Orbinox CW Instruction manual

MODEL
CW
ORBINOX SPAIN Pol.Ind. s/n-20270 ANOETA. Tel:[phone] Fax:[phone] e-mail:[email protected]
ORBINOX COMERCIAL, ORBINOX CANADA, ORBINOX USA, ORBINOX UK, ORBINOX INDIA
www.orbinox.com
INSTALLATION, OPERATION & MAINTENANCE MANUAL
INDEX
Page
0.-Description .........................………..................................... 2
1.-Handling ..................................………................................ 2
2.-Installation .................................……….............................. 2
3.-Actuators .....................................………............................ 5
4.-Maintenance .....................................………....................... 5
4.1.-Gland packing replacement …….………............... 5
4.2.-Seal replacement......………....…....……................ 6
4.3.-Gasket replacement ..…....………........….............. 7
4.4.-Lubrication …………………….……………..……… 8
5.-Flush Ports ……………………………………………………. 8
6.-Storage …………................................…..………................. 8
7.-Parts list & drawing ..................................………............…. 9

. 2004 EDITION
CW-2/9
www.orbinox.com
MODEL
CW
0.-DESCRIPTION
The CW model knife gate is a bonneted, uni-directional valve with full flange. It is designed to
work with high-pressure fluids.
1.-HANDLING
When handling an Orbinox valve please pay attention to the following points:
•Do NOT attach lifting gear to the valve actuators or gate guards. They are not
designed to bear the weight, and could easily be damaged.
•Do NOT lift the valve by the valve bore.
This can cause damage to the seating surfaces and seals.
Ideally when using lifting gear to move an Orbinox valve, it should be supported by two or more
eyebolts screwed into the tapped fixing holes in the valve body.
SAFETY WARNING:
•Check that the lifting gear is rated to carry the weight of the valve.
•Make sure the eyebolts have the same thread as the boltholes and that they are well
secured.
During installation it is recommended to lift the valve via soft straps. These can be to the upper
part of the valve body.
2.-INSTALLATION
To avoid personal injury or damage to property from the release of process fluid:
-Those in charge of handling and maintenance of the valve must be qualified and
trained in valve operations.
-Use appropriate personal protection equipment (gloves, safety shoes, etc).
-Shut off all operating lines to the valve and place a warning sign.
-Isolate the valve completely from the process.
-Release process pressure.
-Drain the process fluid from the valve.
Before installation, inspect the valve body and components for any damage that may have
occurred during shipping or storage. Make sure the internal cavities within the valve body are
clean. Inspect the pipeline and mating flanges, making sure the pipe is free of foreign material
and that the flanges are clean.
The valve is unidirectional. It should be installed with pressure exerted against the seat. The
words “SEAT SIDE” are marked on the valve body to indicate the position of the valve seat.
Installation and the correct orientation with respect to the direction of the flow is the
responsibility of the user.

. 2004 EDITION
CW-3/9
www.orbinox.com
MODEL
CW
It should be noted that the direction of flow and differential pressure, do not always coincide.
Special care should be taken to maintain the correct distance between the flanges and to
ensure that they are parallel to the valve body. Incorrect alignment of the valve can cause
deformations, which can lead to difficulties in operation.
The following table gives the maximum torque values for the valve fixing bolts. Also shown is
the maximum depth (T) allowed for the tapped blind boltholes drilled into the valve body.
DN 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000
T (mm) 13 13 13 13 18 18 21 25 25 25 25 35
Kg.m 6 6 7 7 7 11 11 15 15 19 19 23 23 28 28 34
The valve can be mounted in any position with regard to the pipe. However, it is advisable to
place it vertically in horizontal pipeline (A) if the installation allows it. (Please consult the
technical department at Orbinox).

. 2004 EDITION
CW-4/9
www.orbinox.com
MODEL
CW
With larger diameters (> 300 mm), heavy actuators (pneumatic, electric, etc.), or with the valve
installed horizontally (B) or at an angle (C) on a horizontal pipeline, the installation will require
the construction of suitable supports. (See the following diagram and consult the technical
department at Orbinox).
BB
A
CC
C*
A*
C*
* For these positions please consult Orbinox.
In vertical pipelines, the construction of suitable supports is always required (for further
information please consult the technical department at Orbinox).
Once the valve is installed, test that the flanges have been fastened correctly and that all
electrical and/or pneumatic connections have been properly made.
Where electric accessories are mounted on the valve (i.e. solenoid valves, electro-pneumatic
positioners, etc.), the valve must be earthed correctly before being put into operation.
First, operate the valve with no flow in the pipeline. Then test operation and valve seal with
flow. It should be noted that the packing material might settle in shipping/storage, which can
cause minor leakage. This can be remedied by tightening the gland follower (5) during
installation. Once performance has been tested, the valve can be put into operation.

. 2004 EDITION
CW-5/9
www.orbinox.com
MODEL
CW
3.-ACTUATORS
3.1.-Handwheel
To open the valve turn the handwheel (11) anticlockwise. To close turn the handwheel
clockwise.
3.2.-Pneumatic
Valves are usually supplied with a double acting pneumatic actuator although, upon
request, we can supply single-acting actuators. In both cases, the inlet air pressure should
be, between 3,5 to 10 Kg/cm2.
It is essential for a good maintenance of the cylinder that air should be well dried, filtered
and lubricated.
It is recommended to actuate the cylinder 3-4 times before the start up, once it is installed
in the pipeline.
3.3.-Electric actuator
Depending on the type or make of the electric actuator, specific instructions (i.e. a
manufacturer’s manual) will be supplied.
4.-MAINTENANCE
To avoid personal injury or damage to property from the release of process fluid:
-Those in charge of handling and maintenance of the valve must be qualified and
trained in valve operations.
-Use appropriate personal protection equipment (gloves, safety shoes, etc).
-Shut off all operating lines to the valve and place a warning sign.
-Isolate the valve completely from the process.
-Release process pressure.
-Drain the process fluid from the valve.
The only maintenance required is to change the gland packing (4) or the seal (3) if the valve is
a resilient seated type.
The life of these elements will depend on the working conditions of the valve such as:
pressure, temperature, abrasion, chemical action, number of operations, etc.
4.1. -Replacement of the gland packing (4):
Although the design of the valve bonnet allows the stuffing box of the bonnet to be sealed
from below, we advise that the valve is depressurised prior to beginning any maintenance.
1) Open the valve fully, to tighten the stem against the stuffing box.
2) Remove gate guards (if the valve has them).
3) Loosen the nuts of the gland follower (5) and remove it. (Photo 1)
4) Remove the old packing (4) and clean the stuffing box.
5) Insert the new packing rings (4), making sure that the ring joints alternate (the first on
one side of the gate, the next on the other and so on). (Photo 2)
6) Once the necessary packing rings (4) have been inserted, proceed with a steady
initial tightening, of the gland follower (5). (Photo 1)

. 2004 EDITION
CW-6/9
www.orbinox.com
MODEL
CW
Photo 1 Photo 2
7) Remount the gate guards (if the valve has them).
8) Carry out some operations with a loaded circuit and then re-tighten the gland follower
(5) to prevent leakage.
4.2.-Replacement of the seal (3) (only applicable to resilient seated valves):
1) Remove the valve from the pipeline.
2) Remove the seal retainer ring (10) which support the seals (3).
3) Remove the worn seal (3) and clean the seal housing.
4) Once the new seal (3) is cut according to size, insert it into the seat housing (making
sure that the union of the seal is at the top). (Photos 3 and 4)
Seal lengths
ND 50 65 80 100 125 150 200 250 300 350 400 450 500 600
Lengths (mm)
205 255 295 365 440 510 680 860 1020 1190 1350 1510 1630 2010
Photo 3 Photo 4
5) Insert the seal retainer ring (10) by hammering gently around the edge. (Photos 5 and
6)
6) Open and close the valve two or three times before returning it to the installation.

. 2004 EDITION
CW-7/9
www.orbinox.com
MODEL
CW
Photo 5 Photo 6
4.3. -Replacement of the gasket (7):
1) Remove the valve from the pipeline.
2) Loosen the nuts between the body (1) and the bonnet (13). (Photo 7)
3) Lift the bonnet (13), until the gate (2) is free. (Photo 8)
Photo 7 Photo 8
4) Change the gasket (7), between body (1) and bonnet (13). (Photo 9)
Photo 9
5) Remount the bonnet onto the valve (with the gate cleaned), and screw it into the body
(1). (Photos 8 and 7)
6) Open and close the valve two or three times before returning it to the installation.

. 2004 EDITION
CW-8/9
www.orbinox.com
MODEL
CW
4.4. -Lubrication:
Twice a year, it is recommended to remove the protection cap (12) and fill up the stem
protector (15) halfway with a calcium-based grease with the following characteristics:
highly water resistant, low ash content, and excellent adherence.
5.-FLUSH PORTS
The valves come fitted with flush ports (14) to allow connection to a cleaning system to flush
the bonnet with water or air. The ports are plugged with threaded metal plugs. These can be
removed for connection to a cleaning system, or for flushing the bonnet in the event of a
blockage.
6.-STORAGE
For long periods it is recommended to store the valves in a well-ventilated room. Valves
should not be exposed to temperatures higher than 30ºC, as some soft seal materials can be
damaged when exposed to higher temperatures.
If outdoor storage cannot be avoided, cover the valve and protect it from sources of heat or
direct sunlight. Provide good ventilation to avoid moisture.

. 2004 EDITION
CW-9/9
www.orbinox.com
MODEL
CW
7.-PARTS LIST & DRAWINGS
1. –BODY 8. –YOKE
2. –GATE 9. –STEM NUT
3. –SEAL 10. –SEAL RETAINER RING
4. –PACKING 11. –HANDWHEEL
5. –GLAND FOLLOWER 12. –CAP
6. –STEM 13. –BONNET
7. –GASKET 14. –FLUSH PORTS
15. –STEM PROTECTOR