Manntek PERC Original operating manual

manntek.se
PERC Service instruction
6"

2 of 9 - Version 180427

3 of 9 - Version 180427
PERC 6“
MATERIAL:SS
Parts needed for service: Spare part kit and Seal kit (see p. 4)
Type of connection: Threaded and Flanged couplings have the
same service instruction.
Perform a service: If leaking
According to application service plan
Tools needed for service: TOOL 001
TOOL 030
Screwdriver
17mm Wrench

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MAINTENANCE AND SERVICE INSTRUCTION
Always depressurise the system and rinse off the parts before beginning any
maintenance work. Use protective goggles.
Use tweezers and wear gloves which are sufficient for cryogenic applications.
Do not touch adjacent parts with unprotected hands. Rinse off the parts once again
before starting the “daily inspection”
DAILY INSPECTION
All couplings should be briefly inspected at the start of each day’s operation. Check for dirt,
seal damage and any obvious physical damage (such as impacts, etc.).
REGULAR SERVICE
Regular service interval is very much depending on local regulations and application
conditions. If nothing else is specified and it is a new application with unknown parameters,
we recommend to make a first service after one year and decide then depending on the
inspection result about further intervals.
The service procedure shall be as follows:
1. Exchange sealing at least once a year.
2. Replace worn or damaged components.
REASSEMBLING AFTER RELEASE
Follow steps 1-2 & 11-17 to reassemble the coupling after release.
USE ONLY ORIGINAL MANNTEK SPARE PARTS FOR MAINTENANCE.
SPARE PART KIT
Example for a 6” coupling (NCP6…)
Seal kit (O-NCP6-06)
Bolt kit (S-NCP6-44-xx)
xx means the break force on the bolt. The break force can be found on the ID plate and on
each bolt.
PLEASE NOTE!
Make sure that you are using no grease for cryogenic applications.
PICTURES MAY DIFFER FROM ORIGINAL PRODUCT

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1. AFTER RELEASE
When the coupling should go into service there is a danger
that the fluid will spurt out. Special protective measures such
as personal protective equipment must therefore be adopted.
Always ensure the system is cleaned in a proper manner.
After cleaning, remove any residue from the cleaning agent.
a Wear suitable personal protective
equipment.
b Make sure that the coupling is
depressurized and empt
y
.
c Clean coupling before disassembly
(use cleaning agent suitable for the
pumped fluid).
2. VISUAL INSPECTION
Screw out the destroyed parts of the breaking bolts.
Check for dirt, seal damage and any obvious physical
damage (such as impacts, etc.).
3. DISASSEMBLE
Unscrew the three screws that lock the spindle steering.
There is a distance pin in the piston protruding
from the housing.
For disassembling a support plate with a hole in the middle,
where the distance pin will get free, will avoid any damage of
the inner parts
4. DISASSEMBLE
Press down the spindle steering and turn it free. Release it
carefully
Piston guide is spring loaded. Risk of injury.
Using our special tool makes work easier and therefore
increases safety.
Repeat the same procedure as described in step 3+4 with
the second half.

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5. DETAIL PARTS AFTER DISASSEMBLING
Take out all the parts from the body
Pos.2 – Piston
Pos.7 – Spring
Pos.5 – Spring cap
Pos.4 – Spindle steering
Pos.18 – Body
6. PISTON O-RING
Replace the O-ring (pos.3) on the piston with a new O-ring.
Be careful when removing the O-ring. Do not
scratch the sealing surface.
Make sure that the seal doesn’t get scratched
when mounting.
For mounting the new O-ring use MannTek spare parts only.
7. PERC
Test if the Perc valve is rotating without problems
8. MOUNTING PISTON
The piston is bigger in diameter than the three brackets for
the piston guide.
Introduce the piston as shown. Put it into a relaxing position
in the valve seat. Take care; the piston is sticking out on the
other side.
For assembling a support plate with a hole in the middle will
be helpful.
9. Reassemble coupling halves
Fit the spring with spring cap and spindle steering with
guidance bushing. Press down the spindle steering and turn,
to fix it in its position.
2 7
4+5
18

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10. LOCKING THE SPINDLE STEERING
Fit the screws into the given holes in the body and fix the
spindle steering by mounting the three locking screws. Use
Loctite® 243 for locking the screws.
Repeat the same procedure with the second half.
11. OUTER BODY SEALING RING
Replace the sealing rings (pos.15, pos.50, pos.51, pos.52,
pos.53) on the body with a new one.
Be careful when removing the lip-seal. Do not
scratch the sealing surface.
Make sure that the seal doesn’t get scratched
when mounting. The open profile should be in the
direction which is shown in the picture.
12. BREAKING BOLTS
Replace the bolts only by original spare parts from MannTek
with the same breaking force.
Total break force for the bolts can be found on the head of
each bolt. (13 kN in the pictures)
Left: destroyed bolt after release
Right: new breaking bolt
13. BREAKING BOLTS
Screw in the bolts into the intended position.
If necessary, tighten the bolt with a wrench.
Do not use a screwdriver over the weak section
15
51
52 50

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14. REASSEMBLE COUPLING
Set both halves onto each other and press them carefully
together. The breaking pins should align to the bore holes in
the second half.
It is important that the bodies align to each other
when pressing the halves together. Do it carefully,
not to destroy the lip-seal.
Using a press and a fixture makes work easier.
15. FIX BREAKING BOLTS
Screw on the nuts by hand until stop when halves are
pressed together.
Do not use force for tightening! Risk of destroying
bolts.
16. FIX BREAKING BOLTS
Fasten it a little bit with a wrench, max 45 degrees.
Tool: Standard wrench 17mm
It is important that all 3 bolts are mounted in the
same way. Risk that one bolt will be destroyed
before the others.
17. FIX BREAKING BOLTS
Screw on the second nut and lock the first one. Hold the first
one with a wrench to avoid forces on the breaking bolt.
After the coupling is completely reassembled provide a
pressure test according to test procedure on page 9.
Loctite® is registered trademark of Henkel.

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TEST PROCEDURE
After each service a tightness test of each coupling is mandatory.
The following test parameters are in accordance with EN12266, EN14432 and ISO5208:
Shell tightness test (air/N2): 6 bar +/- 1bar stop time 60 s.
Instead of dry air / N2 we recommend making the tightness test with liquid nitrogen or with
LNG.
If a pressure test should be achieved for the coupling mounted in an assembly, follow the
respective test instructions for the equipment but do not exceed our recommended maximum
test pressure of the coupling which you will find in the following table. If testing with higher
pressure is necessary, please ask our sales department for a special test bolt kit.
It is not recommended to use liquids for the tests which will freeze under operation with LNG.
If so, it must be guaranteed that the coupling is completely free of liquid before it will be used
in operation.

Maximum Test Pressure depending on size and breaking force:
DN 25 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150
kN ba
r
kN ba
r
kN ba
r
kN ba
r
kN ba
r
kN ba
r
kN ba
r
4 10 7 10 11 10 18 10 28 10 40 10
6 16 10 16 15 16 24 16 37 16 54 16
7 20 12 20 18 20 28 20 45 20 65 20
9 25 15 20 23 25 36 25 56 25 81 25
92 25
3 16 12 50 20 30 30 32 48 35 75 40 108 40
3,2 16 13 37,5 22 37,5 33 37,5 52 37,5 81 37,5 117 37,5
Approved couplings get stamped on the piston.
Number tested: 100%
STORAGE
Store coupling in a dry, dust free, dark place, in ambient temperature.
© Copyright 2016 Mann Teknik AB. Mann Teknik AB reserves the right to make changes at any time in
prices, materials, specifications and models and to discontinue models without notice or obligations.