Orbinox EB Instruction manual

INSTALLATION, OPERATION &
MAINTENANCE MANUAL
MODEL EB
EBEB
EB
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.
EDITION 01-2017
EB-2/11
MODEL
EB
INDEX
INDEXINDEX
INDEX Page
0.- Description .........................…………………………………..……................................. 2
1.- Handling ..................................………..............................……………………………… 2
2.- Installation .................................………..................................................................... 4
3.- Actuators .....................................………................................................................... 6
4.- Maintenance .....................................……….............................................................. 7
4.1.- Gland packing and seal replacement .…....................................................... 7
4.2.- Lubrication …………………….………………………………………………..…… 9
5.- Storage …………................................…..………....................................................... 10
6.- Parts list & drawing ..................................……………………………………..…............ 11
0.- DESCRIPTION
The EB model knife gate is a bi-directional valve and consequently it can be installed without
considering the flow direction.
This valve is designed for general industrial service applications. The design of the body and seat
assures non-clogging shut-off with suspended solids.
The EB valve complies with the following European directives:
- DIR
DIR DIR
DIR 2006
20062006
2006/
//
/42
4242
42/EC (machines)
/EC (machines)/EC (machines)
/EC (machines)
- DIR
DIR DIR
DIR 2014/68/EU
2014/68/EU 2014/68/EU
2014/68/EU (PED)
(PED)(PED)
(PED) luid: Group 1 (b), 2 (Cat. I, mod.A)
It may also comply with the directive:
DIR
DIR DIR
DIR 2014/
2014/2014/
2014/34
3434
34/EU
/EU /EU
/EU (Explosive Atmospheres)
(Explosive Atmospheres)(Explosive Atmospheres)
(Explosive Atmospheres)
The EB valve may comply with the directive regarding equipment and protective systems for their
use in explosive atmospheres. In these cases, the logotype shall appear on the identification
label of the valve. This label shows the exact classification of the zone where the valve can be
used. The user will be liable for its use in any other zone.
This directive only applies in the following atmospheric conditions:
0,8 bar ≤ P ≤ 1,2 bar
-20ºC < T < 60ºC
Any increase in temperature due to frictional warmth is negligible, since the relative speed of
the moving parts is extremely low.
The risk analysis associated to this directive does not take into account the fluid that goes
through the valve, even when such fluid produces an explosive atmosphere. The user must take
into account the risks that the fluid generates, such as:
-heating of the valve surface.
-generation of electrostatic charges caused by displacement of the fluid.
-shock waves caused by the installation (water hammer), internal crashes generated by the
pellets or the risks due to foreign bodies susceptible of being present in the installation.
1.- HANDLING
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The valves are packed according to the appropriate transport standards. If you receive the packing
damaged, please inform the transport company in writing and speak to a company
representative. .

.
EDITION 01-2017
EB-3/11
MODEL
EB
When handling an Orbinox valve please pay attention to the following points:
•Do NOT attach lifting gear to the valv
Do NOT attach lifting gear to the valvDo NOT attach lifting gear to the valv
Do NOT attach lifting gear to the valve actuators or gate guards
e actuators or gate guardse actuators or gate guards
e 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
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 can cause damage to the seating surfaces and seals.
•Check that selected lifting gear is rated to carry the weight of the valve.
•The valve can 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
secured. 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.
•Soft straps: with the valve in the closed position, the straps should be placed between the
gland area and the bore such that the valve is balanced.
ig. 1 Handling with eyebolts
ig. 1 Handling with eyeboltsig. 1 Handling with eyebolts
ig. 1 Handling with eyebolts
ig. 2 Handling with soft straps
ig. 2 Handling with soft strapsig. 2 Handling with soft straps
ig. 2 Handling with soft straps
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.
EDITION 01-2017
EB-4/11
MODEL
EB
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.
•According to EN 13463
EN 13463EN 13463
EN 13463-
--
-1 (15),
1 (15), 1 (15),
1 (15), during installation and maintenance operations, use hand
tools (non electric)
(non electric) (non electric)
(non electric) with Working Allowance.
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 placement of a gasket between the valve and the counter flanges is not required, since the valve is
equipped with “O” rings in the flange face.
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
DNDN
DN 50
5050
50 65
6565
65 80
8080
80 100
100100
100 125
125125
125 150
150150
150 200
200200
200 250
250250
250 300
300300
300 350
350350
350 400
400400
400 450
450450
450 500
500500
500 600
600600
600 700
700700
700 800
800800
800 900
900900
900 1000
10001000
1000 1200
12001200
1200
T (mm)
T (mm)T (mm)
T (mm) 10 10 12 12 14 14 14 18 21 21 28 30 40 26 20 20 20 20 35
Kg.m
Kg.mKg.m
Kg.m 6 6 6 6 7 7 7 11 11 15 15 19 19 23 23 28 28 34 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).
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).
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.
EDITION 01-2017
EB-5/11
MODEL
EB
A
CC
C* C*
A*
BB
* or these positions please consult 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.
These instructions must be observed when installing an Orbinox knife gate valve in an ATEX zone:
•Make sure the valve is ATEX marked according to the requested zone and it includes all
anti-static devices.
•Check continuity between the body of the valve and the pipe (test in accordance with EN
12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).
•This check must be done every time the valve has been removed from the line, serviced,
and put back to the line.
The operation of automated valves is limited only with fitted gate covers.
irst, 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. The nuts shall be
tightened gradually and crosswise until the leakage stops (see the next figure). Check that there is no
metal contact between the glandfollower (5) and the gate (2).
If the glandfollower nuts are overtorqued, the force needed to operate the valve will increase,
the valve function will be affected and the box packing lifetime will be shortened.
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.
EDITION 01-2017
EB-6/11
MODEL
EB
The table below shows the absolutely maximum torque value for tightening the glandfollower nuts.
Overtorque might result in body and/or packing gland breakage.
D
DD
DN
NN
N Torque (N.m)
Torque (N.m)Torque (N.m)
Torque (N.m)
50 - 100 15
125 - 200 20
250 - 600 30
700 - 1200 35
Once performance has been tested, the valve can be put into operation.
Approximate weight of the handwheel-operated valve (rising stem):
DN
DNDN
DN 50
5050
50 65
6565
65 80
8080
80 100
100100
100 125
125125
125 150
150150
150 200
200200
200 250
250250
250 300
300300
300 350
350350
350 400
400400
400 450
450450
450 500
500500
500 600
600600
600 700
700700
700 800
800800
800 900
900900
900 1000
10001000
1000 1200
12001200
1200
Kg
KgKg
Kg 7 8 9 11 15 18 30 44 58 96 124 168 192 245 405 512 680 865 1055
3.- ACTUATORS
3.1.- Handwheel
To open the valve turn the handwheel (12) anticlockwise. To close turn the handwheel
clockwise.
3.2.- Lever
To operate the valve with this device, first loosen the locking clamp located on the top of the
yoke (8). Then either open or close the valve by moving the lever in the desired direction. inally,
fix the position of the lever with the locking clamp.
3.3.- Pneumatic
Valves are usually supplied with a double acting pneumatic actuator although, upon request,
we can supply single-acting actuators. In either case the feed pressure can vary between 3,5
and 10 Kg/cm2.However, the size of the actuator for each valve has been designed for a feed
pressure of 6 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.
3.4.- Electric actuator
Depending on the type or make of the electric actuator, specific instructions (i.e. a
manufacturer’s manual) will be supplied.
•Allowed actuators for ATEX zones: Hand wheel, Chain Wheel, Bevel Gear, Lever,
Pneumatic Actuator (double acting ONLY
ONLYONLY
ONLY) and Electric Motor
•Make sure these actuators are ATEX marked according to the requested zone.
•Maximum travel speed of the gate must equal or below 0,05 m/s
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.
EDITION 01-2017
EB-7/11
MODEL
EB
4.- MAINTENANCE
The valve must not undergo any modifications 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
components.
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.
•According to EN 13463
EN 13463EN 13463
EN 13463-
--
-1 (15),
1 (15), 1 (15),
1 (15), during installation and maintenance operations, use hand
tools (non electric)
(non electric) (non electric)
(non electric) with Working Allowance.
The only maintenance required is to change the gland packing (4) or the seal (3).
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.
4.1. 4.1.
4.1. -
--
- Replacement of the gland packing (4) and the seal (3):
Replacement of the gland packing (4) and the seal (3):Replacement of the gland packing (4) and the seal (3):
Replacement of the gland packing (4) and the seal (3):
1. Depressurise the circuit and place the valve in close position.
2. Remove the gate guards (for automatically actuated valves only).
3. Non rising stem valves. Photo1: Release the stem nut (7) from the gate (2). Rising stem valves,
Photo 2: Release the spindle or stem (6) from the gate (2).
Photo 1 Photo 2
4. Loosen the screws of the yoke (8) and remove it (without loosing the actuator).
5. Loosen the nuts of the gland follower (5) and remove it. (Photo 5)
6. Remove the old packing lines (4).
7.1.- Up to DN-500 (monoblock body valves)
7.1.1.- Remove the gate (2)
7.1.2.- Remove the old seal (3) and clean the stuffing box.
7.1.3.- Insert the new seal (3) and the cleaned gate (2)
7.2.- Above DN-500 (split body valves)
7.2.1.- Loosen the screws which hold together body (1) and counter body (1.1).
7.2.2.- Separate carefully the counter body (1.1) from the body (1)
7.2.3.- Remove the gate (2) and clean it.
7.2.4.- Remove the worn seal (3) and clean the seal housing.
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.
EDITION 01-2017
EB-8/11
MODEL
EB
7.2.5.- Remove the worn O-ring (3.1) and clean the O-ring housing.
7.2.6.- Put the new seal (3) and the new O-ring (3.1) into the housings of the body (1).
7.2.7.- Assembly body (1) and counter body (1.1) back.
7.2.8.- Place all the screws between body (1) and counter body (1.1). Leave them loose.
7.2.9.- Tighten only the screws at the bottom part of the flange (Photo 3)
Photo 3
7.2.10.- Put the valve in vertical position.
Photo 4
7.2.11.- Put grease on the edges of the cleaned gate (2).
7.2.12.- Insert the gate (2). If too tight, loosen slightly the screws.
7.2.13.- Tighten all screws placed on body (1) and counter body (1.1).
8. Once the necessary new packing lines (4) have been inserted, proceed with a steady initial
tightening of the gland follower (5).(Photo 5)
9. Place the yoke (8) (with the actuator) and screw it.
10. ix the stem nut (7) to the gate (2)(Non rising stem valves. Photo 1) or fix the stem (6) to the
gate (2)( Rising stem valves.Photo 2).
11.Remount the gate guards (for automatically actuated valves only).
12.Carry out some operations with a loaded circuit and then re-tighten the gland follower (5) to
prevent leakage.
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.
EDITION 01-2017
EB-9/11
MODEL
EB
Photo 5
4.2
4.24.2
4.2.
. .
. -
--
- Lubrication:
Lubrication:Lubrication:
Lubrication:
Lubricate the stem every 30 days with a calcium-based grease with the following characteristics: highly
water resistant, low ash content, and excellent adherence.
Special requirements for ATEX valves
Special requirements for ATEX valvesSpecial requirements for ATEX valves
Special requirements for ATEX valves:
•The maintenance personnel must be made fully aware of the risks of explosion, and it is
advisable that they receive specific training regarding ATEX.
•Periodicity of check and evaluation of graphite packing status and valve electrical conductivity
must be determined by end user according to valve working conditions. In any case, once the
valve is put into operation, the packing area must be revised after the valve has been stroked
100 times or after 3 months of operation, whatever happens first. After this preliminary check,
new checking periods must be determined by end user based on the results of this first check.
•Clean the valve periodically to prevent dust accumulation. Do not sweep or dump the dust.
Always use a vacuum cleaner system
•Dead en service is not allowed.
•Do not apply any new coating to the valve. Should it require new coating, please contact our
closest representative.
•Allowed seals: EPDM, VITON, NITRILE, GRAPHITE and METAL (no seal)
•Allowed packing: ST and GRAPHITE packing
•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 continuity among carbon steel parts, coated
in epoxy, yoke and body and stainless steel guards for coating thicknesses up to 200 microns)
ST and GR packing 
oORBINOX ST: Synthetic packing impregnated with PT E
oGR: Graphite packing  MONTERO Ecograflex 780R
•After any maintenance of ATEX valves, it is mandatory to check that the valve is earthed through
the pipe, and there is continuity among the different valve components, such as the body, the
gate, the supports, and guards (test in accordance with EN 12266-2 Standard, annex B, points
B.2.2.2. and B.2.3.1).
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.
EDITION 01-2017
EB-10/11
MODEL
EB
MAXIMUM LUID TEMPERATURES
MAXIMUM LUID TEMPERATURESMAXIMUM LUID TEMPERATURES
MAXIMUM LUID 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 cloud ignition
temperature minus 85ºK
Note: these maximum fluid temperatures apply to all categories. The differences between categories are
the consideration of foreseeable malfunction cases and rare malfunctions cases
MAXIMUM
MAXIMUM MAXIMUM
MAXIMUM SEAL AND PACKING
SEAL AND PACKINGSEAL AND PACKING
SEAL AND PACKING TEMPERATURES
TEMPERATURESTEMPERATURES
TEMPERATURES
Max Temperature
Max Temperature Max Temperature
Max Temperature
(
((
(ºC)
C)C)
C)
SEAL
SEALSEAL
SEAL
EPDM
EPDM EPDM
EPDM VITON
VITON VITON
VITON NITRILE
NITRILE NITRILE
NITRILE GRAPHITE
GRAPHITE GRAPHITE
GRAPHITE
120 200 120 600
Max Temperature
Max Temperature Max Temperature
Max Temperature
(
((
(ºC)
C)C)
C)
PACKING
PACKINGPACKING
PACKING
ST
ST ST
ST GRAPHITE
GRAPHITE GRAPHITE
GRAPHITE
240 600
Note: Most of the times seals maximum temperature capacity is the key limitation factor when
evaluating valve maximum working temperatures. In ATEX zones these temperatures must be compared
to those above related to limitation of fluids temperatures. Always consider the most restrictive as
maximum valve working temperature.
5.- STORAGE
•or long storage periods keep the valves indoors in a safe and dry place and protect it from any
impact and or vibrations.
•Storing temperatures: -10ºC to +40ºC
•Valves must be stored in either full open or full closed position.
•or any component installed in the valves, electric motors, solenoid valves, etc, please refer to their
own instructions manuals
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.
EDITION 01-2017
EB-11/11
MODEL
EB
6.- PARTS LIST & DRAWINGS
11
10
12
8
2
3
4
1
5
7
6
9
1.- BODY 7.- STEM NUT
2.- GATE 8.- YOKE
3.- SEAL 9.- BRASS COLLARS
4.- PACKING LINE 10.- NYLON COLLAR AND WASHER
5.- GLAND OLLOWER 11.- PIN
6.- STEM 12.- HANDWHEEL
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