Böhmer BBF Manuale utente

Operating Instructions

Böhmer Fully Welded Ball Valves - Type BBF

Rev.: 06/2013

Authorized Distributor:

Liberty Sales and Distribution, LLC

2880 Bergey Road, Suite F

Hatfield, PA 19440

Phone: (877) 373-0118

Fax: (888) 850-3787

Email: [email protected]

TABLE OF CONTENTS PAGE

1. Safety instructions 3

1.1 Use in accordance with the intended purpose 3

1.2 Action in the case of malfunctions 4

2. Acceptance and transport 5

2.1 State as delivered 5

2.2 Checking of the delivery 5

2.3 Storage 5

2.4 Transport 5

3. Fitting and commissioning 6

3.1 Mounting position 6

3.2 Welding 7

3.3 Water pressure test 7

4. Operating and test for tightness 9

4.1 Opening and shutting off 9

4.2 Proof of tightness under operating conditions 9

4.2.1 Ball valves without test connection 9

4.2.2 Ball valves with test connection 9

5. Maintenance / repairs 11

5.1 Leaks on the actuation journals 11

5.1.1 Ball valves without test connection 11

5.1.2 Ball valves with test connection 12

5.2 Variants 13

•Variant 1 13

•Variant 2 14

•Variant 3 15

6. Accessories 16

6.1 Injecting of sealing agent 16

1. SAFETY INSTRUCTIONS

1.1 Use in accordance with the intended purpose

The fully welded type BBF ball valve is designed exclusively for opening pipes fully

for the flow of materials or for shutting them completely. Every other form of use, e.g.

for regulating flows, counts as not being in accordance with the intended purpose.

Use in accordance with the intended purpose also includes the observation of the

instructions in these operating instructions, the maintaining of the operating

conditions as stated on the type plate, acceptance certificates and drawings as well

as the observation of the relevant accident prevention and environmental protection

regulations applying at the place of use.

These operating instructions are intended for the expert personnel of the operator of

the ball valve.

The safety instructions are to be read before the ball valve is transported, fitted or

repaired and are to be kept safely.

In these operating instructions the safety instructions are high-lighted clearly from the

remaining text. There are two different types of safety instruction:

IMPORTANT

Signifies a situation that could be dangerous and gives hints on how

damage can be avoided.

DANGER

Indicates the direct risk of danger for health and life and limb or the risk

of serious material damage, in each case in the event of the instructions

not being observed.

1.2 Action in the case of malfunctions

The following safety instructions are to be observed.

Repairs to the ball valve, which become necessary in the course of the normal

operation of the ball valve, may be carried out but only after the permission thereto

has been obtained from Böhmer GmbH for each individual case.

All other repairs, e.g. that become necessary following damage through force

majeure or through causes which do not lie in the field of normal operation of the ball

valve, are to be carried out solely by Böhmer GmbH.

In the case of repairs to be carried out by the ball valve operator's, the following

manufacturer's instructions are to be observed:

-The statement of position of Böhmer GmbH is to be obtained before the repair is

carried out.

-Photos are to be taken before and after each repair.

-Repairs are to be carried out only using spare parts from and in accordance with

the fitting instructions of Böhmer GmbH.

-A report is to be prepared with the following statements:

•Cause of damage, effect of damage

•Spare parts, special tools and fitting devices used

•Repair measures and tests carried out

•Names of the persons carrying out the repairs, of the person responsible

therefor and the date on which the repairs were carried out

•Photos

2. ACCEPTANCE AND TRANSPORT

2.1 State as delivered

The ball valves are provided with a coating and type plate in accordance with the

particular order and - in so far as the order does not contain something different - are

supplied in the following form:

•The ends on to which welding is to be carried out and the flange connection

sides are provided with an anti-corrosion agent.

•Connection openings are closed with PE protective caps or wood lids to

prevent dirt and moisture getting in.

•The ball valves are packed on wooden pallets or in skeleton containers.

2.2 Checking of the delivery

Check the delivery without delay following receipt for transport damage. In the case

of damage observe the instructions of the insurance companies which - amongst

other things - will prescribe an immediate recording of the state of affairs by the

forwarding agent. Wherever possible document damage with photos.

In addition check the delivery for completeness against the delivery notes. Inform

Böhmer GmbH without delay if anything is missing.

2.3 Storage

•Leave the ball valves in the transport devices and in the packing material.

•Protect the ball valves against dirt if necessary. Cover them with plastic film.

Ball valves have to be stored in dry conditions and under cover.

•Do not actuate the ball valves while they are being stored.

2.4Transport

IMPORTANT

Transport each ball valve in such a way that you do not damage it

thereby. If using chains for lifting, place something suitable between the

ball valve and the chain to prevent damage to the external paintwork.

The paintwork has a protective function. Accordingly you must not allow

it to be damaged at any point.

DANGER

If the ball valve is delivered with the drive mounted on it, do not secure

the lifting devices (ropes, chains etc.) to the drive but only to the ball

valve itself. DANGER TO LIFE AND LIMB!

Secure the load in such a way that it cannot tip over to the side.

DANGER TO LIFE AND LIMB!

3. FITTING AND COMMISSIONING

3.1 Mounting position

The ball valves are supplied in the open position. Fit them into the line in this state.

IMPORTANT

Do not put the ball valves into circuit until the pipes have been cleaned

since otherwise the balls and seating rings will be unnecessarily

subjected to or even damaged by dirt, rust and assembly residues.

In its standard version, the ball valve is designed for fitting in lines of pipes running

horizontally. In this situation the actuation shaft is aligned vertically upwards.

Other modes of fitting (e.g. pipe vertical, actuation shaft horizontal) are possible when

this is specified in the order.

The type BBF fully welded ball valves in sizes up to DN 100 (4“) can be fitted in all

fitting positions without approval having to be obtained therefor from Böhmer GmbH.

IMPORTANT

Consult Böhmer GmbH before planning a different fitting position for the

ball valves of sizes in excess of DN 100.

If it is necessary for the weight of the ball valve to be supported, the ball valve must

be provided with and stand on its own foundation or be supported separately in

another way whereby in each case it must be free to slide in its axial direction. Do

not use the ball valve as a fixing point for the line of pipes but support these

separately.

IMPORTANT

In the case of ball valves with a test connection, the inside of the

housing should be drained prior to commissioning prior to the periods in

which frost can be expected.

IMPORTANT

Before subjecting a ball valve to pressure, check that the test connection

is in the fully closed position if one is fitted.

3.2 Welding

Depending on what is ordered, each ball valve has either two flange ends, one flange

end and one welding-on end, or two welding-on ends.

The welding-on ends and the flange connection sides of the ball valve are protected

with an anti-corrosion agent when supplied. Accordingly you must remove this

before welding on the welding-on end or connecting the flange.

IMPORTANT

Do not remove the protective caps until the ball valve is at the location at

which it is to be used and then only immediately before it is to be fitted!

The ball valve is to be fitted in its 100 % open position and should first of all NOT be

actuated. When welding the ball valve on, take care that the seals inside the ball

valve will not be heated to a temperature in excess of the permitted level of 140 °C.

In this connection the distances to the welding seam stated in the following table hold

good (if necessary the region between the welding seam and the seals must be

properly cooled).

Nominal width Distance to welding seam

1“ - 3“ 50 mm

4“ - 8“ 70 mm

10“ - 16“ 90 mm

> 16“ 150 mm

The above also holds good for all preheating work carried out as a preparatory stage

for welding.

3.3 Water pressure test

Only clean water of drinking water quality may be used as the pressure medium.

Carry out the measures in the sequence given below:

Prior to carrying out the water pressure test, clean the line of pipes and the ball

valves in order to completely remove all dirt, rust and assembly residues.

After filling the pipe with water, move the ball to the closed position and then open it

again a little (10-20 degrees). In this way you equalize the pressure on the sealing

rings and ball and protect these in this way from being overloaded by the test

pressure which will be well in excess of the nominal pressure.

IMPORTANT

The test pressure may not be more than 1.5 times the nominal pressure

or, as the case may be, 1.5 times the permitted operating pressure.

Carry out the water pressure test.

After the water pressure test, move the ball to the fully open position again (or where

necessary to the fully closed position) and drain the line.

If there is a test connection on the ball valve, drain the inside of the housing of the

ball valve via this connection.

Actuate the ball valve once or twice with the test connection open. Then close the

test connection again.

If there is not a test connection, the ball valve should be actuated once or twice.

4. OPERATING AND TEST FOR TIGHTNESS

4.1 Opening and shutting off

The open or closed position of the ball valve is defined by turning the actuation shaft

by 90 ° to its limit position, i.e. so that the delivery flow has the full cross-sectional

area open to it or so that the flow is completely shut off.

Note:

To ensure that the ball valve will have a long service life, pay attention to the fact that

the ball must always be moved to the fully OPEN or the fully CLOSED position and is

never left in an intermediate position in the operating mode.

Lines for measuring and monitoring purposes can be connected to the test

connection if there is one.

IMPORTANT

Keep to the operating conditions stated on the type plate.

4.2 Proof of tightness under operating conditions

Differentiation is made here between the following forms of execution:

4.2.1 Ball valves without test connection

With this form of execution a leakage test can only be carried out downstream of the

closed ball valve.

4.2.2 Ball valves with test connection

With this form of execution a leakage test can be carried out via the test connection.

IMPORTANT

The test pressure may not be more than 1.1 times the nominal pressure

or, as the case may be, 1.1 times the permitted operating pressure.

A tightness test must be carried out with the ball valve in its closed position. If this

has been agreed in the order, the tightness can also be checked when the ball valve

is open.

Open the test connection slowly to depressurize the inside of the housing - but do

this only when the ball is in its closed position. (If this has been agreed in the order,

the test can also be carried out when the ball valve is in its open position.) Danger of

injury!

The general safety regulations applying at the place of installation are to be observed

in respect of the medium escaping into the atmosphere.

DANGER

There can be a DANGER TO LIFE depending on the medium!

Wait until the complete system has been depressurized and that no more medium is

escaping. After allowing a period for equilibrium to be reached, a check is then made

to see whether further medium is escaping. If there is, then the amount can be

measured by counting the number of drops or bubbles per minute.

If there is a leak at the spindle passage seal, then this can often be eliminated by

opening and closing the ball valve several times.

Then close the test connection again!

Option: Injecting in of sealing agent

When a system for injecting in sealing agent has been agreed in the order and if the

level of leakage cannot be accepted, a suitable sealing agent can be forced in via the

injection nipples until the leakage stops. An analogous procedure can be carried out

with the actuation journals (see Fig. 1).

For a description and the mode of procedure see section 6.

Fig. 1

Injection nipple

Indice

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