DeZurik PEF Bedienungsanleitung

DeZURIK 3–36" PEF

100% PORT ECCENTRIC

PLUG VALVES

Instruction D10453

April 2015

DeZURIK

3-36" PEF 100% Port Eccentric Plug Valves*

Instructions

These instructions provide information about PEF 100% Port Eccentric Plug Valves. They are for use

by personnel who are responsible for installation, operation and maintenance of PEF 100% Port

Eccentric Plug 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 PEF 100% Port Eccentric Plug 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.

* Patent Applied For

DeZURIK

3- -- 36" PEF 100% Port Eccentric Plug Valves

April 2015 Page 3 D10453

Table of Contents

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

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

Required Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

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

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Liquids without Suspended Solids and Clean Gases - - - - - - - - - - - - - - - - - - - - - - - - - 5

Liquids with Suspended Solids and Dirty Gases - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Actuator Stop Adjustments

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

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

Packing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Plug Journals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Thrust Washers and O-rings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Packing Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

3 – 8" Lever and Nut Operated Valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

All Other Actuators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Parts Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

Packing Replacement

Replace packing with Actuator Removed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

Replace Packing without Removing Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

Reassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Removing Valve from Pipeline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Field Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Valve Exercising - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Emergency Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Predict Wear of Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

DeZURIK

3- -- 36" PEF 100% Port Eccentric Plug Valves

D10453 Page 4 April 2015

Description

The 3– 36” PEF 100% Port Eccentric Plug 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 seating and

unseating the plug and maintaining the valve plug position with flow in the pipeline.

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.

Required Tools

This valve is assembled using only metric fasteners. To service this valve, you should have a full set of

combination wrenches, Allen wrenches, a large flat tipped screwdriver, a flat pry bar, a pin punch and a

dead blow hammer.

Note:

You may want to machine a shaft to aid you in removing the lower bearing from the body. See

“Disassembly”

section.

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

3- -- 36" PEF 100% Port Eccentric Plug Valves

April 2015 Page 5 D10453

Installation

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

installation procedure.

Liquids without Suspended Solids and Clean Gases

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

pipeline.

2. Prepare pipe ends and install valves in accordance with the pipe manufacture’s instructions for

the joint used.

Note:

See Figure 1 for proper valve orientation.

Do not deflect the pipe-valve joint. Minimize bending stresses in the valve end

connection with pipe loading.

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

3- -- 36" PEF 100% Port Eccentric Plug Valves

D10453 Page 6 April 2015

Installation(Continued)

Figure 1—Liquids without Suspended Solids and Clean Gases

DeZURIK

3- -- 36" PEF 100% Port Eccentric Plug Valves

April 2015 Page 7 D10453

Installation(Continued)

Liquids with Suspended Solids and Dirty Gases

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

pipeline.

2. Prepare pipe ends and install valves in accordance with the pipe manufacture’s instructions for

the joint used.

Note:

See Figure 2 for proper valve orientation.

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.

Do not deflect the pipe-valve joint. Minimize bending stresses in the valve end

connection with pipe loading.

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

3- -- 36" PEF 100% Port Eccentric Plug Valves

D10453 Page 8 April 2015

Installation(Continued)

Figure 2—Liquids with Suspended Solids and Dirty Gases

DeZURIK

3- -- 36" PEF 100% Port Eccentric Plug Valves

April 2015 Page 9 D10453

Actuator Stop Adjustments

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:

This valve is a pressure vessel. The bonnet will blow off the valve if the bonnet

bolts are removed with pressure in the valve and pipeline media can be hazardous.

Completely release pressure before disassembling the valve.

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 maintenance lubrication, except for special application. If the valve

is disassembled, lubricate the packing and the plug journals as follows:

Packing

Packing lubrication requirements are dependent upon the packing material.

•PTFE PACKING: Requires no lubrication.

•ALL PACKING OTHER THAN PTFE:

Apply a light coat to the inside and outside diameters of the packing rings using one of these

lubricants.

- Lubriplate Clearplex-2 (recommended)

- Amoco FG (alternate)

- Mobilgrease FM 101 (alternate)

- Petro-Canada Purity FG 2 (alternate)

- Phillips Philube PF (alternate)

Note:

Ensure lubricant is compatible with flow media.

DeZURIK

3- -- 36" PEF 100% Port Eccentric Plug Valves

D10453 Page 10 April 2015

Lubrication(Continued)

Plug Journals

Plug journal lubrication is dependent upon the materials used in construction of the valve.

•CAST IRON VALVES: Lubricate the journals on the plug using one of these lubricants.

- Lubriplate Clearplex-2 (recommended)

- Amoco FG (alternate)

- Mobilgrease FM 101 (alternate)

- Petro-Canada Purity FG 2 (alternate)

- Phillips Philube PF (alternate)

Note: Ensure lubricant is compatible with flow media.

Thrust Washers and O-rings

Apply a light coat to all surfaces of thrust washers and O-rings using one of these lubricants.

- Lubriplate Clearplex-2 (recommended)

- Phillips Philube PF (alternate)

- Mobilgrease FM 101 (alternate)

- Amoco FG (alternate)

Note:

Ensure lubricant is compatible with flow media.

Packing Adjustment

The stem seal tightening procedure is dependent upon the type of actuator on the valve. If a packing

leak should occur, tighten the packing as follows:

3” – 8" Lever and Nut Operated Valves

Table A: Actuating Torque

Valve Size Actuating Torque

Standard Packing

in mm ft lbs Nm

3 & 4 100 28 37

5 & 6 125-150 60 81

8 200 104 141

All Other Actuators

Tighten the gland nuts evenly only until the leak stops.

Note:

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

gland nuts, the packing must be replaced.

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