Flowserve GESTRA GAV 54F Handbuch

GAV 54F

Installation & Operating

Instructions 819025-00

English

Shut-Off Valve

E N

Contents

Important Notes

Usage for the intended purpose .................................................................................... 4

Safety note .................................................................................................................. 4

Danger........................................................................................................................ 4

Attention ..................................................................................................................... 4

PED (Pressure Equipment Directive) .............................................................................. 4

ATEX (Atmosphère Explosible)....................................................................................... 4

Explanatory Notes

Scope of supply ........................................................................................................... 5

Description .................................................................................................................. 5

Function...................................................................................................................... 5

Attention ..................................................................................................................... 5

Danger........................................................................................................................ 5

Technical Data

Pressure & temperature ratings .................................................................................... 6

Attention ..................................................................................................................... 6

Corrosion resistance .................................................................................................... 6

Design

GAV 54F...................................................................................................................... 7

Key ............................................................................................................................. 7

Installation

GAV 54F...................................................................................................................... 8

Attention ..................................................................................................................... 8

Danger........................................................................................................................ 8

Attention ............................................................................................................... 8 – 9

Danger........................................................................................................................ 9

Attention ..................................................................................................................... 9

Installation notes.......................................................................................................... 9

Danger...................................................................................................................... 10

Commissioning Procedure

GAV 54F ................................................................................................................... 10

Danger...................................................................................................................... 10

Attention ................................................................................................................... 11

Functional test ........................................................................................................... 11

Attention ................................................................................................................... 11

Page

Contents

Maintenance

GAV 54F.................................................................................................................... 12

Attention ................................................................................................................... 12

Danger...................................................................................................................... 12

Spare Parts

GAV 54F.................................................................................................................... 13

Attention ................................................................................................................... 13

Decommissioning

Danger...................................................................................................................... 13

Disposal .................................................................................................................... 13

Transport and Storage

Transport................................................................................................................... 14

Attention ................................................................................................................... 14

Storage ..................................................................................................................... 14

Hoisting the valve for installation into horizontal pipeline ............................................... 15

Hoisting the valve for installation into vertical pipeline................................................... 15

Page

Usage for the intended purpose

Use the shut-off valve GAV 54 F only for isolating and throttling neutral gases, steam,

vapours and liquids within the speciﬁed pressure and temperature ratings and check the

corrosion resistance and chemical suitability for the application in question.

Safety note

The equipment must only be installed and commissioned by qualiﬁed and competent staff.

Retroﬁtting and maintenance work must only be performed by qualiﬁed staff who –

through adequate training – have achieved a recognised level of competence.

Danger

The valve is under pressure during operation.

When loosening ﬂanged connections, sealing plugs or stufﬁng box connections,

hot water and steam will escape.

This presents the risk of severe scalding all over the body!

Before carrying out installation and maintenance work make sure the system is

depressurized. Isolate the valve from both upstream and downstream pressure.

The valve becomes hot during operation. Risk of severe burns to hands and arms.

Before carrying out installation and maintenance work make sure that the steam

trap is cold.

Sharp edges on parts present a danger of cuts to hands.

Always wear industrial gloves when replacing valves or parts of valves.

Danger of bruising! During operation moving parts can pinch one's hands or ﬁngers,

causing severe injuries. Do not touch moving parts.

Attention

The name plates specify the technical properties of the devices.

Do not commission or operate any item of equipment that does not bear its speciﬁc name

plate.

PED (Pressure Equipment Directive)

The equipment fulﬁlls the requirements of the Pressure Equipment Directive PED 97/23/EC.

For use with ﬂuids of group 1 and 2.

With CE marking (apart from equipment that is excluded from the scope of the PED as

speciﬁed in section 3.3).

ATEX (Atmosphère Explosible)

The equipment does not have ist own potential source of ignition and is therefore not

subject to the ATEX Directive 94/9/EC. Applicable in Ex zones 1, 2, 21, 22 (1999/92/EC).

The equipment is not Ex marked.

Important Notes

Explanatory Notes

Scope of supply

GAV 54F

1 Shut-off valve GAV 54F

1 Installation manual

Description

Maintenance-free bellows-sealed shut-off valve with straight-through body, ﬂanged to

EN 1092-2. The shut-off valve is equipped with a stainless steel bellows seal

and a safety stufﬁng box made from pure graphite.

Shut-off valves from DN 15 to DN 100 are ﬁtted with a throttling plug as standard.

DN125 to DN300 valves come with a ﬂat plug as standard. The handwheel features a

non-rising stem and a

locking device.

Function

To close the shut-off valve turn handwheel to the right and to open it turn handwheel to the

left. Direction symbols are found on the top of the handwheel.

The valve stem is sealed off by means of a stainless steel bellows and a safety

stufﬁng box made from pure graphite.

Use the locking device to lock the handweel in place by turning it to the right until it hits

the stop. When supplied the handwheel is not locked in place.

Attention

Incorrect operation of the valve may have a substantial impact on the entire system, for

example:

Leakage of the ﬂuid

System / machine brought to a standstill

Impairment / reduction / increase of the system's / machine's function / effect

Danger

When delivered ex factory, the safety stufﬁng box is not fully tightened. In the event of the

bellows failure, the stufﬁng box screws (safety stufﬁng box) must be tightened in order to

avoid ﬂuid leakage (observe dange note on page 4!). The stem seal with bellows is main-

tenance free.

Technical data

Pressure & temperature ratings

GAV 54F, ﬂange PN 16, EN 1092-2

PS (max. admissible pressure) [barg] 16 16 14.4 12.8 11.2 9.6

TS (max. admissible temperature) [°C] 20 120 150 200 250 300

PS (max. admissible pressure) [psig] 232 232 208 185 162 139

TS (max. admissible temperature) [°F] 68 248 302 392 482 572

ΔP (admissible differential pressure) [bar] 16

[psi] 232

Attention

If the following differential pressures are exceeded, a pressure balance plug is required.

DN 200 250 300

ΔP (admissible differential

pressure)

[bar] 12 9 6

[psi] 174 130 87

The pressure balance plug only takes effect when pressures builds up above the valve

plug. As a consequence, the ﬂow through the valves is reversed. Note that the embossed

ﬂow direction arrow is reversed.

Corrosion resistance

If the equipment is used for the intended purpose, its safety is not impaired by corrosion.

Design

GAV 54F

Key

1Handwheel

2Stem

3Body cover

4Gland packing

5Hexagon-head screws

Fig. 1

6Joint ring

7Bellows

8Valve plug

9Seat ring

0Body

GAV 54F

Responsibility for positioning and installing the valves always lies with the engineering

company, construction company or operator/user. Planning and installation errors may

impair the reliable function of the valves and pose a substantial safety hazard.

For this reason it is particularly important to observe the following:

Attention

The piping must be laid such that detrimental thrust and torsional forces are kept away

from the valve body during installation and operation to avoid both leakage and damage to

the body.

The caps on the connection ports, if any, shall be removed immediately prior to installation.

The mating ﬂange faces must be clean and undamaged .

Danger

The gaskets on the ﬂange faces must be properly centered.

Only fasteners (for ex. to DIN EN 1515-1) and ﬂange gaskets (for ex. to DIN EN 1514)

made of materials suitable for the respective valve size may be used.

For the ﬂange connection between valve and pipe use all ﬂange bolt holes provided.

Attention

When using steel ﬂanges to DIN EN 1092-1 in conjunction with cast iron valves with

ﬂanges machined to DIN EN 1092-2, make sure that for nominal diameter

DN 65 the mating ﬂanges are ﬁtted offset by 22.5° to prevent an oblique position of the

valve.

This procedure is required by the difference in the number of bolt holes: DIN EN 1092-1

speciﬁes 8 holes for steel, whereas DIN EN 1092-2 speciﬁes only 4 holes for cast iron.

DN 65 (steel / steel):

DIN EN 1092-1 with DIN EN 1092-1,

Bolts through 8 holes

DN 65 (steel / cast iron):

DIN EN 1092-1 with DIN EN 1092-2,

Bolt hole circle to DIN EN 1092-1 turned

through 22.5°, bolts through 4 holes,

4 holes free

Installation

Fig. 2

Attention - continued -

When the valve is installed outdoors, sufﬁcient weather protection must be provided to

prevent corrosion and other damage caused by penetrating moisutre.

When painting pipes or equipment, do not apply paint to the stem and plastic components

(valve function will be impaired).

If construction work is still in progress, the valves must be protected against dust, sand

and building material (cover with suitable material).

Neither the valve nor its actuating elements (e. g. handwheel, actuator, cover) must be

subjected to excessive loads (e. g. used as footholds).

The valve body and/or cover must not be subjected to any sudden impacts (with tools, for

example) as they could be destroyed.

Danger

For safety reasons, valves and piping systems operated at high (> 50 °C) or low (<0 °C)

temperatures must be insulated, or a warning sign must point out the risk of personal

injury involved when touching the hot or cold components.

Attention

If there is a risk of condensation water or ice formation, for example in air-conditioning,

cooling and refrigerating systems, it is important to ensure that the complete valve

including handwheel, if required, is provided with a proper diffusion-tight insulation. The

formation of ice introduces the risk of actuator blocking.

Installation Notes

Flow through shut-off valves should be in the direction of the embossed arrow on the valve

body. An alternating direction of ﬂow is permissible with the standard plug but not with

the pressure balance plug. If equipment from DN 200 exceeds the following differential

pressures, a pressure balance plug is required.

DN 200 250 300

ΔP (admissible differential

pressure)

[bar] 12 9 6

[psi] 174 130 87

The pressure balance plug only takes effect when pressures builds up above the valve

plug. As a consequence, the ﬂow through the valves is reversed (the embossed ﬂow

direction arrow is reversed).

Installation - continued -

Danger

The valves should not be installed with the stem pointing downwards to prevent dirt

deposits between the folds of the bellows which might cause valve failure.

In steam service, the valve must not be installed with the stem pointing downwards

(risk of steam hammer due to condensate collecting in the valve neck).

Shut-off valves must be installed in the line so that the ﬂuid enters the valve beneath

the disc and ﬂows out above the disc. However, they can also be installed in lines with

alternating ﬂow.

If the valves are to be used for throttling applications, a throttling valve disc (standard

variant DN 15 – 100) must be used.

In valves with pilot plug, the ﬂow direction must correspond to the direction indicated by

the arrow on the valve. Valves with pilot plug must always be installed so that the pressure

to be sealed off lies above the plug.

Installation - continued -

GAV 54F

Prior to commissioning / start-up compare the material, pressure and temperature data

on the valves with the operating conditions of the piping to check the material's chemical

resistance and stability under load.

Danger

Venting the valve by undoing the bonnet / cover bolting or removing the stufﬁng box

packing is dangerous and therefore not permitted.

It is generally not allowed to use lamellar graphite cast iron (EN-JL1040) in systems where

surge pressures might develop, since this material does not withstand pressure surges

and, therefore, the valves may be damaged or destroyed. In such cases valves made of

nodular cast iron (EN-JS1025) or steel shall be used.

In new systems and particularly after repair, the complete piping must be thoroughly

ﬂushed with the valves fully opened so that particles and/or welding beads that might

damage the seat/disc interface are removed.

Valve actuation

Viewed from above, the valve is closed with a clock-wise turn of the handwheel, and

opened with a counter-clockwise turn.

Direction symbols are found on the top of the handwheel.

Commissioning Procedure

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