Orbinox FAGERBERG EK Instruction manual

ORBINOX SPAIN Pol.Ind. s/n-20270 ANOETA. Tel:[phone] Fax:[phone] e-mail:[e-mail]
ORBINOX CANADA, ORBINOX USA, ORBINOX COMERCIAL, ORBINOX UK, ORBINOX FRANCE, ORBINOX GERMANY,
ORBINOX INDIA, ORBINOX CHINA.
www.orbinox.com
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
MODEL EK

.
2009 EDITION
EK-2/9
www.orbinox.com
MODEL
EK
INDEX Page
0. - Description .........................………............................... 2
1. - Handling ..................................………......................... 2
2. - Installation .................................………........................ 3
3. - Actuators .....................................………...................... 5
4. - Maintenance .....................................………................ 6
4.1. - Gland packing replacement …….………............... 6
4.2. - Seal replacement ......………....…....…….............. 7
4.3. - Lubrication …………………….……………..……. 8
5. - Storage …………................................…..……….......... 8
6. - Parts list & drawing ..................................……..…........ 9
0.- DESCRIPTION
The EK model knife gate is a uni-directional wafer valve designed for general industrial service
applications. The design of the body and seat assures non-clogging shut-off with suspended solids.
The EK valve complies with the following European directives:
-DIR 98/37/EC (machines)
-DIR 97/23/EC (PED) Fluid: Group 1 (b), 2 (Cat. I, mod.A)
It may also comply with the directive:
-DIR 94/9/EC (Explosive Atmospheres)
The EX 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
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.

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2009 EDITION
EK-3/9
www.orbinox.com
MODEL
EK
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.
-According to EN 13463-1 (15), during installation and maintenance operations, use hand
tools (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 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.
It should be noted that the direction of flow and differential pressure, do not always coincide.

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2009 EDITION
EK-4/9
www.orbinox.com
MODEL
EK
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 50 65 80 100 125 150 200 250 300 350 400 450 500 600
T (mm) 10 10 10 10 10 14 14 18 18 22 24 24 24 24
Kg.m 6 6 6 6 7 7 7 11 11 15 15 19 19 23
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).
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.), or is in an ATEX zone, the corresponding earth connections must be made before
it is put into operation.
The operation of automated valves is limited only with fitted gate covers.
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

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2009 EDITION
EK-5/9
www.orbinox.com
MODEL
EK
leakage. This can be remedied by tightening the gland follower (7) 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 gland follower (7) and the gate (2).
4
2
1
3
If the glandfollower nuts are pulled to hard, the force needed to operate the valve will increase, the
valve function will be affected and the box packing lifetime will be shortened.
The table below shows the maximun torque value for tightening the glandfollower nuts.
DN Torque (N.m)
50 - 100 20
125 - 200 30
250 - 1000 35
Once performance has been tested, the valve can be put into operation.
In an ATEX zone, the continuity between the body of the valve and the pipe must be checked (test
in accordance with EN 12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).
It must also be verified that the pipe is connected to earth and that there is electrical conductivity
between the two pipes (outlet/inlet).
3.- ACTUATORS
3.1. - Handwheel
To open the valve, turn the handwheel (14) 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 (10). Then either open or close the valve by moving the lever in the desired direction.
Finally, 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.

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2009 EDITION
EK-6/9
www.orbinox.com
MODEL
EK
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 13463-1 (15), during installation and maintenance operations, use hand
tools (non electric) with Working Allowance.
In an ATEX zone, there may be electrostatic charges in the internal parts of the valve. These
electrostatic charges, caused by the evacuation of the fluid, may entail a risk of explosion. It is the
responsibility of the user to take extreme precautions to minimize this risk.
Safety in an ATEX zone:
- The maintenance personnel must be made fully aware of the risks of explosion, and it is
advisable that they receive specific training regarding ATEX.
- Should the fluid transported create an internal explosive atmosphere, the user must check
periodically the correct water-tightness of the installation
- Clean the valve periodically to prevent dust accumulation.
- Assembly at the end of the line is not allowed.
- Avoid repainting the products supplied.
The only maintenance required is to change the gland packing (6) 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 (6):
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.Photo 1: Release the stem nut (8) from the gate (2).
- Rising stem valves.Photo 2: Release the spindle or stem (9) from the gate (2).
Photo 1 Photo 2

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2009 EDITION
EK-7/9
www.orbinox.com
MODEL
EK
4) Loosen the screws of the yoke (10) and remove it (without loosing the actuator).
5) Loosen the nuts of the gland follower (7) and remove it. (Photo 3).
6) Remove the old packing rings (6) and clean the stuffing box.
7) Insert the new packing rings (6), making sure that the ring joints alternate (the first on one
side of the gate, the next on the other and so on). (Photo 4).
8) Once the necessary packing rings (6) have been inserted, proceed with a steady initial
tightening of the gland follower (7). (Photo 3).
9) Place the yoke (10) (with the actuator) and screw it.
10)Fix the stem nut (8) to the gate. (Non rising stem. Photo 1) or fix the stem (9) 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 (7)
to prevent leakage.
Photo 3 Photo 4
4.2. - Replacement of the seal (3) (only applicable to resilient seated valves):
1) Remove the valve from the pipeline.
2) Remove the gate guards (for automatically actuated valves only).
3) Release the stem nut (8) from the gate (2). (Non rising stem.Photo 1) or release the spindle
or stem (6) from the gate (2). (Rising stem valves.Photo 2).
4) Loosen the screws of the yoke (10) and remove it (without loosing the actuator).
5) Loosen the nuts of the gland follower (7) and remove it.(Photo 3)
6) Remove the old packing (6) and the gate (2) and clean the stuffing box.
7) Remove the seal retainer ring (5) which supports the seal (3).
8) Remove the worn seal (3) and clean the seal housing.
9) Insert the new seal (3) in the retainer ring (5).
If the valve has PTFE seal (3): first, place an O-ring (4) in the retainer ring (5) and later
place the PTFE seal (3). (see the following detail).
3
53 45
EPDM / NITRILE PTFE

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2009 EDITION
EK-8/9
www.orbinox.com
MODEL
EK
10)Insert the seal retainer ring (5) and the seal (3) altogether by hammering gently around the
edge.
11)Remount the gate (2).
12)Once the necessary packing rings (6) have been inserted, proceed with a steady initial
tightening of the gland follower (7). (Photo 3) following the steps of point 4.1.
4.3. - 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.
After maintenance, and in an ATEX zone, it is obligatory to verify the electrical continuity between
the pipe and the different valve components, such as the body, the gate, the supports,... (test in
accordance with EN 12266-2 Standard, annex B, points B.2.2.2. and B.2.3.1).
5.- 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.

2009 EDITION
EK-9/9
www.orbinox.com
MODEL
EK
6.- PARTS LIST & DRAWINGS
1. - BODY 8. - STEM
2. - GATE 9.-YOKE
3.-SEAL 10.-BUSHING
4. - “K” RING 11. - BUSHING + WASHER
5. - PACKING 12. - SPRING PIN
6. - GLAND 13. - HANDWHEEL
7. - STEM NUT 14. - KNOB
Gustaf Fagerberg AB,Klangfärgsgatan 25-27,
Box 12105, 402 41 Göteborg
Telefon: [phone], Fax: [phone],
E-post: [e-mail]
www.fagerberg.se