KLINGER 3530 Owner's manual

MANUAL
Installation / Operation / Maintenance
Flange STD：ANSI 150, PN10/16, JIS 10K
Temp. ：-20℃~120℃
Work Pres. ：10 / 16 BAR：DN40~DN600
10 BAR：DN650~DN1200
Pd. Date ：2017.1.13
Please Read All Of This Instruction Before
Installing Your 3530/353333/737 Valve
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 1 of 14
Operating Manual I s s u e D a t e 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73-O
1.CE MARKING AND THE PRESSURE EQUIPMENT DIRECTIVE 97/23/EC
This has been implemented in European Union law by the pressure Equipment Regulations SI
1999/2001.
The regulations apply to all valves with a maximum allowable pressure higher than 0.5 bar. Valves
with a maximum allowable pressure not exceeding 0.5 bar are outside the scope of the Directive.
Valves are categorized in accordance with the maximum working pressure, size and ascending
level of hazard, which is dependent on the fluid being transported. Fluids are classified as Group 1,
dangerous fluids or Group 2, all other fluid including steam. Categories are SEP (sound
engineering practice) and for ascending levels of hazard, I, II, III or IV. All valves designated as
SEP do not bear the CE mark. Categories I, II, III or IV carry the CE mark and require a Declaration
of Conformity. (Note – all valves up to and included 25 mm (1”) having a maximum allowable
pressure greater than 0.5 bar are designed SEP regardless of fluid group.)
2.PRODUCT LIFE CYCLE
The life of the valve is dependent on its application, frequency of use and freedom from misuse.
Compatibility with the system into which it is installed must be considered. The properties of the
fluid being transported such as pressure, temperature and the nature of the fluid must be taken into
account to minimize or avoid premature failure or non-operability. A well-designed system will take
into consideration all the factors considered in the valve design, but additionally electrolytic
interaction between dissimilar metals in the valve and the system must be examined. Before
commissioning a system, it should be flushed to eliminate debris and chemically cleaned as
appropriate to eliminate contamination, all of which will prolong the life of the valve.
3.LIMITS OF USE
The valves to which these installation, operation and maintenance instructions apply have been
categorized in accordance with the Pressure Equipment Directive.
The fluid to be transported is limited to Group 2 fluids i.e. non-hazardous and on no account
must these valves be used on any Group 1 fluid.
The seat material of these valves determines the limit of application as noted in the following table:
Fluid Group 2 Gas and Group 2 Liquid
Seat Material PN DN Category
Nitrile
Epdm
10
40 - 100
125 – 350
400 – 500
550 – 1200
SEP
I*
II*
III*
16
40 - 50
65 – 200
250 – 300
350 – 600
SEP
I*
II*
III*
* Category I, II and III require CE mark
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

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Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
4. OPERATING PRESSURES AND TEMPERATURES
4.1 PN rated valves
Seat
Material
Non-shock pressure at
Temperature range
Non-shock
pressure at
Max. temperature
EPDM 10 bar from -20 to 120℃℃10 bar at 120℃
16 bar from -20 to 120℃℃16 bar at 120℃
Nitrile 10 bar from -10 to 80℃℃10 bar at 80℃
16 bar from -10 to 80℃℃16 bar at 80℃
Not suitable for fatigue loading, fire testing, fire hazard environment, corrosive or erosive service,
transporting fluids with abrasive solids.
4.2 PRESSURE/TEMPERATURE RATING
Valves rated at PN10 to EN12334 must be installed in a piping system whose normal pressure
and temperature do not exceed these ratings.
If system testing will subject the valve to pressure in excess of the working pressure rating,
this should be within the test pressure for the body with the pressure applied upstream of the
obturator.
The maximum allowable pressure in valves as specified in the standards is for non-shock
conditions. Water hammer and impact for example, should be avoided.
If the limits of use specified in these instructions are exceeded or if the valve is used on
applications for which it was not designed, a potential hazard could result.
5. STORAGE CONDITION
For tentative storage before piping operation or for long-term storage, keep valves indoors in a cool
(temperature: -10 to 50 deg., humidity: 70% or less) and dark room, and maintain valve open at
round 10 degree. Do not remove the plastic bag covering the valve body. Keep away from
excessive dust and take care in protecting the valve and driving unit from excessive load.
If the valve remains unpacked for a long duration, dust and any foreign materials may enter the
seat, which may cause seat leakage.
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 3 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
6. INSTALLATION
Unpack the valve and check the inner parts are clean and free from foreign material and the
disk could be operated smoothly. All special packaging material must be removed.
The Fig. 3530/3533/737 butterfly valves are wafer pattern and are designed for bi-direction
tight shut off and to fit between flanges, located within the flange bolting.
Valves are precision manufactured items and as such, should not be subjected to misuse such
as careless handling, allowing dirt to enter the valve through the end ports, lack of cleaning
both valve and system before operation and excessive force during bolting.
When large valves are provided with lifting lugs or nuts, these should be used to lift the valve.
When installing butterfly valve directly to a check valve or pump, an extension piece should be
employed to prevent the disc of valve from touching check valve or pump.
Valves must be provided with adequate support. Adjoining pipework must be supported to
avoid the imposition of pipeline strains on the valve body.
Valve end protectors should only be permanently removed immediately before installation. The
valve interior should be inspected through the end ports to determine whether it is clean and
free from foreign matter.
The mating faces of the valve and of the adjoining pipework flanges should be checked for
correct flange, surface and condition. Do not use the flange gasket. If a condition is found
which might cause leakage, no attempt to assemble should be made until the condition has
been corrected.
Install the valve after the completion of all welding operations around the valve in order to
prevent damage caused by adhesion of welding patters.
Wait until the welded flange has cooled before installing the valve to the pipe. Never weld the
flange with the valve installed.
Parallel alignment of flanges is especially important in the case of the assembly of a valve
into an existing system.
Chamfer the edged of the flange mating with valve seat ring to avoid possible damage to the
seat ring.
Do not blow air after the valve installed in the pipe. Otherwise this may damage seat ring.
Clean the matching flange surface, if any rust or foreign matter adhere, remove with solution
such as organic solvent.
Check and see any distortion of the piping flange, misalignment, and damage to the gasket
surface of the flange.
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 4 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
Set a jack bolt to maintain the gap between flanges to insert the valve, the distance between
flanges should be 10mm wider than valve body, then the valve could be inserted without
interfere with flanges.
After center the pipe, insert bolts through the lugs of the valve and prevent it from dropping.
Before tightening the piping bolts, make sure the disc at an opened position and does not
interfere with the flange.
Tighten the piping bolts with a torque not higher than the torque shown in following table.
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 5 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
B
OLT TIGHTENING SEQUENCE
The piping bolts should be tightened alternately and evenly. Tighten one bolt and another
diagonally, and then repeat the same procedure to insure well balanced tightening. Please
refer to above BOLT TIGHTENING SEQUENCE.
On the completion of the piping, open and close the valve to make sure that the disc does not
touch the piping.
7. OPERATING
Prior to operation, clean the outside of the piping by air-purging, and the inside of the piping by
running water through the pipe.
On the completion of piping, open and close the valve once every two weeks, if the valve was
not in use for a long duration, open and close several times before actual operation.
Keep the valve fully open during the pressure test (in which applied pressure exceeds the
rated pressure). Never fully close the valve and use it as a blind flange.
To avoid possible damage to the lever, hand-wheel and valve, never use an extension bar on
the lever or “F” wrench on the hand-wheel. Unlike gate valves or glove valves, no torque
tighten is required.
Do not release the piping bolts before de-pressure the pipe system.
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 6 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
8. MAINTENANCE
The many Value features minimize wear and maintenance requirements. No routine lubrication is
required. All components - stem, disc, seat, taper pin, bushing, stem- seal, etc., are field
replaceable, no adjustment is required. If components require replacement, the valve may be
removed from the line by placing the disc near the closed position, then supporting the valve and
removing the flange bolts.
9. DISASSEMBLY AND ASSEMBLY
9.1. Disassembly
1. 1.5"(40A) - 12"(300A) Valve.
WAFER TYPE
LUG TYPE
FLANGE TYPE
3530
3533
VF-737
1 1/2 24 40
14 7212
SIZE
DN 40~300
INCH 1 1/2~12
a. Remove handle, manual gearbox or actuator from mounting flange.
b. Open the valve and position the disc around 135 degree from the fully close position. The
retainer pin is then exactly positioned inside the slot of the top flange.
c. Remove the retainer pin with a screwdriver or any sharp tool.
d. Pull out the stem from the body.
e. Take out the disc and liner from the body.
2. 14"(350A) - 24"(600A) Valve.
WAFER TYPE
LUG TYPE
FLANGE TYPE
3530
3533
VF-737
1 1/2 24 40
14 7212
SIZE
DN 350~600
INCH 14~24
a. Remove manual gearbox or actuator from mounting flange.
b. Remove the screws of upper cover. Remove the upper cover.
c. Loose the bottom cover bolts, remove the bottom cover.
d. Pull out both upper & lower stem from the body.
e. Take out the disc and liner from the body.
3. 26"(650A) - 48"(1200A) Valve.
WAFER TYPE
LUG TYPE
FLANGE TYPE
3530
3533
VF-737
1 1/2 24 40
14 7212
SIZE
DN 650~1800
INCH 26~72
a. Remove manual gearbox or actuator from mounting flange.
b. Put a match mark on disc before pull out the pins.
c. Pull out the upper stem and bottom stem.
d. Take out the disc and liner from the body.
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 7 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
9.2 . Assembly
1. 1.5"(40A) - 12"(300A) Valve
WAFER TYPE
LUG TYPE
FLANGE TYPE
3530
3533
VF-737
1 1/2 24 40
14 7212
SIZE
DN 40~300
INCH 1 1/2~12
Push the valve liner into an oval and push it into the body with seat stem holes aligned to
body stem holes.
Insert stem seal and bushing, and then push the stem into the stem hole of the body until
the bottom of the stem is flush with the inner top edge of the liner.
Install a light coating of silicone on the I.D. of the liner. Insert the disc into the seat by
lining up the disc hole with the stem hole of the seat. (Note: The broached octagon hole in
the disc must be toward the bottom of the valve body)
With a downward pressure the stem back and forth and rotating the disc, until the stem
touches the bottom of the body stem hole.
Pull out stem slightly and replace the stem seal and bush, make the dent of square stem
to be parallel with disc, then replace the retainer pin and push back the stem.
Drive the disc clockwise to close position.
Reassemble the actuator and adjust the open and close position.
2. 14"(350A) - 24"(600A) Valve.
WAFER TYPE
LUG TYPE
FLANGE TYPE
3530
3533
VF-737
1 1/2 24 40
14 7212
SIZE
DN 350~600
INCH 14~24
Push the valve liner into an oval and push it into the body with seat stem holes aligned to
body stem holes.
Insert stem seal and bushing, and then push the bottom stem into the stem hole of the
body until the bottom of the stem is flush with the inner top edge of the liner.
Install a light coating of silicone on the I.D. of the liner. Insert the disc into the seat by
lining up the disc hole with the stem hole of the seat. (Note: The broached octagon hole in
the disc must be toward the upper of the valve body)
Upside down the body let the bottom side of the body on the ground vertically and rotating
the disc and the bottom stem will go into the disc hole automatically.
Push the upper stem into the stem hole of the body,
Drive the stem and let the slot parallels with disc, then insert the pin and put on the upper
cover.
Screw up the bolts and tighten them up.
Insert the pin to the lower stem, then put on O-ring seal and bottom cover and tighten.
Reassemble the actuator and adjust the open and close position.
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 8 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
3. 26"(650A) - 48"(1200A) Valve.
WAFER TYPE
LUG TYPE
FLANGE TYPE
3530
3533
VF-737
1 1/2 24 40
14 7212
SIZE
DN 650~1800
INCH 26~72
Push the valve liner into an oval and push it into the body with seat stem holes aligned to
body stem holes.
Insert stem seal and bushing, then push the bottom stem into the stem hole of the Body
until the bottom of the stem is flush with the inner top edge of the liner.
Install a light coating of silicone or grease on the I.D. of the liner. Place the mounting
flange of the body on the ground vertically. Insert the disc into the seat by lining up the
disc hole with the stem hole of the seat. (Note: The match marks made on the disc before
disassemble are recognized which is upper side.)
Upside down the body let the bottom side of the body on the ground vertically and rotating
the disc and the bottom stem will go into the disc hole automatically.
Push the upper stem into the stem hole of the body, and put the pins into the pin holes.
Replace the tape seal of the plugs, and then tighten them up.
Reassemble the actuator and adjust the open and close position.
10. INSPECTION
The valve should be at zero pressure and ambient temperature prior to any inspection.
Maintenance Engineers & Operators are reminded to use correct fitting tools and equipment.
A full risk assessment and methodology statement must be compiled prior to any
maintenance.
The risk assessment must take into account the possibility of the limits of use being exceeded
whereby a potential hazard could result.
A maintenance program should therefore include checks on the development of unforeseen
conditions, which could lead to failure.
In systems where corrosion could be a potential hazard, wall thickness checks on the body
and bonnet should be made. This requires the removal of the valve from the pipeline at zero
pressure. If the wall and disc thickness has reduced by 25%, the valve must be replace.
For the supply of genuine Value spares or technical assistance contact KLINGER Denmark A/S
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 9 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
3530/3533/VF-73_ Series IRON Body 2”~12”
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 10 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
3530/3533/VF-73_ Series Steel Body 2”~12”
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 11 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
3530/3533/VF-73_ Series Iron Body 14”~24”
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 12 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
3530/3533/VF-73_ Series Steel Body 14”~24”
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 13 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
3530/3533/VF-73_ Series 26”~36”
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk

Page 14 of 14
Operating Manual Issue Date 1, 13, 2017 Edition 3
Installation，Operation & Maintenance Instructions Number 73_-O
3530/3533/VF-73_ Series 38”~48”
KLINGER Denmark A/S | Nyager 12-14, DK-2605 Broendby | T [phone] | www.klinger.dk