Pfeiffer 28z Series User manual

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 1 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004
Declaration of Conformity as per Directive
97/23/EC
and Manufacturer’s Declaration as per Directive 98/37/EC
The manufacturer Pfeiffer Chemie-Armaturenbau GmbH, 47906 Kempen, Germany
declares that:
Piggable ball valves Series 28y and piggable end stations Series 28z,
with packing
•with pneumatic/electric/hydraulic actuator
•with free shaft end for subsequent mounting of an actuator
1. The valves are pressure accessories within the meaning of the Pressure Equipment Directive
97/23/EC and conform with the requirements of this Directive,
2. The valves are not complete machinery within the meaning of the Machinery Directive
98/37/EC, but meet the relevant requirements of this Directive,
3. They may only be operated observing the operating instructions <BA28y-01_EN> delivered
together with the valve.
The commissioning of these valves is only permitted after the valve has been installed from both sides in
the pipeline and a risk of injury can be ruled out.
(For piggable ball valves which are intended for dead-end service, see section 2.3).
Applied standards:
AD 2000 Regulations
DIN-EN 292-2000
Regulations for pressurized valve body parts
Safety of Machinery, Part 2: Technical requirements
Type designation and technical features:
Pfeiffer data sheets <TB28y_EN and TB28z_EN>
NOTE: This Manufacturer’s Declaration applies to all valve types listed in this catalog.
Applied conformity assessment procedure:
Conforming to Annex II of the Pressure Equipment Directive 97/23/EC, Module H
Name of notified body: Identification number of the notified body:
TÜV Anlagentechnik GmbH
Am Grauen Stein
51101 Köln
Germany
0035
These Declarations become invalid when modifications are made to the piggable ball valves and/or
assemblies that affect the technical data of the piggable ball valve or the <Intended use> described in
section 1 of the operating instructions, and considerably change the valve or an assembly delivered with it.
Kempen, 1. June 2004 Lorenz Stolzenberg, Managing Director
These Declaration of Conformity and operating instructions have been generated electronically and are legally binding without signature

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 2 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004
Operating instructions
piggable ball valve
actuated
Contents
0 Introduction 3
1 Intended use 3
2 Safety instructions 3
2.1 General safety instructions 3
2.2 Safety instructions for the operator 3
2.3 Particular hazards 4
2.4 Designation of the piggable ball valve 4
3 Transport and storage 5
4 Installation in the pipeline 5
4.1 General 5
4.2 Installation instructions 5
5 Pressure check in pipeline section 6
6 Standard operation and maintenance 6
7 Troubleshooting 7
8 Further information 7
600767 / PDF=613

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 3 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004
0 Introduction
These instructions are designed to assist the user during installation, operation and maintenance of piggable ball valves from the
Series 28y and Series 28z.
These instructions apply only to the piggable ball valve itself. In addition, refer to the instructions of the mounted actuator.
Note
The WARNING and CAUTION notes must be strictly adhered to. Otherwise this may lead to personal injury and
equipment damage and the manufacturer’s warranty may become void.
Please contact the manufacturer if you have any queries, see section 8 for contact address.
1 Intended use
After installing the valve in the pipeline and connecting the actuator to the control equipment, these piggable ball valves are designed
exclusively for shutting off or controlling media (often corrosive) within the permissible pressure and temperature ranges.
The permissible pressure and temperature ranges for these piggable ball valves are specified in the data sheets <TB28y_EN or
TB28z_EN>.
Danger
Do not operate a piggable ball valve when its permissible pressure/temperature rating is not sized for the operating
conditions specified in the data sheets <TB28y_EN or TB28z_EN>.
Failure to follow these safety precautions may result in personal injury and can damage equipment installed in
the pipeline.
Interpretation of declaration to the Directive 94/9/EC
Note
Pfeiffer valves have no own potential ignition source after testing the hazardous ignition in accordance to
DIN EN 13463-1:2002. Therefore Pfeiffer valves do not come under the directive 94/9/EC.
Relating to this directive a CE-marking is not permissible.
The valve could be incorporated into potential compensation of plants independent of the directive, valid for metallic parts
in hazardous areas.
Observe the restrictions in the specified data sheets if the piggable ball valve is intended for throttling services.
The piggable ball valve body may contain small amounts of medium in the closed and open position:
In the case that the heat in the surroundings where the valve is installed can heat up the process medium in the valve, use the piggable
ball valve version with a relief bore to prevent an impermissible rise in pressure.
Observance of section 2 <Safety instructions> is presumed for the Intended use.
2 Safety instructions
2.1 General safety instructions
For piggable ball valves, the same safety regulations apply as for the pipelines in which they are installed, as well as for the control
equipment connected to the actuator. These instructions only specify those safety instructions which need to be additionally observed
concerning piggable ball valves.
Additional safety instructions are specified in the instructions for the actuator assemblies.
2.2 Safety instructions for the operator
The manufacturer does not assume any responsibility. Therefore, on using the piggable ball valve, make sure the following instructions
are observed:
ÖThe valve is to be used only for its intended use as described in section 1.
Warning
Preventing misuse of the piggable ball valve:
It is especially important to make sure that the selected materials for wetted parts in the piggable ball valve are suitable for
the media used as well as the prevailing pressures and temperatures.
Failure to follow these safety precautions may result in personal injury and can damage equipment installed in
the pipeline. The manufacturer does not assume any final responsibility.
Warning
Protection against using the wrong pig:
The valve shape and size have been adapted to the pigs to be used according to the customer specifications. In case
other pigs are to be used, Pfeiffer must check and confirm the valve’s suitability first.
Failure to follow these safety precautions may result in personal injury and can damage equipment installed in
the pipeline.

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 4 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004
ÖAn actuator unit mounted subsequently onto the valve must fit the piggable ball valve properly and its final positions, especially
the open position, need to be correctly adjusted.
ÖMake sure that the pipeline and control equipment have been installed correctly and are checked at regular intervals. The valve
body wall thickness must be designed to take into account an additional load Fz in the usual order (Fz = π/4•DN²•PS) for a
correctly sized pipeline.
ÖThe valve needs to be connected correctly to the pipeline and to the control equipment.
ÖMake sure the usual flow velocities are not exceeded in continuous service in this pipeline. Exceptional operating conditions such
as oscillations, water hammering, cavitation and large proportions of solid matter in the process medium, especially abrasive,
must be clarified beforehand with the manufacturer.
ÖPiggable ball valves that are operated at temperatures greater than +50°C or lower than -20°C must be protected, together with
the pipeline connections, against being touched.
ÖOnly for pressure-containing pipelines and pigging pipelines: The valve must be operated and service by trained personnel.
2.3 Particular hazards
Danger
Prior to removing the piggable ball valve from the pipeline, relieve pressure entirely in the pipeline to ensure the
process medium cannot escape uncontrollably from the pipeline.
Warning
Should it be necessary to remove a piggable ball valve from the pipeline, process medium may escape from the pipe or
out of the piggable ball valve. In the case of process media that can damage health or are dangerous, drain the pipeline
completely before removing the piggable ball valve from the pipeline.
Take special care concerning any remaining media that may still be in the pipeline or have collected in the
cavities of the valve.
Warning
Only unscrew or loosen any screws or bolts connecting the body parts after the valve has been removed from the
pipeline. Tighten the screws on reassembly with a torque wrench according to repair instructions <EB28y_EN or
EB28z_EN>.
Warning
For piggable ball valves intended for dead-end service:
During standard operation, in particular, with gases or hot and/or dangerous media, mount a blank flange at the free
end connection or ensure that the piggable ball valve is properly protected against unauthorized operation.
Warning
If a piggable ball valve used for dead-end service must be opened in a pressurized pipeline, special care must be taken
to ensure that any process media escaping under pressure do not cause any damage.
2.4 Designation of the piggable ball valve
The designation of the piggable ball valve includes the following details:
Details Designation Comments
Manufacturer Pfeiffer Address, see section 8 <Information>
Valve type BR (and number) e.g. BR 28y = Series 28y, see Pfeiffer catalog
Body material e.g.: 1.4571 Material number acc. to DIN EN 10272
Size DN (and number) Value in mm, e.g. DN50
Maximum pressure PN (and number) Value in bar at room temperature
Perm. temperature TS (and number)
Perm. pressure PS (and number)
PS and TS are associated values at maximum permissible operating
temperature and maximum permissible operating pressure.
203 0153 /001 /001
Valve No. into the Item
Item in order
Order
Serial no. e.g.: 2030153/001/001
Year of manufacture (e.g. 203=2003)
year of manufacture e.g.: 2003 On request of customer the year of manufacture is stamped on the
valve.
Conformity CE Conformity is certified separately by the manufacturer
Identification no. 0035 Notified body as per EU Directive = TÜV Anlagentechnik GmbH
Direction of flow ÎNote: see note in section 4.2 <Installation instructions>
Table 1 – Designation of the piggable ball valve
Keep the labeling on the valve body and on the nameplate to ensure that the valve can be identified at all times.

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 5 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004
3 Transport and storage
Piggable ball valves must be carefully handled, transported and stored:
ÖStore the valve with its protective packing and/or with its protective caps in place in the end connections. Store and transport the
piggable ball valves that weigh over approx. 10 kg on pallets (or a similar type of support) right up to the point of installation.
ÖStore the valve in a closed room before it is installed. Protect it against damaging influences such as dirt or moisture.
ÖMake sure, in particular, that the actuator and the end connections intended to connect the valve to the pipeline are not damaged
through mechanical or other influences.
ÖAs a rule, piggable ball valves are delivered in the completely open position. Store the valves in the condition they were delivered
in. Do not operate the actuating device.
4 Installation in the pipeline
4.1 General
The same instructions apply for installing the piggable ball valves in the pipeline as for connecting pipes and similar pipeline equipment.
The following instructions additionally apply for piggable ball valves. Also observe section 3 for transporting the piggable ball valve to the
point of installation.
Note
The mating flanges must have smooth facings
Contact the manufacturer if you intend to use other flange forms.
Danger
If an actuator unit has been mounted subsequently, torque, direction of rotation, operating angle as well as the final
positions OPEN and CLOSED must be adapted to the piggable ball valve.
Failure to follow these safety precautions may result in personal injury and can damage equipment installed in
the pipeline.
Warning
The actuating device is set for the operating data specified in the order.
Do not alter the settings for the final positions OPEN and CLOSED without the manufacturer’s prior consent.
Warning
Only for piggable ball valves with electric actuator:
Make sure that the actuator is switched off in the final positions by the limit switch’s signal. If the actuator is switched off
in an intermediate position by the torque switch’s signal, this signal should be used additionally for fault indication.
Remedy any faults as quickly as possible. See section 7 <Troubleshooting>.
See the instructions for the electric actuator for further details.
The following warnings are to be observed for actuators:
Warning
Actuators are not designed to be used as step-ladders:
Do not apply any weight/load to the actuators. This can damage or destroy the piggable ball valve.
Warning
Actuators that weigh more than the piggable ball valve:
Support any actuator which due to its size and/or mounting situation would otherwise cause the valve to bend under the
load.
4.2 Installation instructions
ÖTransport the valve in its original packaging right up to the point of installation. Remove packaging first at the point of installation
to protect it from dirt.
ÖCheck valve and actuator for signs of damage that may have occurred during transportation. Do not install a damaged piggable
ball valve or actuator.
ÖMake sure that only piggable ball valves are installed when their pressure rating, end connections and face to face dimensions
match the conditions of application. See the designation of the piggable ball valve.
Danger
Do not install a piggable ball valve if its permissible pressure/temperature ranges do not apply to the operating conditions.
The limits of application are marked on the valve, see section 2.4 <Designation>. The permissible range is determined in
section 1 <Intended use>.
Failure to follow these safety precautions may result in personal injury and can damage equipment installed in
the pipeline.

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 6 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004
ÖThe connecting specifications for the actuator unit must match those of the control equipment. See nameplate(s) on the actuator
unit.
ÖMake sure the end connections of the pipeline are aligned with the piggable ball valve’s end connections and their ends have
parallel planes.
ÖPrior to installation, carefully clean the valve and the connecting section of the pipeline from dirt, especially hard foreign material.
ÖThe valve can be installed in any position. However, if possible, the actuator should not be located directly underneath the
piggable ball valve.
ÖMake sure the arrow on the valve body corresponds with the direction of flow in the pipeline.
Note
In special cases, it may be necessary for the valve to be tightly shut against the direction of flow. The installation in such
special cases must be determined by the operator of the pipeline (e.g. to protect a pump).
ÖOn inserting the valve (and any flange gaskets) into a ready mounted pipeline, keep a certain clearance between the pipeline
ends to ensure that all facings (and gaskets) remain undamaged.
ÖThe associated instructions apply for connecting the actuator unit to the control equipment.
ÖAfter completing installation, carry out a function check using the signals issued by the control equipment. The valve must open
and close properly corresponding with the control signals. Any function errors that are recognized must be remedied before
commissioning. See also section 7 <Troubleshooting>.
Warning
Control commands that are not carried out correctly may result in personal injury and can damage equipment
installed in the pipeline.
5 Pressure check in pipeline section
The pressure check of valves has already been carried out by the manufacturer. To check the pressure of a section of pipeline with
installed valves, the following points must be observed:
ÖCarefully flush newly installed pipes to remove any foreign material.
ÖValve OPEN: The test pressure should not exceed the value 1.5 x PN (see nameplate).
ÖValve CLOSED: The test pressure should not exceed the value 1.1 x PN (see nameplate).
If a valve leaks, see section 7 <Troubleshooting>.
6 Standard operation and maintenance
Operate the valve/actuator unit over the control equipment signals. Piggable ball valves delivered with the actuator already mounted are
precisely set and should not be readjusted.
The shaft is sealed with a V-ring packing preloaded with a set of spring washers and does not require any maintenance.
Normal manual force is sufficient to operate the manual override on the actuator (if required). It is not permissible to use extensions to
increase the operating torque.
Regular maintenance work on the piggable ball valves is not necessary. But, on checking the pipeline section, there should be no
leakage at the flanged and bolted connections of the valve body or at the shaft packing. If a valve leaks, proceed as described in section
7 <Troubleshooting>.

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 7 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004
7 Troubleshooting
Observe the safety instructions listed in section 2 on troubleshooting.
Warning
To remove a valve from a pipeline containing dangerous media and to take it out of the plant:
Decontaminate the valves properly first.
Type of fault Action to be taken Comment
Leak at the
connection to the
pipeline
Tighten flange bolts.
If the medium leaks out at the flanges even after tightening the flange bolts:
Remove the valve (observing the instructions in section 2.3 <Particular hazards>) and
replace the gaskets.
Leak at the
connection
between valve
body parts
Tighten bolts/screws with a torque wrench, see Pfeiffer repair instructions
<EB28a_EN or EB28a/x_EN
If the valve still leaks:
Remove the valve (observing the instructions in section 2.3 <Particular hazards>) and
replace the gaskets. Contact Pfeiffer for spare parts and necessary instructions.
Leak at the shaft
packing
Remove the valve (observing the instructions in section 2.3 <Particular hazards>),
dismantle the valve and replace the shaft packing. Contact Pfeiffer for spare parts
and necessary instructions.
No tight shut-off
when the valve is
closed
Remove the valve (observing the instructions in section 2. 3 <Particular hazards >)
and check it.
If the valve is damaged:
If it must be repaired, remove the valve, observing section 2.3 <Particular hazards>.
Contact Pfeiffer for spare parts and necessary instructions.
Malfunction
Check actuator unit and control signals
If actuator and control equipment are in order:
Remove the valve (observing the instructions in section 2.3 <Particular hazards>) and
check it.
If the valve is damaged:
If it must be repaired, remove the valve, observing section 2.3 <Particular hazards>.
Contact Pfeiffer for spare parts and necessary instructions.
If a pneumatic
actuator with
springs must be
removed from the
valve Caution: Risk of injury
Before removing the actuator from the valve, disconnect the signal pressure.
Note 1:
When ordering spare
parts, include all the
specifications listed in the
valve designation. Only
use original parts from
Pfeiffer.
Note 2:
If, after removing the
valve from the pipeline, it
is found that the body
and/or internal parts are
not sufficiently resistant to
the process medium,
select parts made of a
suitable material.
For malfunctioning actuator units, refer to the actuator instructions.
8 Further information
Contact the address below for the listed <Data sheets> and <Repair instructions> as well as further information.
Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 •47906 Kempen
Phone: [phone] - 0 •Fax [phone]
E-Mail: [email protected] •Internet: www.pfeiffer-armaturen.com

Pfeiffer Chemie-Armaturenbau GmbH
Hooghe Weg 41 • 47906 Kempen
Phone [phone] • Fax [phone] Page 8 of 8
Operating instructions
BA 28y-01_EN
Edition June 2004