Orbinox BR Instruction manual

CANADA
CANADACANADA
CANADA
,
, ,
,
USA
USAUSA
USA
, BRAZIL,
, BRAZIL, , BRAZIL,
, BRAZIL,
CHILE,
CHILE, CHILE,
CHILE,
SPAIN,
SPAIN, SPAIN,
SPAIN,
UK
UKUK
UK
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FRANCE
FRANCEFRANCE
FRANCE
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GERMANY
GERMANYGERMANY
GERMANY
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INDIA
INDIAINDIA
INDIA
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CHINA
CHINACHINA
CHINA
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,
SOUTH EAST ASIA
SOUTH EAST ASIASOUTH EAST ASIA
SOUTH EAST ASIA
www.orbinox. om
www.orbinox. omwww.orbinox. om
www.orbinox. om
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
MODEL BR

.
EDITION 01-2016
BR-2/10
www.orbinox. om
MODEL BR
INDEX
INDEXINDEX
INDEX Page
0.- Des ription .........................…………………………………..……................................. 2
1.- Handling ..................................………..............................…………………………….. 2
2.- Installation .................................………..................................................................... 4
3.- A tuators .....................................………................................................................... 6
4.- Maintenan e .....................................……….............................................................. 6
4.1.- Gland pa king repla ement and sleeve …….………................................... 7
4.2.- Lubri ation ......………………...…....…….................................................... 8
5.- Storage …………................................…..………....................................................... 9
6.- Parts list & drawing ..................................……………………………………..…......... 10
0.- DESCRIPTION
The BR model knife gate is a bi-dire tional valve and onsequently it an be installed without
onsidering the flow dire tion.
This valve is designed for general industrial servi e appli ations. The design of the body and seat
assures non- logging shut-off with suspended solids.
The BR valve omplies with the following European dire tives:
- DIR
DIR DIR
DIR 2006
20062006
2006/
//
/42
4242
42/EC (ma hines)
/EC (ma hines)/EC (ma hines)
/EC (ma hines)
- DIR 97/23/EC (PED)
DIR 97/23/EC (PED)DIR 97/23/EC (PED)
DIR 97/23/EC (PED) Fluid: Group 1 (b), 2 (Cat. I, mod.A)
It may also omply with the dire tive:
DIR 94/9/EC (Explosive Atmospheres)
DIR 94/9/EC (Explosive Atmospheres)DIR 94/9/EC (Explosive Atmospheres)
DIR 94/9/EC (Explosive Atmospheres)
The BR valve may omply with the dire tive regarding equipment and prote tive systems for their
use in explosive atmospheres. In these ases, the logotype shall appear on the identifi ation
label of the valve. This label shows the exa t lassifi ation of the zone where the valve an be
used. The user will be liable for its use in any other zone.
This dire tive only applies in the following atmospheri onditions:
0,8 bar ≤ P ≤ 1,2 bar
-20ºC/-4Fº < T < 60ºC/140Fº
Any in rease in temperature due to fri tional warmth is negligible, sin e the relative speed of
the moving parts is extremely low.
The risk analysis asso iated to this dire tive does not take into a ount the fluid that goes
through the valve, even when su h fluid produ es an explosive atmosphere. The user must take
into a ount the risks that the fluid generates, su h as:
-heating of the valve surfa e.
-generation of ele trostati harges aused by displa ement of the fluid.
-sho k waves aused by the installation (water hammer), internal rashes generated by the
pellets or the risks due to foreign bodies sus eptible of being present in the installation.
1.- HANDLING
The valves are pa ked a ording to the appropriate transport standards. If you re eive a shipment with
damaged pa kaging, please inform the transport ompany in writing and onta t your Orbinox
representative.

.
EDITION 01-2016
BR-3/10
www.orbinox. om
MODEL BR
When handling an Orbinox valve please pay attention to the following points:
•Do NOT atta
Do NOT attaDo NOT atta
Do NOT atta h lifting gear to the valve a tuators or gate guards
h lifting gear to the valve a tuators or gate guardsh lifting gear to the valve a tuators or gate guards
h lifting gear to the valve a tuators or gate guards. They are not designed to
bear the weight, and ould easily be damaged.
•Do NOT lift the valve by the valve bore
Do NOT lift the valve by the valve boreDo NOT lift the valve by the valve bore
Do NOT lift the valve by the valve bore.
This an ause damage to the seating surfa es and seals.
•Che k that sele ted lifting gear is rated to arry the weight of the valve.
•The valve an be handled using eyebolts, soft straps or slings.
•Eyebolts: make sure the eyebolts have the same thread as the boltholes and they are all well
se ured. Ideally when using lifting gear to move an Orbinox valve, it should be supported by
two or more eyebolts s rewed into the tapped fixing holes in the valve body.
•Soft straps: with the valve in the losed position, the straps should be pla ed between the
gland area and the bore su h that the valve is balan ed.
Fig. 1 Handling with eyebolts
Fig. 1 Handling with eyeboltsFig. 1 Handling with eyebolts
Fig. 1 Handling with eyebolts
Fig. 2 Handling with soft straps
Fig. 2 Handling with soft strapsFig. 2 Handling with soft straps
Fig. 2 Handling with soft straps

.
EDITION 01-2016
BR-4/10
www.orbinox. om
MODEL BR
2.- INSTALLATION
To avoid personal injury or damage to property from the release of pro ess fluid:
•Those in harge of handling and maintenan e of the valve must be qualified and trained in
valve operations.
•Use appropriate personal prote tion equipment (gloves, safety shoes, et ).
•Shut off all operating lines to the valve and pla e a warning sign.
•Isolate the valve ompletely from the pro ess.
•Release pro ess pressure.
•Drain the pro ess fluid from the valve.
•A ording to EN 13463
EN 13463EN 13463
EN 13463-
--
-1 (15),
1 (15), 1 (15),
1 (15), during installation and maintenan e operations, use hand
tools (non ele tri )
(non ele tri ) (non ele tri )
(non ele tri ) with Working Allowan e.
Before installation, inspe t the valve body and omponents for any damage that may have o urred
during shipping or storage. Make sure the internal avities within the valve body are lean. Inspe t the
pipeline and mating flanges, making sure the pipe is free of foreign material and that the flanges are
lean. Note that these bi-dire tional knife gate valves are not suitable for dead-end servi e without a
slight modifi ation or a ounter flange, please onsult fa tory.
Spe ial are should be taken to maintain the orre t distan e between the flanges and to ensure that
they are parallel to the valve body. In orre t alignment of the valve an ause deformations, whi h an
lead to diffi ulties in operation.
The following table gives the maximum torque values for the valve installation bolts. Also shown
is the maximum depth (T) allowed for the tapped blind boltholes drilled into the valve body.
With heavy a tuators (pneumati , ele tri , et .), with the valve installed horizontally (B) or at an angle
(C) on a horizontal pipeline, the installation might require the onstru tion of suitable supports. (See the
following diagram and onsult the te hni al department Orbinox).
BB
A
CC
C*
A*
C*
* These positions are not re ommended.
DN
DNDN
DN
2”
50
2,5”
65
3”
80
4”
100
5”
125
6”
150
8”
200
10”
250
12”
300
T (in h
)
(mm)
11/32”
11
11/32”
11
11/32”
11
11/32”
11
3/8”
14
3/8”
14
3/8”
14
1
8
/32”
18
1
8
/32”
18
Kg.m
lbf x ft
6
43
6
43
6
43
6
43
7
50
7
50
7
50
11
80
11
80

.
EDITION 01-2016
BR-5/10
www.orbinox. om
MODEL BR
On e the valve is installed, test that the flanges have been fastened orre tly and that all ele tri al
and/or pneumati onne tions have been properly made.
These instru tions must be observed when installing an Orbinox knife gate valve in an ATEX zone:
•Make sure the valve is ATEX marked a ording to the requested zone and it in ludes all
anti-stati devi es.
•Che k ontinuity between the body of the valve and the pipe (test in a ordan e with EN
12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).
•This he k must be done every time the valve has been removed from the line, servi ed,
and put ba k to the line.
The operation of automated valves requires fitted gate overs (optional in some ountries).
First, operate the valve with no flow in the pipeline. Then test operation and valve seal with flow. It
should be noted that the pa king material might settle in shipping/storage, whi h an ause minor
leakage. This an be remedied by tightening the gland follower (6) during installation. The nuts shall be
tightened gradually and rosswise until the leakage stops (see the next figure). Che k that there is no
metal onta t between the gland follower (6) and the gate (2).
If the gland follower nuts are over-tigtened, the for e needed to operate the valve will in rease, the
valve fun tion will be affe ted and the pa king lifespan will be shortened.
The table below shows the maximum torque value for tightening the gland follower nuts.
DN (in h/mm)
DN (in h/mm)DN (in h/mm)
DN (in h/mm) Torque (N.m)
Torque (N.m)Torque (N.m)
Torque (N.m) Lbsf x ft
Lbsf x ftLbsf x ft
Lbsf x ft
2”/50 – 4”/100 20 144
5”/125 – 8”/200 30 216
10”/250 – 12”/300 35 263
On e performan e has been tested, the valve an be put into operation.
Approximate weight of the handwheel-operated valves (rising stem):
DN
DNDN
DN (in h)
(in h)(in h)
(in h)
(mm)
(mm)(mm)
(mm)
2”
50
2,5”
65
3”
80
4”
100
5”
125
6”
150
8”
200
10”
250
12”
300
Weight
WeightWeight
Weight
(lbs
(lbs(lbs
(lbs
)
))
)
(kg)
(kg)(kg)
(kg)
15
7
17
8
20
9
24
11
33
15
40
18
66
30
97
44
127
58

.
EDITION 01-2016
BR-6/10
www.orbinox. om
MODEL BR
3.- ACTUATORS
3.1.- Handwheel
To open the valve turn the handwheel (14) ounter lo kwise. To lose turn the handwheel
lo kwise.
3.2.- Pneumati
Valves are usually supplied with a double a ting pneumati a tuator although, upon request,
we an supply single-a ting a tuators. In either ase the air supply pressure an vary between
55psi/3,5 Kg/ m2 and 150psi/10 Kg/ m2. However, the size of the a tuator for ea h valve
has been designed for an air supply pressure of 90psi/6 Kg/ m2.
It is essential for a good maintenan e of the ylinder that air should be well dried, filtered and
lubri ated.
It is re ommended to a tuate the ylinder 3-4 times before the start up, on e it is installed in the
pipeline.
Air quality requirements a ording to ISO 8573-1 Grade 5:4:3 for normal pro esses, Grade
5:3:3 for old temperature appli ations (min. -20º C water dew point); for ylinders with
positioners Grades 3:4:3 (standard) / 3:3:3 (-20ºC).
3.3.- Ele tri a tuator
Depending on the type or make of the ele tri a tuator, spe ifi instru tions (i.e. a
manufa turer’s manual) will be supplied.
•Allowed a tuators for ATEX zones: Hand wheel, Chain Wheel, Bevel Gear, Lever,
Pneumati A tuator (double a ting ONLY
ONLYONLY
ONLY) and Ele tri Motor
•Make sure these a tuators are ATEX marked a ording to the requested zone.
•Maximum travel speed of the gate must equal or below 0,05 m/s
4.- MAINTENANCE
The valve must not undergo any modifi ations without a previous agreement with ORBINOX.
ORBINOX shall not be liable for any damages that may arise due to the use of non original parts or
omponents.
To avoid personal injury or damage to property from the release of pro ess fluid:
•Those in harge of handling and maintenan e of the valve must be qualified and trained in
valve operations.
•Use appropriate personal prote tion equipment (gloves, safety shoes, et ).
•Shut off all operating lines to the valve and pla e a warning sign.
•Isolate the valve ompletely from the pro ess.
•Release pro ess pressure.
•Drain the pro ess fluid from the valve.
•A ording to EN 13463
EN 13463EN 13463
EN 13463-
--
-1 (15),
1 (15), 1 (15),
1 (15), during installation and maintenan e operations, use hand
tools (non ele tri )
(non ele tri ) (non ele tri )
(non ele tri ) with Working Allowan e.
The only maintenan e required is to hange the gland pa king (5) or the sleeve (3).
The life of these elements will depend on the working onditions of the valve su h as: pressure,
temperature, abrasion, hemi al a tion, number of operations, et .
To hange the sleeve, remove the valve from the line.

.
EDITION 01-2016
BR-7/10
www.orbinox. om
MODEL BR
4.1.
4.1. 4.1.
4.1. -
--
- Repla ement of the gland pa king (
Repla ement of the gland pa king (Repla ement of the gland pa king (
Repla ement of the gland pa king (5
55
5) and the s
) and the s) and the s
) and the sleeve
leeveleeve
leeve (3)
(3)(3)
(3):
::
:
1. Depressurise the ir uit and pla e the valve in lose position.
2. Remove the gate guards (for automated valves only).
3. Non rising stem valves. Photo1: Release the stem nut (8) from the gate (2). Rising stem valves,
Photo 2: Release the spindle or stem (7) from the gate (2).
Photo 1 Photo 2
4. Loosen the s rews of the yoke (9) and remove it (without loosing the a tuator).
5. Loosen the nuts of the gland follower (6) and remove it. (Photo 5)
6. Remove the old pa king rows (5), gate (2), 2 seat rings (4) and the old sleeve (3). Clean the
stuffing box area.
7. In order to have the sleeve orre tly positioned, have the new sleeve (3) greased and insert it in
the body (1) avity.
8. Introdu e the gate (2) ompletely until the sleeve is totally entered. (Photo 3)
9. Fix the 2 seat rings (4) and se ure them by means of two bolts. (Photo 4)
Photo 3 Photo 4
10. On e the ne essary new rows of pa king (5) have been inserted, pro eed with a steady initial
tightening of the gland follower (6). (Photo 5)

.
EDITION 01-2016
BR-8/10
www.orbinox. om
MODEL BR
Photo 5
11. Reinstall the yoke (9) (with the a tuator) and tighten it.
12. Reinstall the stem nut (8) to the gate (2) (Non rising stem valves. Photo 1) or reinstall the stem
(7) to the gate (2)( Rising stem valves. Photo 2).
13. Reinstall the gate guards (for automated valves only).
14. Carry out some operations with a loaded ir uit and then re-tighten the gland follower (6) to
stop any leakage.
4.2.
4.2. 4.2.
4.2. -
--
- Lubri ation:
Lubri ation:Lubri ation:
Lubri ation:
Lubri ate the stem every 30 days with a al ium-based grease with the following hara teristi s: highly
water resistant, low ash ontent, and ex ellent adheren e.
Spe ial requirements for ATEX valves
Spe ial requirements for ATEX valvesSpe ial requirements for ATEX valves
Spe ial requirements for ATEX valves:
•The maintenan e personnel must be made fully aware of the risks of explosion, and it is
advisable that they re eive spe ifi training regarding ATEX.
•Periodi ity of he k and evaluation of graphite pa king status and valve ele tri al ondu tivity
must be determined by end user a ording to valve working onditions. In any ase, on e the
valve is put into operation, the pa king area must be revised after the valve has been stroked
100 times or after 3 months of operation, whi hever o urs first. After this preliminary
inspe tion, new inspe tion and s hedule must be determined by end user based on the results of
this first inspe tion.
•Clean the valve periodi ally to prevent dust a umulation. Do not sweep or dump the dust.
Always use a va uum leaner system
•Dead en servi e is not allowed.
•Do not apply any new oating to the valve. Should it require new oating, please onta t our
losest representative.
•Allowed sleeves: EPDM, FKM-FPM and NITRILE.
•Allowed pa king: ST
•Any other materials but those above are not allowed to be used in ATEX zones.
•In order to keep the ATEX approval, always use original spares from Orbinox.
Washer  DIN 6798A (This washer guarantees ontinuity among arbon steel parts, oated
in epoxy, yoke and body and stainless steel guards for oating thi knesses up to 200 mi rons)
ST pa king  ORBINOX ST: Syntheti pa king impregnated with PTFE
•After any maintenan e of ATEX valves, it is mandatory to he k that the valve is grounded
through the pipe, and there is ontinuity among the different valve omponents, su h as the
body, the gate, the supports, and guards (test in a ordan e with EN 12266-2 Standard, annex
B, points B.2.2.2. and B.2.3.1).

.
EDITION 01-2016
BR-9/10
www.orbinox. om
MODEL BR
MAXIMUM FLUID TEMPERATURES
MAXIMUM FLUID TEMPERATURESMAXIMUM FLUID TEMPERATURES
MAXIMUM FLUID TEMPERATURES
Atmosphere
AtmosphereAtmosphere
Atmosphere
Gas/air, steam/air, and mist/air
Gas/air, steam/air, and mist/airGas/air, steam/air, and mist/air
Gas/air, steam/air, and mist/air Dust/air
Dust/airDust/air
Dust/air
80% of minimum fluid ignition
temperature, minus 10ºK
2/3 of minimum dust loud ignition
temperature minus 85ºK
Note: these maximum fluid temperatures apply to all ategories. The differen es between ategories are
the onsideration of foreseeable malfun tion ases and rare malfun tions ases
MAXIMUM
MAXIMUM MAXIMUM
MAXIMUM S
SS
SLEEVE
LEEVELEEVE
LEEVE AND PACKING
AND PACKINGAND PACKING
AND PACKING TEMPERATURES
TEMPERATURESTEMPERATURES
TEMPERATURES
Max Temperature
Max Temperature Max Temperature
Max Temperature
(
((
(ºC)
C)C)
C)
(F
(F(F
(Fº)
))
)
SLEEVE
SLEEVESLEEVE
SLEEVE
EPDM
EPDM EPDM
EPDM FKM
FKMFKM
FKM-
--
-FPM
FPMFPM
FPM NITRILE
NITRILE NITRILE
NITRILE
120
248
200
392
120
248
Max Temperature
Max TemperatureMax Temperature
Max Temperature
(
((
(ºC)
C)C)
C)
(F
(F(F
(Fº)
))
)
PACKING
PACKINGPACKING
PACKING
ST
ST ST
ST
240
464
Note: Most of the time the sleeve´s maximum temperature apa ity is the key limitation fa tor when
evaluating valve maximum working temperatures. In ATEX zones these temperatures must be ompared
to those above related to limitation of fluids temperatures. Always onsider the most restri tive as
maximum valve working temperature.
5.- STORAGE
•For long storage periods keep the valves indoors in a safe and dry pla e and prote t it from any
impa t and or vibrations.
•Storage temperatures: -10ºC/ 14ºF to +40ºC/104ºF
•Valves must be stored in either full open or full losed position.
•For any omponent installed on the valves, ele tri motors, solenoid valves, et , please refer to their
own instru tion manuals

.
EDITION 01-2016
BR-10/10
www.orbinox. om
MODEL BR
6.- PARTS LIST & DRAWINGS
1.- BODY 8.- STEM NUT
2.- GATE 9.- YOKE
3.- SLEEVE 10.- AXIAL FIXING BUSH
4.- SEAT RING 11.- FRICTION WASHER
5.- PACKING 12.- GUIDE BUSH
6.- GLAND FOLLOWER 13.- SPRING PIN
7.- STEM 14.- HANDWHEEL