PERSTA 808 GJ User manual

Gate valves
GJ, HJ, JJ and JN
Operating instructions
Read the instructions prior to performing any task!

Dok.-Nr. 6415.DE.STD.12.2015, 2, 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
20.05.2021Gate valves GJ, HJ, JJ and JN2

This manual enables safe and efficient handling of the gate valve.
The manual is a component of the product and must be kept in the
vicinity of the gate valve where it is available to personnel at all
times.
Furthermore, the local occupational safety regulations and general
safety requirements must be complied with for the area in which
the valve is used.
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.
The diagrams 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.
This manual applies to the following versions:
Designation Series Nominal diameter
(DN) [mm]
Pressure rate Class*
Small gate valve 808 GJ / GN 10–40 PN 10–100 -
Small gate valve/
VALTRA
800 GJ / 808 GJ 15–50 PN 10–40 800
Gate valves 700 HJ / 700 JJ
(700 GA / 700 JN)
50–150 PN 10–100
PD 10
600
Gate valves 700 HJ / 700 JJ
(700 GA / 700 JN)
200–250 PN 10–40 -
Gate valves 700 HJ / 700 JJ /
700 JN
200–300 PN 63–100 600
Gate valves 400 JJ / 400 JN 350–700 PN 63–100 600
Gate valves 700 JJ / 700 JN 300–1000 PN 10–25 -
Gate valves 700 JJ / 700 JN 300–700 PN 40 -
Gate valves 700 JJ / 700 JN 50–300/250 PN 160 / PD 18 900
* Assignment number in the pipe construction
Information about the operating
instructions
Scope of the document
Supplemental directives
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nIgnition hazard assessment GA004
nConnection diagram provided
nRisk analysis according to Pressure Equipment Directive
nRisk analysis according to Machinery Directive
nActuator instructions
nTechnical data sheet
nBolt tightening torques according to the website:
www.persta.com
nAs well as the other documents included in the delivery
Mülheimer Str. 18
59581 Warstein-Belecke
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
Other applicable documents
Customer Service - Stahl-Arma-
turen PERSTA GmbH
Revision overview
Supplemental directives
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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 Safety devices............................................................ 14
2.5 Residual risks............................................................. 17
2.5.1 Basic dangers at the workplace............................... 17
2.5.2 Hazards due to electric current (in versions with
electric actuator)...................................................... 18
2.5.3 Hazards due to hydraulics (in versions with
hydraulic actuator)................................................... 18
2.5.4 Hazards due to the pneumatic system (in versions
with pneumatic actuator).......................................... 19
2.5.5 Mechanical hazards................................................. 19
2.5.6 Thermal dangers...................................................... 20
2.5.7 Dangers due to hazardous substances and oper-
ating materials......................................................... 20
2.6 Behaviour in the event of an emergency.................... 22
2.7 Personnel requirements.............................................. 23
2.8 Responsibility of the operating company.................... 25
2.9 Personal protective equipment................................... 26
2.10 Spare parts............................................................... 28
2.11 Environmental protection.......................................... 29
3 Functional description..................................................... 31
3.1 Operating principle of the gate valve.......................... 31
3.2 External seal............................................................... 32
3.3 Versions of the gate valve .......................................... 34
3.3.1 Shut-off element....................................................... 34
3.3.2 Actuator variants...................................................... 34
3.3.3 Display elements..................................................... 38
3.3.4 Connections............................................................. 39
4 Transport and storage...................................................... 41
4.1 Safety instructions for transport and storage.............. 41
4.2 Transport of packages................................................ 42
4.3 Storage of the valve.................................................... 43
4.4 Storage of spare parts................................................ 43
5 Installation......................................................................... 45
5.1 Safety instructions for installation............................... 45
5.2 Before the installation................................................. 47
5.3 Installing the valve...................................................... 48
5.4 Attaching additional safety devices............................. 48
5.5 For electric actuator: connecting the power supply.... 49
Table of contents
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5.6 For hydraulic actuator: connecting the hydraulic
system........................................................................ 49
5.7 For pneumatic actuator: connecting the pneumatic
system........................................................................ 50
5.8 After the installation.................................................... 50
5.8.1 Pickling the valve..................................................... 51
5.8.2 Painting the valve.................................................... 51
5.8.3 Performing a system pressure test and leak test..... 52
5.8.4 Applying thermal insulation...................................... 52
6 Commissioning................................................................. 55
6.1 Safety instructions for commissioning........................ 55
6.2 Prior to commissioning............................................... 58
6.3 Carrying out the commissioning process.................... 59
7 Operation........................................................................... 61
7.1 Safety instructions for operation................................. 61
7.2 Operating the valve..................................................... 63
7.2.1 Valve with manual actuator (handwheel)................. 63
7.2.2 Valve with electric actuator...................................... 63
7.2.3 Valve with hydraulic or pneumatic actuator ............ 64
7.3 Operating the valve in an emergency......................... 65
7.3.1 Valve with manual actuator (handwheel)................. 65
7.3.2 Valve with electric actuator...................................... 66
7.3.3 Valve with hydraulic or pneumatic actuator............. 66
8 Maintenance...................................................................... 67
8.1 Safety instructions for maintenance............................ 67
8.2 Maintenance schedule................................................ 71
8.3 Maintenance tasks...................................................... 72
8.3.1 Visually checking the valve...................................... 72
8.3.2 Replacing the gland packing and cover gasket....... 73
8.3.3 Lubricating moving parts (stem thread)................... 78
9 Faults and troubleshooting.............................................. 79
9.1 Safety instructions for fault correction......................... 79
9.2 Fault table................................................................... 82
10 Dismantling, disposal....................................................... 85
10.1 Safety instructions for dismantling............................ 85
10.2 Dismantling............................................................... 88
10.3 Disposal.................................................................... 89
11 Index................................................................................... 91
Table of contents
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1 Overview
Fig. 1: Gate valve
1 Actuator (in the example: handwheel)
2 Stem
3 Bonnet (fixed permanently to cover)
4 Cover
5 Body
6 Shut-off element (in the example: flexible discs)
7 Flow passage
The valves that are termed “gate valves” are installed in pipes. The
body (Fig. 1/5) of the valve is flanged or welded in the pipework,
depending on the version.
The shut-off element is moved up and down via the stem (Fig. 1/2).
When the shut-off element (Fig. 1/6) is moved down into the flow
passage (Fig. 1/7), no medium can flow through the valve. When
the valve is open, the medium flows through the entire body.
The stem is moved differently depending on the version:
nmanually via handwheel
nelectrically
Brief description
Actuator variants
Overview
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nhydraulically
npneumatically
See
Ä Chapter 3.3.2 “Actuator variants” on page 34.
Depending on the version of the gate valve, it is suitable for use
with water, steam, oil and other non-aggressive media.
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.
Hoist
Hoist with sufficient load-bearing capacity for transporting valves
and components.
Packing extractor
Tool for removing gland packing elements.
Sling gear
Functional and approved gear for attaching valves and compo-
nents on the hoist.
Media
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
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Example:
1. Loosen the bolt.
2.
CAUTION!
Risk of getting trapped by the cover!
Close the cover carefully.
3. Tighten the bolt.
The following symbols are used in the safety instructions to indi-
cate special hazards:
Warning signs Type of danger
Warning – high-voltage.
Warning – danger zone.
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
Special safety instructions
Tips and recommendations
Additional symbols
Safety
Symbols in this manual
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