SCHUCK U User manual

Franz Schuck GmbH
Installation/operation manual
Type U ball valve
Translation of the original Operation Manual
Keep for future use!
avrora-arm.ru
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Introduction
This manual is written for installation, operating, maintenance and supervisory
personnel.
This manual also describes components and auxiliary units that are not included
or are only partially included in the scope of supply.
The manual must be read, understood and observed by the user. We emphasize
that Franz Schuck GmbH assumes no liability for damage or malfunctions arising
from non-compliance with this manual.
With regard to the illustrations and information in this manual, we reserve the right
to make technical modifications.
Copyright
The copyright for this manual remains with Franz Schuck GmbH.
The instructions and drawings contained herein may not be reproduced or dissem-
inated either fully or in part, nor used for competitive purposes or communicated
to other parties without authorization.

2013-02-09 I
Table of Contents
Table of Contents
Chapter 1 1-1Preliminary remarks
1.1 1-1Legal notes
1.2 1-1Application range
Chapter 2 2-1Safety
2.1 2-1Fundamental safety instructions
2.1.1 2-1General
2.1.2 2-3Intended use
2.1.3 2-4Organizational measures
2.1.3.1 2-4Special hazard points
2.1.3.2 2-5Workplace and personal protective gear
Chapter 3 3-1Description
3.1 3-1System overview
3.1.1 3-3Identification plate
3.1.2 3-4Construction and design
3.1.3 3-4Sealing off the outlet
3.1.4 3-4Sealing out the atmosphere
3.1.5 3-4Actuating stem
3.1.6 3-5Actuation
3.1.7 3-5Accessories and connections
Chapter 4 4-1Assembly
4.1 4-3Preparation
4.1.1 4-3As-delivered condition
4.1.2 4-4Inspection
4.1.3 4-4Storage
4.1.4 4-4Transport
4.2 4-6Installation
4.2.1 4-6General installation instructions
4.2.2 4-7Ball valves with weld ends
4.2.3 4-8Ball valves with flanges

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Table of Contents
4.2.4 4-9Valve installation
4.2.5 4-9Connection and start-up of actuator and control system
4.3 4-10Testing
4.3.1 4-10Function test
4.3.2 4-10Pressure/leak tightness test
Chapter 5 5-1Operation
5.1 5-1Safety instructions for operation
5.2 5-2Operation
5.2.1 5-2Open/close valve
Chapter 6 6-1Maintenance
6.1 6-2Inspection
6.1.1 6-2Regular maintenance
6.1.2 6-2Venting/drain
6.1.3 6-3Double block and bleed test
6.1.4 6-3Injecting sealant (optional)
6.1.4.1 6-3Internal leaks on seat rings
6.1.4.2 6-4Sealing the actuating stem
6.1.4.3 6-4Sealing the bonnet sealing
6.1.5 6-5Faults and troubleshooting
6.1.6 6-5Inspection intervals
6.2 6-6Repairs
Chapter 7 7-1Appendix
7.1 7-1Tightening sequence for flange bolts
7.2 7-2Conversion factors
7.3 7-3Calculation formula to determine the carbon equivalent (CEV)
7.3.1 7-3Calculation formula (standard)
7.3.2 7-3Calculation formula for steels with different consistencies
7.4 7-4Sealant requirement per ball valve (above ground)

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Table of Contents
7.5 7-5Marking of packages
7.5.1 7-5Marking of packages according to DIN 55402 and ISO R 780
7.5.2 7-6Schuck symbols –transporting and unpacking packages

Type U ball valve
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Codeword: XML Source: 100: Kugelhahn
Created with: TeXML v.schuck-latex-130207
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2013-01-07 Revision: 2013/01
Preliminary remarks
1 Preliminary remarks
CAUTION
Danger of consequential damage due to incorrect operation, maintenance and/
or handling!
We explicitly emphasize that we assume no liability for damage or malfunctions
arising from non-compliance with this manual.
ÖTherefore it is important to comply with all instructions in this manual!
This manual is to provide technicians and users with the necessary information
for assembly and adjustment work and to help in performing work quickly and
correctly.
For your own safety, read this manual carefully and pay particular attention to the
highlighted tips. In any case, keep this manual to hand.
Pay special attention to all safety instructions in this manual. You will find the
safety instructions in Chapter 2, in the introductions to chapters and before prac-
tical instructions. The General Terms and Conditions of the company apply exclu-
sively to all deliveries and performances made by Franz Schuck GmbH, including
any future transactions.
1.1 Legal notes
The component may only be installed and operated by skilled personnel.
Please check parts upon receipt for any possible damage that may have occurred
during transport. Only undamaged parts may be fitted or used.
No warranty can be claimed if maintenance work is neglected or carried out incor-
rectly. Only original spare parts guarantee quality, reliability and exchangeability.
Any modification(s) of the component are in general prohibited by Franz Schuck
GmbH. The manufacturer guarantee becomes void if this prohibition is not com-
plied with!
1.2 Application range
This operation manual applies to the Franz Schuck GmbH product described in this
manual.
The appropriate operation manuals for optional accessories must also be ob-
served.
These operation manuals are included in the overall documentation if the acces-
sories belong to the scope of supply from Franz Schuck GmbH.

Type U ball valve
2013-02-09 2-1
Codeword: XML Source: 100: Kugelhahn
Created with: TeXML v.schuck-latex-130207
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2013-01-07 Revision: 2013/01
Safety
2 Safety
CAUTION
Dangers to the health and safety of operating and maintenance staff as well
as to the functioning capacity of the valve. Dangers to the environment due to
escaping gaseous or liquid media.
Escaping sour gas or sulphinic lye might cause life danger hazard!
Non-compliance with these instructions jeopardizes the obligation by Franz
Schuck GmbH to follow through on the warranty/guarantee.
ÖThe instructions in the “Safety”Chapter must be unconditionally observed!
2.1 Fundamental safety instructions
2.1.1 General
Modifications on valves and attachments which could affect safety may not be
carried out without written permission from the manufacturer.
The guarantee becomes void if this prohibition is not complied with!
i
•This product has been manufactured according to the recognized rules of
technology and according to internal Schuck quality standards; the product is
shipped from the factory in a perfect technical condition
•Nevertheless, valves can cause hazards to people, material goods and the en-
vironment if operating personnel use them improperly or in a manner that is
contrary to their intended use
•Any person dealing with assembly, commissioning, operation and/or mainte-
nance of the valve must have read and understand this entire manual, and must
be able to prove they possess professional qualifications for implementing the
work
•Please observe the valid accident prevention regulations when installing the
component
•Suitable protective gear must be worn when carrying out the works
•The manual must be kept safe and accessible at all times at the place where
the valve is in use
•If malfunctions occur, notify Franz Schuck GmbH immediately and take appro-
priate measures
•Work on ball valves (such as inspection, servicing and/or maintenance work)
may only be carried out in a depressurized state and with the energy supply
secured and switched off

Type U ball valve
2013-02-09 2-2
Codeword: XML Source: 100: Kugelhahn
Created with: TeXML v.schuck-latex-130207
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2013-01-07 Revision: 2013/01
Safety / Fundamental safety instructions
•Valves must be effectively covered and/or protected when work is being carried
out that could lead to contamination or damage to the valve, the assembled
parts and/or the anti-corrosion protection

Type U ball valve
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Codeword: XML Source: 100: Kugelhahn
Created with: TeXML v.schuck-latex-130207
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2013-01-07 Revision: 2013/01
Safety / Fundamental safety instructions
2.1.2 Intended use
The ball valve supplied is designed exclusively to allow or block the flow of media
in pipelines.
Depending on the sealing system, the ball valve can be used both for gaseous and
liquid media.
Any other media and/or applications outside the permissible pressure and temper-
ature range can lead to damage and/or leaks.
Intended use includes observing the instructions in this operating manual and ad-
hering to the operating conditions on the identification plate, the final inspection
certification and drawings, as well as observing the locally applicable accident pre-
vention guidelines and regulations for protecting the environment.
Any operating conditions or applications which differ from those prescribed are
only valid with the agreement of Franz Schuck GmbH!

Type U ball valve
2013-02-09 2-4
Codeword: XML Source: 100: Kugelhahn
Created with: TeXML v.schuck-latex-130207
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2013-01-07 Revision: 2013/01
Safety / Fundamental safety instructions
2.1.3 Organizational measures
2.1.3.1 Special hazard points
There is no immediate danger from a valve that is installed and serviced according
to instructions.
•Danger from escaping media
–depending on the working medium, fire or explosion hazards can arise from
electrical contact, naked flames, light and/or smoking
–there is a risk of poisoning, chemical burns, scolding and environmental
pollution
–hazardous materials must be collected or sucked up, if necessary, and dis-
posed of properly
•The voltage in electrically operated ball valves poses a potential danger
–all work on electrical installations may only be carried out by trained elec-
tricians and only at zero potential
•Stored energy is an imminent danger in the case of ball valves that are actuated
pneumatically, hydraulically or gas-hydraulically
–all energy-storing systems must be depressurized during servicing and
maintenance works
–Work on the ball valve may only be carried out in a depressurized state. This
also applies for the disassembly of caps and screw connections as well as
adjustment works on the ball valve.