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Mounting and operating instruction for valves - type sheet 1300.1300

1. General remarks

For the utilization of valves attention must be paid to the recognized technical rules, as for instance DIN-standards, DVGW codes of practice, VDI instructions, VDMA standard sheets etc..

ln the case of plants liable to supervision the
laws, regulations, as for instance industrial
codes, regulations for the prevention of
accidents, boiler code, regulation for high
pressure gas tubes, regulation for combustible
liquids as well as the technical rules TRD, SR,
TRG, TRbF, TRGL, TRAC, UVV, AD codes of
practice etc. are applicable.

2. ldentification

ln accordance with DIN EN 19 all valves are provided with identification marks for nominal diameter (DN), nominal pressure (PN), material of body, sign of manufacturer, and, if necessary, with a flow direction arrow.

2.1 Range of application

For the range of application and the operational limits attention must be paid to the enclosures to our offers.

3. Mounting

The valves must be stored in dry rooms and protected against pollution and damages.
Remove the protective covers only immediately prior to mounting the valves.
Before mounting the valve, the opening must be cleaned and the sealing surfaces controlled, as far as possible. In the case of stop valves, control valves and check valves attention must be paid to the flow direction.

When mounting the valve you must take care that the seals at the connecting flanges are well centered and that the flanges of the following tube are axially and parallely aligned one to the other.

The flange bolts must be tightened 'crosswise'.

ln the case of valves with welded ends, it must be paid attention to weld in the valves under absolute clean conditions, in order to guarantee that no impurities can enter into the body.

When welding it in, the valve must be opened. For the welding in the welding bevels of valve and tube must be centered. The weld seam should be carefully executed with an heat input as low as possible.

The laying of tube shall be executed in such a way that harmful forces of the tube are kept away from the valve body.

ln case that construction work is executed still near to or over the valve, the valve is to be  covered as a protection against the building site operation.

ln the case of laying the tube underground, you  must see to a careful bedding of tube on both  sides of the valve, in order to avoid a  sagging of tube within the reach of valve and the bending  stress resulting therefrom.

The valve shall not be used as check point of the tube.

In the case of painting the plants, the stems,  stuffing boxes, closing plates of gate valves,  position indicators and marking plates must not  be painted. lf the plant first was sandblasted for
cleaning the above parts would have to be provided with a special covering. lf solvents were used for cleaning it would have to be taken care that the solvents cannot penetrate into connecting gaps of bodies, into grooves of stuffing boxes, stem or shaft seals, to the hose
installation fittings, and not between the connecting flanges with the tube and destroy the seals.

4. Putting into service and operation

Prior to the putting into service of new installations, in particular, however, after the  execution of repairs the tube system must be  flushed with the valve fully opened. The materials of valve must not be affected during this procedure.

During pressure tests only the nominal  pressure and the maximum admissible service pressure respectively should be applied to the closed valve.

As standard the closing is executed by turning to the right.

The stems and actuators are dimensioned in such a way that the valve can be operated by one man using an handlever, handwheel or operating key.
Extensions for operation are not allowed and might cause damages to the valve by overload.

A limit stop is provided for at the hand lever and gear respectively in case of valves with swivel motion of 90°, as discs and ball valves. A further rotating by use of force might result in breaking.

Verify the function by opening and closing several times.

For hot running tubes possible cover bolts and stuffing box nuts are to be retightened uniformly after the first heating up. For this purpose the valve has to be opened first by about two turns.

For electrically operated valve it must be paid attention to the fact that the valves have to be switched as follows:

Elastomer coated valves and steel casting valves:

"CLOSED" torque-dependent
"OPENED" limit-dependent.

All other types:
"CLOSED" and "OPENED" limit-dependent.

5. Dismounting

5.1 Safety instructions!

Prior to dismounting the complete valve from the tube or to repair and maintenance work on the valve, i.e.

- before unscrewing the body connecting bolts, body cap cover, gland flanges, plugs,

- prior to dismounting directly mounted actuators,

the valve must be made pressure-less and has to be cooled down in the case of hot running tubes down under the evaporation temperature of the medium.

ln case of toxic media the valve, in addition, must be drained and ventilated.


lf actuators which are fed by external energy (electric, pneumatic, hydraulic) must be dismounted from the valve the safety instructions under 5.1 must be taken into, consideration and the external energy is to be switched off.

The operating and maintenance instructions must be followed for the operation and maintenance of the various valve types.

6. Supplementary operating instructions, taking aspects of Directive 94 / 9 / EC  (ATEX 100a) into account

6.1 Safety

This symbol indicates safety    measures which must be heeded, particularly in relation to the use of valves in potentially explosive areas in the sense of directive 94 / 9 / EC (ATEX 100a) to prevent personal injury and material damage.

• lf the valves are used in potentially explosive areas, care must be taken that inadmissible operating methods are prevented. ln particular, exceeding the specified temperatures is not permitted.

• In potentially explosive areas, the owner-operator is obliged to install and operate explosion-proof working tools only.

6.2 lnstallation

• Valves used in potentially explosive areas must always be integrated in the equipotential bonding of the system.

• The spring space of the pneumatic actuators must be connected to a non-exploding air reservoir for ventilation when working in a potentially explosive atmosphere.

6.3 Operation

• When the valve is in use, it is assumed that the system and thus the interior of the valve in contact with the medium is continually filled with pumping medium, thus preventing a potentially explosive atmosphere from being built up. lf the owner-operator cannot guarantee this, appropriate monitoring measures must be designed, see ATEX100a, Annex ll, Section 1.5.5 and EN 1127-1.

• The surface temperature occurring at the valve body corresponds to the temperature of the medium to be pumped. Making sure the specified temperature of the medium (working temperature) is observed at all times is the responsibility of the system's  owner-operator. The maximum permissible temperature depends on the temperature class involved.

• Additional loads above normal levels (e.g. external forces and moments) must be avoided.

6.4 Maintenance / Repairs

• Maintenance and repair work is the responsibility of the owner-operator and must be carried out in such a way that no ignition sources (e.g. electrostatic discharge, mechanically produced sparks) can develop or be triggered.

• Air-tightness to the outside, both at the body as well as at the different sealing spots, must be checked at regular intervals, e.g. using a special maintenance program.

• Dust and dirt deposits on the surface of the valves should always be avoided.

• Only a damp cotton cloth should be used to clean plastic surfaces or plastic-coated
surfaces in order to prevent static charge.

• Only original spare parts may be used.

6.5 Marking

• Valves are components without their own potential ignition source and are thus not subject to directive 94 / 9 / EC.
For this reason they must not be marked with the ATEX sign.

6.6 Final remark

lf the instructions included in the above-mentioned general operating instructions and those included in these supplementary instructions in the sections "Safety, Installation, Operation and Maintenance/Repairs" are not observed, proper operation of the valves in the sense of directive 94 / 9 / EC is no longer guaranteed. Their use in potentially explosive areas is then prohibited.
The operation of faulty valves in potentially explosive environments is always inadmissible.

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