Wey Sistag Sluice gate valve 3 User manual

Instruction manual 3.30.12
zertifiertes
Qualitätssystem
ISO9001
EN29001
Reg-Nr.
11001-01
WEY®Sluice Gate Valve Type 3
SISTAG Absperrtechnik
CH-6274 Eschenbach
Switzerland
Phone ++41 41 449 99 44
Fax ++41 41 448 34 31
[email protected]
www.sistag.com

WEY®Sluice Gate Valve Type 3: Instruction Manual
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WEY® SLUICE GATE VALVE TYPE 3:
INSTRUCTION MANUAL
1. GENERAL
1.1 - Safety
1.2 - Designated service
2. TRANSPORTATION, STORAGE
2.1 - Transportation
2.2 - Storage
3. INSTALLATION
3.1 - Preparation before installation
3.2 - Mounting aids
3.3 - Sluice gate with fixing clamps
3.4 - Sluice gate with anchor bolts for embedding
3.5 - Actuating components
4. COMMISSIONING
4.1 - General measures
4.2 - Safety measures
4.3 - Function test
4.4 - Manually operated equipment
4.5 - Pneumatically operated equipment
4.6 - Hydraulically operated equipment
4.7 - Electrically operated equipment
5. MAINTENANCE
5.1 - Operating cycles
5.2 - Cleaning / Lubrication
6. TROUBLE SHOOTING
7. REMOVAL
8. DISPOSAL
9. FINAL REMARKS
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1. GENERAL
1.1 Safety
Prior to any work or start-up and in order to ensure a proper functioning of our
products,
the instruction manual for installation and operation must be observed.
Alterations on the products need our written approval. For consequential damages
due to neglect of this direction, any liability will be rejected.
This symbol marks safety and risk advice. Follow all such advice in order to prevent any
damages to human life and objects.
This symbol refers to important information.
The installation must be carried out according to established procedures and only by
qualified personnel.
Project related data of valves, e.g. dimensions, materials and service range are found
in the respective documentation.
1.2 Designated service
The WEY®sluice gate is used in drain channels and basins at sewage treatment
plants and retaining reservoirs.
The sluice gate is suitable to shut-off pressure containing systems for water and
sewage. The technical application limits referred to in the relevant project data
documentation and this maintenance manual must be observed.
Should the WEY® sluice gate be installed in a explosive environment, the valve as
non-electrical equipment, as well electrical equipment must be conform to RL
94/9EG, ATEX.
2. TRANSPORTATION, STORAGE
2.1 Transportation
The transportation of sluice gates shall take place in a careful way. Lifting devices
shall not be hooked onto stems nor other actuating components. Sluice gates shall be
placed on even surface only, never tilted onto an edge, to prevent distortion of the
frame. The equipment shall be protected against exterior damage and atmospheric
exposure.
Large equipment will be supplied with additional transportation supports. These
supports shall not be removed before final mounting.
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2.2 Storage
Until final installation the equipment shall be stored in a dry, vented area. All function
relevant parts shall be suitably covered against humidity, dust or other contamination.
For longer storage periods or in case of unfavourable storage conditions which could
affect later the proper functioning, all blank surfaces, e.g. stem, piston rod shall be
suitably protected by long term preservatives against corrosion.
Factory applied preservatives shall be checked for possible transport damages and
appropriately repaired, if necessary.
For mounted accessories such as electric actuators, limit switches, solenoids, etc.,
the
3. INSTALLATION
3.1 Preparation before installation
Onsite construction work details, recesses, walls, etc. shall be checked for accuracy,
flatness, finish, etc. before starting with mounting the equipment.
Dimensions of any recesses have to comply with manufacturer’s drawings and shall
be checked acc. Fig. 1 and Fig. 2.
The walls shall be checked with plumb and level for its perpendicular (fixation of
frame, stem guides and actuating components) as well as its horizontal and vertical
flatness.
Fig. 1 Fig. 2
Larger deviations must be corrected on site prior to mounting, as follows:
a) by grinding, removal, equalizing of uneven surface;
b) by applying concrete filler according to requirements (tightness, strength).
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3.2 Mounting aids
In order to offset construction discrepancies, plastic or stainless steel shims or spacer
plates in various thickness may be used to level and position the fixing frame, wall
bracket and actuating components. Minor discrepancies can be compensated that
way. The frame gets therewith enough wall support that it cannot be distorted when
tightening the fixing bolts.
Major discrepancies must be compensated with threaded rods of suitable size if
assigned bolts
are too short (bad concrete quality, anchor hole too long or if many spacer plates had
to be used). Cut to size threaded rods must be inserted and tightened with 2 nuts.
After tightening the counter nuts must be removed and the threaded rod can be used
in replacement of a short bolt.
To seal between frame and wall, paste type, medium resistant sealants are most
suitable.
If filler or sealant is used, observe manufacturer’s instructions with priority.
3.3 Sluice gate with fixing clamps
Mounting and embedding work shall take place with sluice gate in completely closed
position only. For best sealing between wall and frame, the wall construction must be
dry.
Procedure
- Position sluice gate in the respective recess or in front of the wall opening to
shut-off and align with plumb and level, acc. Fig. 3.
- Drill anchor bolt holes at the transverse seal which serve as mounting aids.
- Set both anchor bolts and tighten them temporarily.
- With the set screws at the transverse seal (see Fig. 6) the required compression
of the seal against the gate can be adjusted. The adjustment shall be in a way
that an optimal compression of the sealing lips is reached.
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Fig. 3
- Check alignment with plumb and level. Readjust position of sluice gate, if
necessary.
Upper level of bottom profile must comply with finished floor level according to site
plan.
- Drill and set remaining dowels for all clamps, according supplier's specification.
- Prior to final fixation, pull frame slightly away from the wall in order to place two
rows of sealant (according supplier's instructions) behind the frame and
transverse seal up to the max. height of water head, respectively to the
transverse seal (Fig. 4 and 6). If bottom seal is bolted, sealant shall also be
placed there.
- All bolts can then be firmly tightened with the torque key, according to the
product/
supplier's specification, starting at the transverse seal and afterwards the
clamps.
Further information is found on the relevant project drawings.
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Fig. 4 Fig. 5
- When tightening the bolts, the sealant gets squeezed out on both sides of the
frame. Smoothen sealant with finger to a clean grout (Fig. 5).
- For sluice gates with transverse seal an additional grout is necessary after
tightening between wall and transverse seal acc. Fig. 7.
- After mounting the actuating components (acc. 3.4) the sluice gate shall be
opened and the sealant on the inside of the frame and transverse seal shall be
smoothened to a clean grout acc. Fig. 5 and Fig. 7.
- The bottom profile, if existent, requires onsite embedding with filler or mortar acc.
Fig. 8.
When filling these recesses never use any vibrators !
ottom and transverse seal profile shall be free of any concrete or other contamination.B
Fig. 6 Fig. 7
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Fig. 8
3.4 Sluice gate with anchor bolts for embedding
Mounting and embedding work shall take place with gate in completely closed position
only.
Procedure
- Position sluice gate in respective recess and align with plumb and level acc.
Fig. 9.
- Depending on size and weight of sluice gate, 2-3 dowels per side should be set
into
the recess and bolts be inserted (Fig.10).
- If supplied with transverse seal, set bolts and seal thereafter, as described in
3.2.
- Align sluice gate with plumb and level and fix frame.
- If necessary, tighten bolts at the transverse seal.
- Connect anchor and dowel bolts in the recess with a bar profile by welding acc.
Fig. 10.
Always position sluice gate with mounting aids of steel, never use wood wedges.
Sluice gate must never be weld-connected to concrete reinforcement bars.
- Check alignment with plumb and level. Realign sluice gate, if necessary.
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Fig. 9 Fig. 10
Upper level of bottom profile to comply with finished floor level according to site plan.
- The positioned sluice gate is now ready for onsite embedding.
When filling these recesses never use any vibrators !
Bottom and guide profile shall be free of any concrete or other contamination.
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3.5 Actuating components
Sluice gates with separately supplied actuating components, must not be actuated prior
to embedding.
Fig. 11
Procedure:
- Extension rod with coupling to be pinned to the bare shaft of the stem. For
coupling procedure keep wall bracket loose on the extension rod.
- Align coupled extension rod with plumb and level acc. Fig. 11.
- Position wall brackets and drill holes.
- Check alignment of all components with plumb and level. Realign if necessary,
using suitable shims.
- For additional supports, floor stands etc., appropriate positioning and alignment
is required before drilling holes.
- Set dowels and bolts.
- Check alignment of all components with plumb and level. Realign if necessary,
using suitable shims.
- Mount and fix all actuating components.
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3.5.1 Travel adjustment
For automated sluice gates the final end or travel position must be adjusted.
In the closed position it must be ensured that the gate slightly compresses the bottom
seal.
(see also chapter 4.4./4.5 commissioning).
Pneumatic/Hydraulic Actuators:
In the closed position the piston must mechanically touch the cylinder bottom (Fig. 12
"A").
In order to reach the necessary bottom seal compression adjust stroke by fixing either
piston rod or clevis with an approx. ½ turn setting outwards (longer), see (Fig. 12 "B").
Electric Actuators:
The limit switches must be set acc. manufacturer's instructions.
Close sluice gate first with manual override until slight compression of the bottom seal
is reached, then set the limit switch "closed". Thereafter open the sluice gate and set
the limit switch "open" just before the mechanical travel stop is reached.
B
A
C
Fig. 12
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4. COMMISSIONING
4.1 General measures
Before taking the equipment into service, all function relevant parts (stem, piston rod,
gate, gate guides, seals) shall be thoroughly cleaned.
The equipment is factory preserved and lubricated for transportation and storage, but
it may
require further lubrication before start-up depending on the service conditions.
Lubrication shall take place according to supplier’s schedule. Recommended are
water-repellent, temperature resistant and long lasting lubricants. (Get
recommendations from your supplier).
4.2 Safety measures
For automated equipment installed in an area where gate movement could be
dangerous for people (or animals/objects), it must be ensured by the user at site that all
moving parts are guarded with a suitable cover.
Such covers are optionally available from manufacturer.
Protection goals can also be reached through suitable on-site plant safety measures.
Unprotected valves must not be commissioned.
Ensure that no external interference of the electric control circuits can actuate the valve
unintentionally.
4.3 Function test
Before commissioning a function test must be performed. Therefore open and close
the sluice gate at least once.
For embedded sluice gates a function test shall not take place before grout
compound is dry and capable of bearing the structure.
If a pressure test is performed, ensure that the applied pressure does not exceed the
maximum allowed test pressure of the sluice gate.
4.4 Manually operated equipment
Check sluice gate for ease of operation (reasonable forces).
Also check the setting of the limit switches (if applicable)
4.5 Pneumatically operated equipment
Ensure with suitable measures that the maximum working pressure does not
exceed (8 bar), also not in a breakdown situation
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To operate the actuator, use
dry, filtered air acc. Class 4/5 ISO 8573-1
max. dust particle size 40 µm
max. dust particle concentration 10 mg/m3
max. excess oil concentration 5 mg/m3
pressure dew-point below minimal ambient temperature
Solenoid valves shall be mounted as close as possible to the actuating cylinder.
Air hoses, especially plastic pipes must be mounted and secured so that they cannot be
unintentionally interrupted or pulled-off. In order to keep a valve tight in its closed
position, the piston must be permanently under pressure.
The size of the air supply pipes has to be in relation to the required air volume.
Before start-up, all on-site mounted supply pipes and solenoid valves shall be
thoroughly flushed and cleaned, if necessary.
Factory mounted solenoid valves are normally supplied without accessories like
throttles or mufflers. On-site directives must therefore be observed.
4.6 Hydraulically operated equipment
Before commissioning all on-site mounted supply pipes shall be thoroughly cleaned.
Supplier’s instructions must be observed.
4.7 Electrically operated equipment
For electrical installations observe local rules, standards and directives.
In addition directives and guidelines for the installation and operation of
explosion protection equipment must be observed, if the equipment is
installed in a Ex-zone.
Check if the electrical equipment fulfils the safety requirements at site.
After installation a correct earth-connection must be verified. This is normally ensured
through the flange bolt connection. If this is not the case, suitable measures must be
taken.
For trouble-free commissioning of electric actuators, we recommend to call on our
specially trained customer service specialist.
Electric on-site installations shall be in accordance with the provided connecting
diagram. In addition, the specific operating instructions of the actuator supplier shall
be observed.
Move the gate into an intermediate position with the manual override before starting
operation electrically for the first time.
When connecting to the power supply, the phase sequence must to be observed.
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With wrong phase sequence, limit and torque switches are ineffective.
The switch-off shall be in accordance to our instructions/diagrams, i.e.:
- Switch-off in closing direction: usually by limit switches, exceptionally
with torque
switches possible.
- Switch-off in opening direction: by limit switches only, as the torque
switch serves as overload protection.
5. MAINTENANCE
5.1 Operating cycles
During one year, at least four (4) operating cycles shall be performed, whereby the
functioning of all components shall be checked. Under severe service conditions,
such functional checks shall take place more frequently.
5.2 Cleaning / Lubrication
Gate guides, stems, stem nuts and piston rods shall be free of dirt and
contaminations and shall always be well lubricated.
Grease ports at the handwheel bearing shall be lubricated in regular intervals
depending on the application and service conditions, but at least every three months.
Pneumatic cylinders with cushioned closing are supplied with a self-lubricating piston
rod seal.
The elastomer seal in the gate guides shall also be lubricated to avoid sticking
tendency of gate and seal after longer shut-down periods.
Water-repellent, temperature resistant and long lasting lubricants shall be used (Get
recommendations from your supplier).
For equipment with electric actuators, the lubrication ports on the drive should be
especially observed (version with rising stem).
The respective operating and maintenance instructions of the actuator supplier are
binding.
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6. TROUBLE SHOOTING
Symptom Cause Remedy
Leakage between
gate and trans-
verse seal
Transverse seal
damaged
Gate contaminated
or calcified
Replace transverse seal according to
manufacturer’s instructions
Clean gate
Leakage between
frame and wall
construction
Sealing grout defective
Dowel bolts loose
Repair or remove and renew grout
Tighten dowel bolts
Leakage through
seat
Gate not completely
closed; jammed
particles between gate
and frame members
Manually operated equipment:
- Open gate slightly and repeat
closing action
- Remove jammed particles
Jammed particles
between stem nut and
transverse seal member
Pneumatically and oil hydraulically
operated equipment:
- Open gate slightly and repeat
action.
- Check if new setting of clevis, resp.
stroke is necessary.
- Remove jammed particles
Electrically operated equipment:
- Open gate slightly and repeat
closing action; check; possibly reset
limit switches (acc. supplier’s
recommendation)
- Remove jammed particles
Seals damaged Replace seals according manufacturer’s
instructions
Gate can not
be moved
Actuating components
damaged
Manually operated equipment:
- Check and clean stem, stem nut,
gate and guides; replace if necessary;
lubricate
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6. TROUBLE SHOOTING (Cont’d)
Symptom Cause Remedy
Gate can not be
moved (Cont’d)
Actuating components
damaged
Pneumatically and oil hydraulically
operated equipment:
Check supply pressure. Check if current
onto solenoid existent. Check solenoid
for damages. Check actuating cylinder for
damages (seals).
Clean and lubricate, if necessary replace
damaged components acc. to supplier’s
instructions.
Electrically operated equipment:
Check if current existent.
Check if motor defect.
Check if limit switches defect or mal-set.
Check if gear, stem or stem nut
damaged.
Clean and lubricate, if necessary replace
damaged components acc. to supplier’s
instructions
Closing or open-
ing stroke ceasing
or stagnating
Insufficient supply
pressure
Pneumatically and oil hydraulically
operated equipment:
Check supply pressure; possibly increase
supply pressure
Solenoid valve dirty Remove and clean solenoid valve,
possibly install filter
Piston rod seal
damaged
Remove and clean piston rod seal,
replace cylinder seals and lubricate
Gate guides clogged Clean and lubricate
Pressure loss
on supply net
Pipe connections
damaged
Check pipe connections, tighten, replace
if necessary.
Cylinder seals
damaged
- Check and replace cylinder seals,
lubricate
- Check piston rod, clean, lubricate
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7. REMOVAL
Before removing the valve, consider that the pipe system can be under pressure
and that hazardous media could get into the environment. Respective precaution
measure must be taken.
Sluice gate frames will normally not be removed. They remain fixed to the wall
construction for service life.
Actuators must not be removed if equipment is under pressure.
Before removing electric actuators cut power, respectively disconnected from circuit.
Pneumatic and hydraulic actuators must be de-pressurized and disconnected from
supply lines.
8. DISPOSAL
Observe that sediments or contaminations as well as lubricants, cleansers etc. which
may adhere to the equipment or pipe could be harmful to people and environment.
Respective precaution measures are to be taken.
After finished service life, the valve must be disposed skilful and in conformity with
environmental regulations.
9. FINAL REMARKS
All information presented are to the best of our knowledge and shall provide, in
combination with our technical documentation, information about our products and
their range of applications.
They are not thought to assure particular features of the products nor their suitability
for a specific service.
Faultless quality is assured within our General Sales Conditions.
For any further information, call on our Customer Service Department at ay time.
ALTERATIONS AND ADDITIONS RESERVED
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