PERSTA 640 AA User manual

Swing check valves
640 AA / 640 AE
Operating instructions
Read the instructions prior to performing any task!

Dok.-Nr. 6416.DE.STD.06.2015, 3, en_GB
Translation of the original operating instructions
© Stahl-Armaturen PERSTA GmbH 2015
Stahl-Armaturen PERSTA GmbH
Mülheimer Str. 18
59581 Warstein-Belecke
Germany
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.persta.com
20.05.2021Swing check valves 640 AA / 640 AE2

These instructions enable the safe and efficient handling of the
valve.
The instructions are an integral part of the valve and must be kept
in the vicinity of the valve so that they are available to the per-
sonnel at all times.
The personnel must have carefully read and understood these
instructions before performing any tasks. The basic prerequisite for
safe work is compliance with all the specified safety and handling
instructions.
Furthermore, the local occupational safety regulations and general
safety requirements must be complied with for the area in which
the valve is used.
The figures in these instructions are provided as examples only
and may deviate from the actual version.
Although the size and pressure ratings of the valve
types vary, the information in these instructions
applies generally to all valves, provided nothing to
the contrary is specified.
These instructions apply to the following versions of the 640 AA
series of the swing check valve:
Series Nominal diam-
eter (DN) [mm]
Pressure rate Class*
640 AA/AE 50–250 PN 40 -
640 AA/AE 50–300/250 PD 18 900
640 AA/AE 300–500 PN 100 -
640 AA/AE 300–1000 PN 10 - PN 63 -
* Assignment number in the pipe construction
nIgnition hazard assessment GA004
nRisk analysis according to Pressure Equipment Directive
nRisk analysis as per the Machinery Directive
nTechnical data sheet
nBolt tightening torques according to the website:
www.persta.com
nand other documents included in the delivery
Information about the operating
instructions
Scope of the document
Other applicable documents
Supplemental directives
20.05.2021 Swing check valves 640 AA / 640 AE 3

Mülheimer Str. 18
59581 Warstein
Germany
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
Revision number Change/Supplemented informa-
tion
Date
1 Updates to chapter “ Intended
use”.
05/05/2021
Customer Service - Stahl-Arma-
turen PERSTA GmbH
Revision overview
Supplemental directives
20.05.2021Swing check valves 640 AA / 640 AE4

Table of contents
1 Overview.............................................................................. 7
2 Safety................................................................................... 9
2.1 Symbols in this manual................................................. 9
2.2 Intended use............................................................... 11
2.3 Safety signs................................................................ 12
2.4 Residual risks............................................................. 13
2.4.1 Basic dangers at the workplace............................... 13
2.4.2 Mechanical dangers................................................. 14
2.4.3 Thermal hazards...................................................... 14
2.4.4 Dangers due to hazardous substances and oper-
ating materials......................................................... 15
2.5 Behaviour in the event of an emergency.................... 17
2.6 Responsibility of the operating company.................... 17
2.7 Personnel requirements.............................................. 18
2.8 Personal protective equipment................................... 20
2.9 Spare parts................................................................. 21
2.10 Environmental protection.......................................... 23
3 Functional description..................................................... 25
3.1 How the swing check valve works.............................. 25
3.2 Attachment of the swing check plate (type-specific)... 26
3.3 Optional equipment..................................................... 28
3.4 External seal............................................................... 31
3.5 Connections................................................................ 32
4 Transport and storage...................................................... 33
4.1 Safety notices for transport and storage..................... 33
4.2 Transport of packed items.......................................... 34
4.3 Storage of the valve.................................................... 36
4.4 Storage of spare parts................................................ 36
5 Installation......................................................................... 37
5.1 Safety instructions for installation............................... 37
5.2 Before the installation................................................. 38
5.3 Installing the valve...................................................... 39
5.4 After the installation.................................................... 40
5.4.1 Pickling the valve..................................................... 41
5.4.2 Painting the valve.................................................... 41
5.4.3 Executing the system pressure test and leak test... 41
5.4.4 Applying thermal insulation...................................... 42
5.4.5 Setting the closing support (optional)...................... 43
6 Commissioning................................................................. 47
6.1 Safety instructions for commissioning........................ 47
6.2 Prior to commissioning............................................... 49
6.3 Performing the commissioning process...................... 49
Table of contents
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7 Maintenance...................................................................... 51
7.1 Safety instructions for maintenance............................ 51
7.2 Maintenance schedule................................................ 55
7.3 Visually checking the valve......................................... 55
7.4 After maintenance....................................................... 56
8 Faults and fault correction............................................... 57
8.1 Safety instructions for fault correction......................... 57
8.2 Fault table................................................................... 59
8.3 Fault correction work.................................................. 61
8.3.1 Replacing the body cover gasket............................. 61
8.3.2 Detaching and attaching the swing check plate....... 64
8.3.3 Replacing the gland packing.................................... 75
9 Removal, disposal............................................................ 83
9.1 Safety instructions for dismantling.............................. 83
9.2 Removal...................................................................... 85
9.3 Disposal...................................................................... 86
10 Index................................................................................... 87
Table of contents
20.05.2021Swing check valves 640 AA / 640 AE6

1 Overview
Fig. 1: Swing check valve
The valve referred to as swing check valve has been designed for
installation in pipes.
By using the swing check valve, a medium is only permitted to flow
in one direction within the pipe.
From the other direction, the swing check plate (Fig. 1/1) within the
valve is pressed into its seat by the medium flowing back and the
return flow is thereby prevented.
The following tools are required for the tasks described in the oper-
ating instructions:
Forklift
Forklift with sufficient load-bearing capacity for transport of valves.
Brief description of the 640 AA
swing check valve
Tools
Overview
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Hoist
Hoist with sufficient load-bearing capacity for transporting valves
and components.
Knock-out tool
Pin-like tool for driving the valve shaft out of the body.
Packing extractor
Tool for removing gland packing elements.
Ring bolts
nFor installation in the body cover
nDepending on the version, additionally for installation in the disc
lever.
nThey serve as attachment points of the valve to the hoist.
nIncluded in the scope of delivery of the valve.
Sling gear
Functional and approved gear for attaching valves and compo-
nents on the hoist.
Snap ring pliers
Tool for fitting and removing snap rings.
Tools for machining sealing surfaces and slide faces
Grinding tools, such as fine emery cloth, plastic or wooden tools.
Overview
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2 Safety
2.1 Symbols in this manual
Safety instructions are indicated by symbols in this manual. The
safety instructions are introduced by signal words that indicate the
scope of the hazard.
DANGER!
This combination of symbol and signal word indi-
cates a hazardous situation that, if not avoided, will
result in death or serious injury.
WARNING!
This combination of symbol and signal word indi-
cates a potentially hazardous situation that, if not
avoided, may result in death or serious injury.
CAUTION!
This combination of symbol and signal word indi-
cates a potentially hazardous situation that, if not
avoided, may result in minor or moderate injury.
NOTICE!
This combination of symbol and signal word indi-
cates a potentially hazardous situation that, if not
avoided, may result in damage to property.
ENVIRONMENT!
This combination of symbol and signal word indi-
cates potential hazards for the environment.
Safety instructions may refer to specific, individual instructions.
Such safety instructions are integrated into the specific instruction,
so that the flow of reading is not interrupted during performance of
the task. The signal words described above are used.
Safety instructions
Safety instructions in specific
instructions
Safety
Symbols in this manual
20.05.2021 Swing check valves 640 AA / 640 AE 9

Example:
1. Loosen the bolt.
2.
CAUTION!
Risk of getting trapped by the cover!
Close the cover carefully.
3. Tighten the bolt.
This symbol indicates useful tips and recommen-
dations as well as information on efficient and
trouble-free operation.
The following symbols are used throughout these instructions to
highlight specific instructions, results, lists, references and other
elements:
Symbol Explanation
Step-by-step instructions
ðResults of an action
References to sections of these operating
instructions and other applicable docu-
ments
Lists without a defined sequence
Tips and recommendations
Additional symbols
Safety
Symbols in this manual
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2.2 Intended use
Valves of the specified series are designed for installation in
pipes under the following conditions:
nOperation of the valve as an open/close valve.
nInstallation in horizontal pipes with cover opening facing
upwards.
nInstallation in vertical pipes with flow direction from bottom to
top.
nOperation of the valve with liquid or gaseous media, without
particularly corrosive, chemical or abrasive effect.
nTemperature change speeds not exceeding
6 K/min (6 °C/min).
nMaximum number of 1000 load cycles between a depressur-
ised state and the maximum permissible pressure PS.
nAny number of load cycles at pressure fluctuations of up to
10 % of the maximum permissible pressure PS.
nGenerally used flow rates depending on the type of medium
and the application for which the valve is used.
nOperation of the valve without additional external influences,
such as pipe forces, vibrations, wind loads, earthquakes, cor-
rosive environments, fires, traffic loads, decomposition pres-
sures of unstable fluids.
nOperation of the valve only within the limits specified on the
rating plate (
Ä “Rating plate” on page 12).
nIf the valve is operated in the creep range, the valve is
designed for a maximum operating time of 100,000 h. The
valve must be replaced afterwards.
nNo temperature increases were considered. In case of use in
the hot vapour area, temperature increases must be consid-
ered according to the regulations of the operating company.
nThe test pressure for a recurring test must not exceed the
maximum permitted pressure PS multiplied by 1.3.
nThe valve may only be operated if internal pressure loading is
predominantly dormant. Additional loads (e.g. stationary
thermal stress, unsteady pressure and temperature loads in
case of alternating loads or pipe loads) were not considered.
Intended use includes compliance with all the information con-
tained in this manual.
Any use that deviates from the intended use or any other form of
use constitutes misuse.
Safety
Intended use
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WARNING!
Danger in the event of misuse!
Misuse of the valve can cause dangerous situa-
tions.
– Connect the pipes so that they are free of ten-
sion.
– Pay attention to the correct installation position
of the valve.
– Do not exceed the number of permitted load
cycles ( Ä Chapter 2.2 “Intended use”
on page 11).
– Do not use valves as an anchor point.
– Never operate valves at temperatures near or
below the freezing point of the pipeline medium.
2.3 Safety signs
The following symbols and instruction signs are in the work area.
These symbols and instruction signs refer to the immediate vicinity
in which they are affixed.
WARNING!
Danger if signs are illegible!
Over time, stickers and signs can become fouled
or can become illegible in some other manner, so
that dangers are not recognised and necessary
operating instructions cannot be complied with.
This results in a danger of injury.
– Keep all safety, warning, and operating instruc-
tions that are affixed to the device in legible con-
dition.
– Replace damaged signs or stickers immediately.
The rating plate is located on the valve. Depending on the version,
the following information is given on the rating plate:
nConfirmation number
nArticle number
nYear of manufacture
nNominal diameter
nNominal pressure / design data
The flow direction is indicated by an arrow on the valve.
Pipeline medium flowing in the direction of the arrow opens the
swing check valve and flows through the valve.
Misuse
Rating plate
Flow direction arrow
Safety
Safety signs
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Additional markings (e.g. max. temperature limits) are available on
customer request.
2.4 Residual risks
The valve has been developed and manufactured to the state-of-
the-art and in accordance with generally accepted rules of safety.
Nevertheless residual risks remain that require careful handling.
The residual risks and the resulting behaviours and measures are
listed below.
2.4.1 Basic dangers at the workplace
DANGER!
Risk of fatal injury due to failure to comply with
the rules of conduct specified for potentially
explosive atmospheres!
Depending on the version, the valve can be used
in potentially explosive atmospheres. There is
danger to life if the rules of conduct are not com-
plied with in these areas.
– Ensure that the tasks on the valve can be per-
formed at the installation site.
CAUTION!
Danger of injury due to tripping up!
There is a danger of fall injuries in the area of use
of the valve.
– Install cable and connection lines in such a
manner that there are no trip hazards.
Customer-specific markings
Potentially explosive atmospheres
Trip hazard
Safety
Residual risks > Basic dangers at the workplace
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2.4.2 Mechanical dangers
WARNING!
Danger of injury due to the heavy weight of the
valve!
The heavy weight of the valve, and of its compo-
nents, can result in severe injuries.
– Transport valves with a suitable hoist or forklift.
– Use approved and functional sling gear.
– Safeguard valves and components from falling
over.
WARNING!
Risk of crushing and impact injuries on moving
parts!
Depending on the version, there are moving parts
on the valve (e.g. lever, weight).
There is a risk of injury in the motion range of the
moving parts outside the body.
– Make sure presence is prohibited in the vicinity
of the valve.
– Mark or cordon off the danger zone.
– Established a depressurised state before
working on the valve.
2.4.3 Thermal hazards
WARNING!
Risk of injury due to high or low temperatures!
Depending on the application for which the valve
or pipe is used, injuries may occur due to the high
or low temperature of the components.
– When working on components or using
adjusting equipment, wear protective equip-
ment: protective gloves, safety goggles.
– Prior to performing work on these components,
allow them to cool down or warm up to the
ambient temperature.
– Have the thermal insulation provided by the
operating company attached.
Heavy weight of the valve
Moving parts
Thermal dangers
Safety
Residual risks > Thermal hazards
20.05.2021Swing check valves 640 AA / 640 AE14

WARNING!
Risk of injury due to pipes shattering at
freezing temperatures!
As a result of pipes shattering at freezing tempera-
tures, severe injuries can be caused by fluid being
expelled under high pressure.
– Make sure that the valve is drained completely
before it is taken out of service.
– Never operate valves at temperatures near or
below the freezing point of the pipeline medium.
2.4.4 Dangers due to hazardous substances and operating materials
WARNING!
Risk of injury due to pressurised pipeline
medium!
Depending on the version of the valve, injuries can
be caused by the medium escaping under high
pressure, regardless of whether the system is in
operation or not.
– Do not undo the threaded connections.
– If threaded connections are loose, inform the
operating company and have the pipe section in
question shut off.
– If threaded connections are loose, have the
cause of this clarified and eliminated. If neces-
sary, have the manufacturer check the valve.
WARNING!
Risk of impairing health due to the pumped
medium!
Direct contact with the pumped medium can
adversely affect your health.
– Handle the pumped medium in accordance with
the instructions in the manufacturer’s safety
data sheet.
– Wear the following protective equipment: pro-
tective gloves, safety footwear, safety goggles,
protective work clothing.
– Collect any pumped medium that has run out
without delay and dispose of it in an environ-
mentally responsible manner.
Risk of freezing
Pipeline medium
Safety
Residual risks > Dangers due to hazardous substances and operating materials
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WARNING!
Pickling medium is a health hazard!
Direct contact with the pickling medium used can
have health implications.
– Handle pickling medium in accordance with the
instructions in the manufacturer’s safety data
sheet.
– Wear protective equipment: Protective gloves,
safety footwear, protective goggles, protective
work clothing.
– Soak up escaped pickling medium without delay
and dispose of it in an environmentally respon-
sible manner.
WARNING!
Anticorrosive is a health hazard!
Direct contact with the anticorrosive used can have
health implications.
– Handle anticorrosive in accordance with the
instructions in the manufacturer’s safety data
sheet.
– Wear protective equipment: Protective gloves,
safety footwear, protective goggles, protective
work clothing.
– Soak up escaped anticorrosive without delay
and dispose of it in an environmentally respon-
sible manner.
NOTICE!
Risk of damage to sealing surfaces and slide
faces due to metallic processing!
The metallic processing of sealing surfaces, slide
faces and valve parts can cause damage and
valves to malfunction.
– Sealing surfaces and slide faces of gaskets
must not be
– scratched with a scraper,
– brushed with wire brushes.
– Sealing surfaces and slide faces must be
– dressed using a fine emery cloth,
– machined with suitable grinding tools or
– scraped off with plastic or wooden tools.
Pickling medium
Anticorrosive
Damage to sealing surfaces and
slide faces
Safety
Residual risks > Dangers due to hazardous substances and operating materials
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2.5 Behaviour in the event of an emergency
1. Shut off the pipe sections affected.
2. Comply with the plant regulations.
2.6 Responsibility of the operating company
The operating company is the company that operates the valve for
commercial or economic purposes itself or that provides it to a third
party for use, and that, during operation, bears the legal product
responsibility for protection of the user, personnel or third parties.
The valve is used commercially. The operating company of the
valve is therefore subject to the legal occupational health and
safety obligations.
In addition to the safety instructions in this manual, the local occu-
pational health and safety, accident prevention and environmental
protection regulations that apply to the valve’s area of application
must be observed.
In this regard, the following applies in particular:
nThe operating company is responsible for the installation and
operation of the valve in the pipe.
nThe operating company must ensure that any dangerous situa-
tions caused by the operating conditions are avoided by instal-
ling additional safety systems.
nThe operating company must obtain information about the appli-
cable occupational health and safety regulations and, in a
hazard assessment, identify the additional hazards that may
exist at the installation site of the valve due to the specific
working conditions. The operating company must integrate this
information into operating instructions for the operation of the
valve.
nThe operating company must ensure that the operating instruc-
tions it has drawn up comply with the currently applicable legis-
lation throughout the operating period of the valve and, if neces-
sary, adapt the operating instructions.
nThe operating company must clearly specify and assign the
responsibilities for installation, operation, fault correction, main-
tenance and cleaning.
nAfter the installation, the operating company must ensure the
proper pickling of the valve.
nThe operating company must provide devices that ensure the
safe transition of the valve into a depressurised state.
nThe operating company must provide equipment that can com-
pletely drain the pipe sections in which the valve is installed as
well as the valve itself.
nThe operating company must ensure that all personnel who are
to handle the valve have read and understood this manual. In
addition, the operating company must train the personnel and
inform them of the hazards at regular intervals.
Operating company
Obligations of the operating com-
pany
Safety
Responsibility of the operating company
20.05.2021 Swing check valves 640 AA / 640 AE 17

nThe operating company must provide the required protective
equipment for the personnel and instruct the personnel that
wearing the required protective equipment is compulsory.
nThe operating company must install additional protective
devices around the valve if contact with the valve can result in
injuries due to the medium in the pipe system.
The operating company is also responsible for keeping the valve in
proper working order at all times. Therefore, the following applies:
nThe operating company must ensure that the maintenance inter-
vals described in these instructions are complied with.
In the case of valves with different pipe connections on the inlet
and outlet ends, the operating company must ensure that when
opening the valve the respective pipe connection is not exposed to
impermissibly high pressure or an impermissibly high temperature.
2.7 Personnel requirements
WARNING!
Danger of injury due to inadequate personnel
qualification!
If unqualified personnel perform tasks on the
machine or are present in the danger zone, dan-
gers occur that can cause severe injury and signifi-
cant material damage.
– Only have activities performed by personnel
who are qualified to perform these activities.
– Keep unqualified personnel away from the
danger zones.
In this manual the qualifications of personnel for the various activity
areas are cited below:
Disposal contractor
A disposal contractor is a company qualified in accordance with
local regulations to collect, transport, store, handle, recycle or dis-
pose of waste and recyclables.
Forklift truck driver
The forklift truck driver has demonstrated to the operator their skills
in driving industrial trucks controlled by a sitting or standing oper-
ator and has been assigned to do this by the operator in writing.
Industrial mechanic (for valves within the normal pressure
range)
Based on his or her specialised training, skill, experience and
knowledge of the applicable standards and requirements, the
industrial mechanic must be able to carry out the assigned work on
installations and valves in the normal pressure range and to inde-
pendently identify potential hazards and avoid them.
Safety
Personnel requirements
20.05.2021Swing check valves 640 AA / 640 AE18

The operating company must have instructed the industrial
mechanic on how to handle the plant and provide regular training
for him or her.
The industrial mechanic must be able to independently maintain
and repair installations and valves in the normal pressure range.
Pipeline engineer
Based on their specialised training, skills, experience and knowl-
edge of the applicable standards and provisions, the pipeline engi-
neer is able to carry out the work assigned to them and to inde-
pendently identify potential hazards and avoid them.
The pipeline engineer is able to install valves safely and properly in
the pipework.
Trained person (hoist)
The trained person (hoist) has been instructed, and can provide
evidence of this, by the operator on how to handle the hoist and
sling gear and the potential hazards associated with improper
behaviour.
Trained person (operator)
The trained person (operator) has been instructed, and can provide
evidence of this, by the operating company on how to handle the
plant and the potential hazards associated with improper behav-
iour. This knowledge will be refreshed in regular training provided
by the operating company. The trained person (operator) is familiar
with the content of this manual.
The trained person (operator) is familiar with the operating compa-
ny's plant and the associated hazards. They are assigned with
operating the plant by the operating company.
Only persons from whom it is expected that they reliably perform
their work are approved as personnel. Persons whose capacity to
react is impaired, for example, through drugs, alcohol, or medica-
tion are not approved as personnel.
Comply with the age-specific and job-specific regulations that apply
at the site of implementation when selecting personnel.
Basic requirements
Safety
Personnel requirements
20.05.2021 Swing check valves 640 AA / 640 AE 19

WARNING!
Risk of fatal injury for unauthorised persons
due to hazards in the danger zone and work
area!
Unauthorised persons who do not satisfy the
requirements described here are not aware of the
hazards in the work area. Consequently there is a
danger of severe or fatal injuries for unauthorised
persons.
– Keep unauthorised persons away from the
danger zone and work area.
– If in doubt, speak to these persons and instruct
them to leave the danger zone and work area.
– Interrupt tasks as long as unauthorised persons
are present in the danger zone and work area.
The operating company must instruct personnel on a regular basis.
For better tracking an instruction log must be maintained with at
least the following content:
nDate of the instruction
nName of the instructed person
nContent of the instruction
nName of the instructor
nSignatures of the instructed person and of the instructor
2.8 Personal protective equipment
Personal protective equipment is used to protect personnel from
impairments to health and safety at work.
During the various tasks performed on and with the machine, per-
sonnel must wear personal protective equipment, to which special
reference is made in the individual sections of this manual.
The personal protective equipment is described below:
Chemical resistant safety gloves
Chemical resistant safety gloves are intended to protect hands
against aggressive chemicals.
Unauthorised persons
Instruction
Description of the personal protec-
tive equipment
Safety
Personal protective equipment
20.05.2021Swing check valves 640 AA / 640 AE20