING PTY LTD - PERTH
[email protected]