PERSTA 808 GJ Manuale utente

Gate valves

GJ, HJ, JJ and JN

Operating instructions

Read the instructions prior to performing any task!

Dok.-Nr. 6415.DE.STD.12.2015, 2, en_GB

Translation of the original operating instructions

Stahl-Armaturen PERSTA GmbH

Mülheimer Str. 18

59581 Warstein-Belecke

Germany

Telephone: +49 2902 762-02

Fax: +49 2902 767-03

Email: [email protected]

Internet: www.persta.com

20.05.2021Gate valves GJ, HJ, JJ and JN2

This manual enables safe and efficient handling of the gate valve.

The manual is a component of the product and must be kept in the

vicinity of the gate valve where it is available to personnel at all

times.

Furthermore, the local occupational safety regulations and general

safety requirements must be complied with for the area in which

the valve is used.

The personnel must have carefully read and understood these

instructions before performing any tasks. The basic prerequisite for

safe work is compliance with all the specified safety and handling

instructions.

The diagrams in these instructions are provided as examples only

and may deviate from the actual version.

Although the size and pressure ratings of the valve

types vary, the information in these instructions

applies generally to all valves, provided nothing to

the contrary is specified.

This manual applies to the following versions:

Designation Series Nominal diameter

(DN) [mm]

Pressure rate Class*

Small gate valve 808 GJ / GN 10–40 PN 10–100 -

Small gate valve/

VALTRA

800 GJ / 808 GJ 15–50 PN 10–40 800

Gate valves 700 HJ / 700 JJ

(700 GA / 700 JN)

50–150 PN 10–100

PD 10

600

Gate valves 700 HJ / 700 JJ

(700 GA / 700 JN)

200–250 PN 10–40 -

Gate valves 700 HJ / 700 JJ /

700 JN

200–300 PN 63–100 600

Gate valves 400 JJ / 400 JN 350–700 PN 63–100 600

Gate valves 700 JJ / 700 JN 300–1000 PN 10–25 -

Gate valves 700 JJ / 700 JN 300–700 PN 40 -

Gate valves 700 JJ / 700 JN 50–300/250 PN 160 / PD 18 900

* Assignment number in the pipe construction

Information about the operating

instructions

Scope of the document

Supplemental directives

20.05.2021 Gate valves GJ, HJ, JJ and JN 3

nIgnition hazard assessment GA004

nConnection diagram provided

nRisk analysis according to Pressure Equipment Directive

nRisk analysis according to Machinery Directive

nActuator instructions

nTechnical data sheet

nBolt tightening torques according to the website:

www.persta.com

nAs well as the other documents included in the delivery

Mülheimer Str. 18

59581 Warstein-Belecke

Germany

Phone: +49 2902 762-02

Fax: +49 2902 767-03

e-mail: [email protected]

Revision number Change/Supplemented informa-

tion

Date

1 Updates to chapter

“

Intended

use”.

05/05/2021

Other applicable documents

Customer Service - Stahl-Arma-

turen PERSTA GmbH

Revision overview

Supplemental directives

20.05.2021Gate valves GJ, HJ, JJ and JN4

Table of contents

1 Overview.............................................................................. 7

2 Safety................................................................................... 9

2.1 Symbols in this manual................................................. 9

2.2 Intended use............................................................... 11

2.3 Safety signs................................................................ 12

2.4 Safety devices............................................................ 14

2.5 Residual risks............................................................. 17

2.5.1 Basic dangers at the workplace............................... 17

2.5.2 Hazards due to electric current (in versions with

electric actuator)...................................................... 18

2.5.3 Hazards due to hydraulics (in versions with

hydraulic actuator)................................................... 18

2.5.4 Hazards due to the pneumatic system (in versions

with pneumatic actuator).......................................... 19

2.5.5 Mechanical hazards................................................. 19

2.5.6 Thermal dangers...................................................... 20

2.5.7 Dangers due to hazardous substances and oper-

ating materials......................................................... 20

2.6 Behaviour in the event of an emergency.................... 22

2.7 Personnel requirements.............................................. 23

2.8 Responsibility of the operating company.................... 25

2.9 Personal protective equipment................................... 26

2.10 Spare parts............................................................... 28

2.11 Environmental protection.......................................... 29

3 Functional description..................................................... 31

3.1 Operating principle of the gate valve.......................... 31

3.2 External seal............................................................... 32

3.3 Versions of the gate valve .......................................... 34

3.3.1 Shut-off element....................................................... 34

3.3.2 Actuator variants...................................................... 34

3.3.3 Display elements..................................................... 38

3.3.4 Connections............................................................. 39

4 Transport and storage...................................................... 41

4.1 Safety instructions for transport and storage.............. 41

4.2 Transport of packages................................................ 42

4.3 Storage of the valve.................................................... 43

4.4 Storage of spare parts................................................ 43

5 Installation......................................................................... 45

5.1 Safety instructions for installation............................... 45

5.2 Before the installation................................................. 47

5.3 Installing the valve...................................................... 48

5.4 Attaching additional safety devices............................. 48

5.5 For electric actuator: connecting the power supply.... 49

Table of contents

20.05.2021 Gate valves GJ, HJ, JJ and JN 5

5.6 For hydraulic actuator: connecting the hydraulic

system........................................................................ 49

5.7 For pneumatic actuator: connecting the pneumatic

system........................................................................ 50

5.8 After the installation.................................................... 50

5.8.1 Pickling the valve..................................................... 51

5.8.2 Painting the valve.................................................... 51

5.8.3 Performing a system pressure test and leak test..... 52

5.8.4 Applying thermal insulation...................................... 52

6 Commissioning................................................................. 55

6.1 Safety instructions for commissioning........................ 55

6.2 Prior to commissioning............................................... 58

6.3 Carrying out the commissioning process.................... 59

7 Operation........................................................................... 61

7.1 Safety instructions for operation................................. 61

7.2 Operating the valve..................................................... 63

7.2.1 Valve with manual actuator (handwheel)................. 63

7.2.2 Valve with electric actuator...................................... 63

7.2.3 Valve with hydraulic or pneumatic actuator ............ 64

7.3 Operating the valve in an emergency......................... 65

7.3.1 Valve with manual actuator (handwheel)................. 65

7.3.2 Valve with electric actuator...................................... 66

7.3.3 Valve with hydraulic or pneumatic actuator............. 66

8 Maintenance...................................................................... 67

8.1 Safety instructions for maintenance............................ 67

8.2 Maintenance schedule................................................ 71

8.3 Maintenance tasks...................................................... 72

8.3.1 Visually checking the valve...................................... 72

8.3.2 Replacing the gland packing and cover gasket....... 73

8.3.3 Lubricating moving parts (stem thread)................... 78

9 Faults and troubleshooting.............................................. 79

9.1 Safety instructions for fault correction......................... 79

9.2 Fault table................................................................... 82

10 Dismantling, disposal....................................................... 85

10.1 Safety instructions for dismantling............................ 85

10.2 Dismantling............................................................... 88

10.3 Disposal.................................................................... 89

11 Index................................................................................... 91

Table of contents

20.05.2021Gate valves GJ, HJ, JJ and JN6

1 Overview

Fig. 1: Gate valve

1 Actuator (in the example: handwheel)

2 Stem

3 Bonnet (fixed permanently to cover)

4 Cover

5 Body

6 Shut-off element (in the example: flexible discs)

7 Flow passage

The valves that are termed “gate valves” are installed in pipes. The

body (Fig. 1/5) of the valve is flanged or welded in the pipework,

depending on the version.

The shut-off element is moved up and down via the stem (Fig. 1/2).

When the shut-off element (Fig. 1/6) is moved down into the flow

passage (Fig. 1/7), no medium can flow through the valve. When

the valve is open, the medium flows through the entire body.

The stem is moved differently depending on the version:

nmanually via handwheel

nelectrically

Brief description

Actuator variants

Overview

20.05.2021 Gate valves GJ, HJ, JJ and JN 7

nhydraulically

npneumatically

See

Chapter 3.3.2 “Actuator variants” on page 34.

Depending on the version of the gate valve, it is suitable for use

with water, steam, oil and other non-aggressive media.

The following tools are required for the tasks described in the oper-

ating instructions:

Forklift

Forklift with sufficient load-bearing capacity for transport of valves.

Hoist

Hoist with sufficient load-bearing capacity for transporting valves

and components.

Packing extractor

Tool for removing gland packing elements.

Sling gear

Functional and approved gear for attaching valves and compo-

nents on the hoist.

Media

Tools

Overview

20.05.2021Gate valves GJ, HJ, JJ and JN8

2 Safety

2.1 Symbols in this manual

Safety instructions are indicated by symbols in this manual. The

safety instructions are introduced by signal words that indicate the

scope of the hazard.

DANGER!