DeZurik PEC 3650 Bedienungsanleitung

DeZURIK 3650-7200 PEC

ECCENTRIC VALVES

Instruction D10019

April 2015

DeZURIK

3650-7200 PEC Eccentric Valves

Instructions

These instructions provide information about PEC Eccentric Valves. They are for use by personnel who

are responsible for installation, operation and maintenance of PEC Eccentric Valves.

Safety Messages

All safety messages in the instructions are flagged with an exclamation symbol and the word Caution,

Warning or Danger. These messages indicate procedures that must be followed exactly to avoid

equipment damage, personal injury or death. Safety label(s) on the product indicate hazards that can

cause equipment damage, personal injury or death. If a safety label becomes difficult to see or read, or

if a label has been removed, please contact DeZURIK for replacement label(s).

Personnel involved in the installation or maintenance of valves should be constantly

alert to potential emission of pipeline material and take appropriate safety precautions.

Always wear suitable protection when dealing with hazardous pipeline materials. Handle

valves, which have been removed from service with suitable protection for any potential

pipeline material in the valve.

Inspection

Your PEC Eccentric Valve has been packaged to provide protection during shipment; however, it can

be damaged in transport. Carefully inspect the unit for damage upon arrival and file a claim with the

carrier if damage is apparent.

Parts

Recommended spare parts are listed on the assembly drawing. These parts should be stocked to

minimize downtime.

Order parts from your local DeZURIK sales representative, or directly from DeZURIK. When ordering

parts, please include the 7-digit part number and 4-digit revision number (example: 9999999R000)

located on the data plate attached to the valve assembly. Also include the part name, the assembly

drawing number, the balloon number and the quantity stated on the assembly drawing.

DeZURIK Service

DeZURIK service personnel are available to install, maintain and repair all DeZURIK products.

DeZURIK also offers customized training programs and consultation services.

For more information, contact your local DeZURIK sales representative or visit our website at

www.dezurik.com.

DeZURIK

3650-7200 PEC Eccentric Valves

April 2015 Page 3 D10019

Table of Contents

Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Fusion/Powder Coated Valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Required Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Exploded Assembly Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Closed Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Plug Orientation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Packing Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Packing Replacement

Replacing Packing with Actuator Removed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Replacing Packing Without Removing Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - 12

Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

Reassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

Removing Valve from Pipeline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Field Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Emergency Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Predicted Wear of Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

DeZURIK

3650-7200 PEC Eccentric Valves

D10019 Page 4April 2015

Description

The 3650–7200 PEC Eccentric Valves have welded nickel seats that provide excellent resistance to

corrosion and damage, and prolong the life of the resilient plug facing.

The valve rotates 90 degrees from full open to full closed. Clockwise rotation of the valve stem closes

the valve.

If an actuator other than a DeZURIK is to be mounted, the actuator must be capable of maintaining the

valve plug position with flow in the pipeline.

The following table shows sizes and port as a percentage of pipe area.

Table A: Body and Flange Size and Valve Port Area

As a Percentage of Pipe Area

Valve Size Body Size Flange Size Valve Port Area vs. Pipe Area

3650 36” 36” 105%

4200 36” 42” 79%

4250 48” 42” 136%

4850 48” 48” 104%

5400 48” 54” 82%

5450 60” 54” 124%

6050 60” 60” 100%

6600 60” 66” 100%

7200 60” 72” 79%

This valve is a pressure vessel. Failure to release pipeline pressure may result in

personal injury and/or flow system damage. Completely release pipeline pressure

before removing the actuator from the valve or removing the valve from the pipeline.

Handling

Lifting the valve improperly may damage it. Do not fasten lifting devices to the actuator, plug or through

the seat opening in the body. Lift the valve with slings, chains or cables fastened around the valve

body, or fastened to bolts or rods through bolt holes in the flanges.

Fusion/Powder Coated Valves

Valves with fusion/powder coated exterior paint require flat washers to be installed

under the flange nuts when installing the valve to the pipeline flange to prevent the

paint from cracking or chipping.

DeZURIK

3650-7200 PEC Eccentric Valves

April 2015 Page 5 D10019

Required Tools

To adjust the packing, you will need a socket and ratchet handle to remove the access cover screws.

•1/2" socket for all sizes

To adjust the four packing nuts, you will need a combination wrench.

•15/16" for sizes 3650 and 4200

•1-1/8" for sizes 4250 thru 5400

•1-5/16" for sizes 5450 thru 7200

To disassemble the valve, you will need the tools mentioned above, plus wrenches to remove the

bonnet and lower journal.

You will need wedges and a dead blow hammer to help remove the bonnet from the body.

Lifting devices capable of handling the weights of the components are needed.

A fixture or counterbalance is needed for removing the plug from the body.

Approximate weights of the components are shown in Table B.

Table B: Basic Valve and Component Weights

(does not include actuator weight)

Valve Size Valve Component Weights (pounds)

Total Body Plug Bonnet Journal Cover

3650 11,200 6,000 2,000 1,200 100

4200 11,500 6,200 2,000 1,200 100

4250 22,500 12,000 4,000 2,500 100

4850 23,000 12,500 4,000 2,500 175

5400 23,500 13,000 4,000 2,500 175

5450 36,000 17,000 7,000 4,000 175

6050 38,000 20,500 7,000 4,000 250

6600 39,000 23,000 7,000 4,000 250

7200 44,000 25,000 7,000 4,000 250

DeZURIK

3650-7200 PEC Eccentric Valves

D10019 Page 6April 2015

Exploded Assembly Drawing

Figure 1— Exploded Assembly Drawing

DeZURIK

3650-7200 PEC Eccentric Valves

April 2015 Page 7 D10019

Installation

The type of materials carried in the pipeline and the location of the valve determine the correct

installation procedure.

Liquids and Gases

1. Before installation, remove foreign material such as weld spatter, oil, grease, and dirt from the

valve and pipeline.

2. Install the valve as shown in Figure 2.

Figure 2 — Liquids and Gases

3. Ensure the valve and flanges are concentric to ensure proper flange sealing.

4. Tighten the flange bolts or studs in a crisscross pattern.

DeZURIK

3650-7200 PEC Eccentric Valves

D10019 Page 8April 2015

Installation (continued)

Suspended Solids

If the pipeline carries suspended solids such as paper stock of 2 percent or higher consistency, mining

slurry, or raw sewage:

1. Before installation, remove foreign material such as weld spatter, oil, grease, and dirt from the

valve and pipeline.

2. Install the valve as shown in Figure 3.

a. In HORIZONTAL pipelines, install the valve so that the plug is horizontal and rotates

upward as the valve opens.

b. For VERTICAL pipelines, install the valve with the end marked “SEAT” at top of valve.

Figure 3 — Liquids with Suspended Solids

3. Tighten the flange bolts or studs in a crisscross pattern.

4. Ensure the valve and flanges are concentric to ensure proper flange sealing.

NOTE: In the case of limited space where both the

recommended seat orientation shown and the

recommended plug orientation described in 2a above, are

not possible, the recommended plug position shall

always take precedence.

For Pump Isolation Service, install the discharge valve

with the seat toward the pump and with the plug rotating to

the top of the pipeline in the open position. On the suction

side, install the valve with the seat toward the pump.

DeZURIK

3650-7200 PEC Eccentric Valves

April 2015 Page 9 D10019

Closed Position

Because of the eccentric action of this valve, the closed position of the valve is dependent upon the

pressure drop expected when the valve is closed.

To adjust the valve closed position, follow these steps:

1. Relieve pipeline pressure.

Moving parts from accidental operation of power actuator can cause personal injury or

equipment damage. Disconnect and lock out power to actuator before servicing.

2. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or electrical power

to prevent accidental operation of the actuator.

3. Back off the actuator closed position stop as described in the Actuator Instructions.

4. Close the valve with the torque specified in the Actuator Instructions.

Note: This torque is the amount required to seat the plug for a given pressure drop across the valve. To

avoid excessive plug and seat wear caused by over torquing, use the actual pressure drop across the

valve when determining correct closing torque.

5. After the valve has been closed using the correct amount of torque, set the actuator closed

position stop to limit actuator travel at this position.

Lubrication

This valve does not require routine lubrication.

If disassembled, lubricate the plug journals with a lubricant that is compatible with the flow media. For

most applications, use one of these nickel based compound lubricants.

- Bostik Never-Seez (recommended)

- Keystyone No-Weld #1 (alternate)

Plug Orientation

The orientation of the plug can be determined by the 1/2 inch wide cast lug on the plug stem. This lug is

directly above the centerline of the plug face.

Packing Adjustment

To stop packing leakage, tighten the gland nuts uniformly until the leak stops.

Note:

Do not continue tightening after leak stops. If the leak cannot be

stopped by tightening the gland nuts, replace the packing.

DeZURIK

3650-7200 PEC Eccentric Valves

D10019 Page 10 April 2015

Packing Replacement

Replacing Packing with Actuator Removed

To replace the packing without removing actuator, see “Replacing Packing Without Removing Actuator”

section.

1. Discontinue pipeline flow and relieve pipeline pressure.

2. Scribe the actuator and valve bonnet for alignment when reassembling.

Moving parts from accidental operation of power actuator can cause personal injury

or equipment damage. Disconnect and lock out power to actuator before servicing.

3. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or electrical power

to prevent accidental operation of the actuator.

When an eccentric valve is mounted in a vertical pipeline— or mounted in a horizontal

pipeline with the plug stem horizontal—gravity can cause the plug to swing to a lower

position in the valve body when the actuator is removed. Place the plug in the lowest

position before removing the actuator.

4. Remove the actuator from the valve. See Actuator Instructions.

5. Remove the two access covers from the bonnet.

6. Remove the nuts that hold the packing gland in place, and slide the packing gland off the plug

stem.

7. Remove the packing from the bonnet packing chamber.

8. Scrape the RTV silicone material from the top of the bonnet and access cover mounting

surfaces.

9. Lubricate the new packing, then install it one ring at a time as shown in Figure 4.

Figure 4 — Correct Packing Installation Sequence

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