Coreline Fig.223 Wafer Manuale di istruzioni

Rubber seat butterfly valves

Fig.223 : Wafer

Fig.224 : Lug

English

Introduction

In order to benefit from the excellent properties of the Coreline butterfly valves, it is necessary to follow the instructions of

this user manual carefully. For errors resulting from improper installation, the manufacturer or Distributer can not be held

responsible. Consult the applicable standards for allowable flange dimensions. Dimensions, materials and applicability of

the valves should be derived from the technical datasheets and documentation, which can be found in our latest

catalogue from our website - www.coreline.dk .

Requirements for the maintenance staff

The staff assigned to assembly, operating and maintenance tasks, should be qualified to carry out such jobs and in any

circumstance, ensure personal safety.

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Installation-Operation-Maintenance Manual

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Installation-Operation-Maintenance Manual

page 3 ………………… Transportation and storage

Precautions before installation

Inspection of valve

Confirmation of valve working conditions

Operation of valve

page 4 ………………… Service and medium factor - Actuator Sizing

Installation direction of shaft

Pipe cleaning

Valve installation

page 6 ………………… After installation

Additional information

Use and maintenance

page 7 ………………… Material part list of valve

page 8 ………………… Troubleshooting

General warning

Chart for medium resistance

Installation-Operation-Maintenance Manual

Transportation and storage

Valves must be well protected and gently transported to avoid scratches, damage and enviroment damage. Stock the

valves indoors in dark and cool places to reduce rubber aging. Rubber is organic and lifetime will be reduced if

exposed to light and warm ambient temperatures.

During the storage, the valve disc must be in the slightly open position with an angle between 5~10° (See Fig.1).

Precautions before installation

Before installing the valve, please read the instruction manual carefully, pay attention to the safety matters and precautions

in the instruction manual before and during installation. Follow the instructions in the installation manual to help ensure that

the valve can be installed quickly and correctly.

Inspection of valve

Although valve manufacturers will take certain steps to prevent shipping damage, such damage can still occur and can be

discovered and notified before installation. Do not install valves that are known to be damaged during transportation and

storage. Before installation, check and remove all transport stops, protective plugs or protection covers, and check the

inside of the valve body to ensure that there are no foreign objects.

Confirmation of valve working conditions

Before installing the valve, check that the specification on the identification plate meets the requirements regarding

pressure, temperature and media. The valve shall not be installed, in environment that may cause corrosion or damage to

the valve.

Operation of valve

There is a small triangular shaped figure on the sealing surface of the seat from DN40 to DN300. This triangle indicates

which way the disc has to enter the seat. The operation of the valves, therefor, either free stem, handle or gear operated,

must follow the guidelines as shown below:

Turn the disc clockwise, towards the arrow (See Fig.2) to close the disc. Turn the disc anti-clockwise, towards the arrow to

open. This is to achieve the lowest possible torque - and thus the longest possible lifetime (See Fig.3).

The best angle for a closed valve is 2°. The patented design of the liner make the valve tight at this angle and reduce

torque and wear.

Though the valves are constructed to work as described above, Clockwise rotation can be applied without problems, if you

take in to consideration that the torque in this case will increase.

For butterfly valves ≥ DN350, the valve can be operated with both clockwise and counterclockwise direction, and the

recommended angle for a closed valve is 0°.

Fig.1

Fig.2

Fig.3 Turn clockwise 2° to close

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Installation-Operation-Maintenance Manual

Installation direction of shaft

Most butterfly valves can be installed in any position, but the most common method is to mount the shaft in vertical

direction with the activating upwards. However, if there is lot of dirt floating in bottom of pipeline, we recommend to

mount the valve with horizontal shaft. Then you avoid massive dirt at the turning points, which is sealing to ambient (See

Fig.4). Let the lower disc plate open in flow direction to avoid wear.

Pipe cleaning

Foreign matters in the pipeline may damage the sealing surface of the valve or prevent the movement of the butterfly

disc, resulting in the valve not closing properly. In order to reduce the possibility of dangerous situations, all pipes need

to be cleaned before installing the valve. Check that pipe dirt, metal chips, welding slag and other foreign objects have

been removed. In addition, check the flange surface of the pipe to ensure that there is a smooth surface (If any cleaning

proces after the valve is installed in pipeline, the disc has to be in open position and must not be activated before rinsing

completed, to avoid damage of seat).

Valve installation

Welding operation must not be done nearby the butterfly valve, as welding drops can damage the seat.

Check if the flange inner diameter is too small, it may cause valve disc damaged or the valve cannot be operated (See

Fig.6).

When installing a butterfly valve with rubber seat, there shall be no additional gasket on the flange surface. It is recom-

mended that the flange installed with the butterfly valve meet the relevant standards.

Check that the pipes are in a straight line and the flanges are clean and parallel. Do not install the valve between two

non-parallel flange faces(See Fig.7).

The distance between the flanges must correspond to the face to face dimension of the butterfly valve. If the flange gab

is too small, there is risk of damaging the seat or body surface of the butterfly valve. If the opening is too large, it can

cause leaking.

Fig.4

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Fig.6 Fig.7

Flow direction Flow direction

Service and medium factor - Actuator Sizing

OBS: Butterfly valve torque is 100% by 0° to 6° angle and 33% from 7° to 90° angle.

* Valve is completely closed and opened 2 times a day minimum.

** Valve is completely closed and opened only one time per week or longer.

Having a long period without maneuvering the valve, will increase the breakaway torque.

Service factor [SF] Multiply by Medium factor [MF] Multiply by Medium factor [MF] Multiply by

ON/OFF operation 1.15 Lubricating liquid/gas 0.9 For dry service (Dry gas/air) 1.25

Modulating operation 1.25 Viscous Liquids, Molasses 1.3 Dirty air slurry, natural gas, dirty slurry 1.5-1.8

*) 2 cycle/day “NC” 1.15 Degreasing liquid 1.25 Lime water, chlorin gas,oxygen, powder 1.5-1.8

**) 1 cycle/week “NC” 1.5 Saturated steam 1.2 Hydrodynamic torque NA

Installation-Operation-Maintenance Manual

When the valve is carefully installed, the angle of the valve disc shall be within the face to face dimension (See Fig.8).

Check that the flange covers the area of the seat and the valve is in line with the pipes. Then tighten the bolt on the

flange by hand (Fig.8). Carefully open and close the valve to check that the disc centralizes and the disc does not touch

the flange. With the disc in the open position, tighten crosswise with a wrench (See Fig.9 + Fig.10).

After the installation of the valve, enough space must be reserved around the valve, so that there is enough operation

space during the inspection and maintenance.

Important: Fig.224 Lug butterfly valve installation

The valve has vulcanized seat on back up-ring. This gives many advantages, but the seat is floating in the body. For

Fig.223 Wafer version, the valve will be automatically centered, but Fig.224 Lug butterfly valve must be mounted

according to below description.

Follow Fig.11 about procedures to fasten flange bolts for Fig.224 butterfly valve. The valve will be in right position and

be tight in general afterwards(See Fig.12). Due to a Coreline patent, our Fig.224 Lug butterfly valve can be used as end

of pipe valve. Ensure that the flow arrow direction on valve mounting flange is in accordance with the flow direction of

medium.

It is important to follow procedures showing in Fig.11, otherwise there might be problem as showed in Fig.13.

After the valve is aligned with the pipeline, then gently tighten the bolts, and finally tighten them in a staggered order as

showed in Fig.10, taken 8 bolts as an example. Correct tightening can avoid uneven valve pressing force, prevent

leakage, and also help to avoid flange damage.

Fasteners used during the installation should comply with the laws, regulations and standards of the relevant countries.

Those which do not meet the requirements of the relevant regulations are strictly prohibited to use for the installation.

When tightening the flange bolts and nuts, a reasonable torque should be used according to the relevant regulations.

The following table lists the torque values for reference.

Fig.8

Fig.12 Fig.13

Fig.9

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Fig.10

3 4

Fig.11

Arrow marking on

mounting flange

Firstly fasten flange

bolts on this side.

Secondly fasten flange

bolts on this side.

Flow direction Flow direction

Installation-Operation-Maintenance Manual

After installation

Ensure that the pipeline will not bent due to weight or other force. The pipeline shall not generate pipeline stress and

transmit pipeline stress to the valve.

The valve installation, including accessories (handle, gearbox, actuator etc.), cannot be used to withstand external

forces, for instance as support point or lifting devices.

After the valve is installed, it should be able to open and close smoothly. There should be no jamming during the valve

switching process.

The valve opens when the valve shaft rotates counterclockwise, and closes when it rotates clockwise.

Before commissioning the system, the pipeline and the valve should be subjected to a hydrostatic test to check whether

there is leakage. The system can be commissioned only after the test has passed.

Additional information

The valve has a patent, with two holes underneith the mounting flange (See Fig.14). Here you can hang user's manual or

project code.

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Use and maintenance

The use of the valve shall be carried out in accordance with the instruction manual, and shall not exceed the design

parameters. The operator must go through on-the-job training to understand the basic operationprinciple of the valve.

Prevent incorrect opening and closing of valves. The operator should clearly understand the role of each valve and its

position in the process pipeline to prevent misuse. It should be ensured that the valve can be opened and closed at least

twice within a week to prevent the valve from being stuck due to long-term inactivity. After the valve has been installed,

welding and other operations on the pipeline are not allowed (Fig.15).

Valves should be inspected regularly, at least every three months, or in accordance with the corresponding laws and

regulations, or on-site process conditions to set the frequency of maintenance. Regularly check the valve connections for

looseness and tighten in time. Check whether the valve leaks or malfunctions. If leaks or malfunctions occur, the valves

and pipelines should be repaired in time on the premise of ensuring safety.

If there is an actuator, attention should be paid to the actuator and its connecting mechanism during valve maintenance.

Maintenance should be carried out according to the instruction manual of the actuator.

4.6 5.6 6.8 8.8 10.9 12.9

240 300 480 640 900 1080

6 4-5 5-7 7-9 9-12 13-16 16-21

8 10-12 12-15 17-23 22-30 30-36 38-51

10 20-25 25-32 33-45 45-59 65-78 75-100

12 36-45 45-55 58-78 78-104 110-130 131-175

14 55-70 70-90 93-124 124-165 180-201 209-278

16 90-110 110-140 145-193 193-257 280-330 326-434

18 120-150 150-190 199-264 264-354 380-450 448-597

20 170-210 210-270 282-376 376-502 540-650 635-847

22 230-290 290-350 374-512 512-683 740-880 864-1152

24 300-377 370-450 488-650 651-868 940-1120 1098-1464

27 450-530 550-700 714-952 952-1269 1400-1650 1606-2142

30 540-680 680-850 969-1293 1293-1723 1700-2000 2181-2908

33 670-880 825-1100 1319-1759 1759-2345 2473-3298 2968-3958

36 900-1100 1120-1400 1694-2259 2259-3012 2800-3350 3812-5082

39 928-1237 1160-1546 1559-2079 2923-3898 4111-5481 4933-6577

Bolt strength grade

Yield Strength(N/mm2)

Tightening torque

(N·M)

Nominal Diameter

of bolt (mm)

Fig.14

Fix point -

for tag No. etc.

Fig.15

Installation-Operation-Maintenance Manual

Material part list of the valve

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DN40-DN300 DN350-DN2000

13 13

No. Part name Material Specification No. Part name Material

1 Body Ductile iron EN1563 JS1030 SS420

ASTM A351 CF8 SS431

ASTM A351 CF8M 17-4PH SS

ASTM A351 CF3M SS304

2507 SS316

1.4462 7 Body bearing RPTFE with graphite

1.4529 8 Disc bearing Rainforced nylon

1.4539 9 O ring Same as seat

Hastelloy 10 Weather seal NBR

Aluminium bronze C95800 11 Anti-dust seal NBR

Ductile iron Rilsan, Halar coated 12 Plug Steel galvanized

NBR (Eq. Nitrile) -15℃~+85℃SS304

X-NBR

-15

℃

~+85

℃SS316

NBR-DVGW

-15℃~+60℃14 Bottom cover Same as body

EPDM-H -20℃~+125℃SS304

EPDM-FDA (white)

-20

℃

~+85

℃SS316

EPDM-FDA (black)

-20

℃

~+125

℃

FPM (Eq. FKM, Viton) -15℃~+150℃

FPM-B (Eq. FEPM)

-15℃~+150℃

PTFE

-15

℃

~+150

℃

Seat3

Disc

Stem4/5

Alloy steel

Stainless steel

Preventing plate6

13 Screw

Bolt15

Notes:

1) Well -resistant NBR. 2) German gas certificate. 3) Steam resistant FPM. 4) Depending on the backup rubber material,

available with EPDM and FPM backup.

The above temperature range for the valve seats are provided as reference for general working conditions. Please note that the actual

applications may vary due to the different media, pressure etc. in the pipeline. Contact Coreline in advance for technique supports.

Installation-Operation-Maintenance Manual

Troubleshooting

The relevant safety regulations must be observed when troubleshooting.

General warning

The installation, use and maintenance of the valve must comply with relevant laws and regulations. The installation, use

and maintenance of the valve must be carried out under the environment of safety regulations, and the pipeline engineer

must meet the production process and use requirements on site when selecting the valve. Before purchasing the valve,

the purchaser is obliged to clearly inform the valve manufacturer of the working conditions of the valve. If the user fails to

install, maintain and use the valve according to the regulations and requirements, the user shall bear the consequences.

Problem Possible cause Corrective measures

No flow Flange dust caps were not removed Remove dust caps

Valve not completely open Open valve completely

Piping system clogged Check piping system

Replace valve

Consult supplier

Power failure Check power supply.

Wrong direction of rotation Turn in correct direction (anti-clockwise for opening)

Fouling of the disc and/or seat Remove fouling on the disc and/or seat

Valve not properly closed Close valve properly or readjust limit switch/stop screw

Seat damaged by foreign particles Replace valve or seat

Medium contaminated Clean valve and install dirt screen

Valve with locking device can not be opened Locking device tightened Slacken locking device

Little flow

Valve is impossible or difficult to open or close

Service conditions (e.g. medium, temperature) outside

permissible limits.

Valve leaking

Chart for medium resistance

Liner Suitable for Unsuitable for

EPDM

Water, steam, alcohol, glycol, caustic soda, ozone,food products, glycerine,

milk, oxygen, air, saturated salt, iron chloride, gelatine, dry hydrogen

sulphide, potassium chloride, sodium, magnesium chloride

Mineral oil, chlorine compounds, ketones, acetyl, chloride, asphalt,

bromine, butane, butyl, petrol, diesel oil, acid, fish oil, freon, chlorine,

natural gas, exhaust gas, nitric acid

NBR

Mineral oil, grease, air, seawater, gas, boric acid, aluminium chloride,

ammonia gas, citric acid, diesel oil, fish oil, petrol, gelatine, glycerine,

magnesium chloride, lactic acid, linseed oil, natural gas

Ozone, acetone, aniline, chlorine dioxide, chromic acid, phenol, ethyl

acetate, freon 21+22+23, hot nitric acid, styrene, hydrogen sulphide,

isopropyl acetate, oxygen, sulphuric acid

NATURAL

RUBBER

Abrasive medium, aluminium chloride, sugar beet fluid, boric acid, potassium

chloride, citric acid, magnesium chloride, ferritic nitrate, formic acid,

gelatine, sugar, glycerine, lactic acid, nitrogen

Steam, aniline, asphalt, butadiene, diesel oil, ethane, ethyl acetate,

hydraulic oil, hydrochloric acid, linseed oil, methane, mineral oil, oxygen,

styrene, soyabean oil, turpentine

HYPALON Mineral, organic and inorganic chemicals, air, oxygen, fish oil, glycerine,

citric acid, ozone, sodium solphate

Ammonia, diesel oil, grease, ketone, methyl, phenol, propyl, bromine,

nitric acid, tar, urea, varnish, lectine

SILICONE Food products, ammonia gas, barium, boric acid, potassium, bisulphite,

citric acid, copper cyanide, glycerine, nitrogen, lactic acid

Steam and hot water (max. 100º C), asphalt, diesel oil, ethane, freon,

ethyl chloride, methane, nitric acid, olive oil, propane, turpentine

FPM

FPM-B

Oil, mineral acid, grease, phosphorus, tannic acid,

gelatine, glycol, oxygen, slaked lime, carbon acid,

natural gas, pulp, salt, sugar, sulphur

Acid, alkali, amine hot water, steam Gasoline, naphtha, hydrocarbon solvent, chlorine solvent

PTFE Almost available for all medium applications None

Hot water, steam, ketone, ammonia gas, acetone,

formaldehyde, cellulose acetate, freon, urea,

ethanoic acid, methyl

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2020-08-28 Coreline Valve Co., Ltd.

CORELINE VALVE CO., LTD.

Add: No.210 Xinyuan Road, Ehu Industrial Park, 214116 Wuxi, China

Phone: +86 510 8852 5336

Http: // www.coreline.dk E-mail : [email protected]

The contents of this catalogue are confidential

and proprietary to Coreline, we reserve the right

to change the specifications without any notice.

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