Flowserve Gestra GAV 56F Bedienungsanleitung

Shut-Off Valve

GAV 56F

Original Installation Instructions

819237-01

Contents

Preface ...............................................................................................................................................3

Availability.............................................................................................................................................3

Text layout ............................................................................................................................................3

Safety..................................................................................................................................................3

Usage for the intended purpose..............................................................................................................3

Basic safety notes .................................................................................................................................4

Typographic features of warning notes....................................................................................................5

Typographic features of information on environmental & property damage ................................................5

Description .........................................................................................................................................5

Scope of supply and equipment specification ..........................................................................................5

Purpose and function.............................................................................................................................8

Storing and transporting the equipment...........................................................................................8

Storing the equipment ...........................................................................................................................9

Transporting the equipment ...................................................................................................................9

Mounting and connecting the equipment.........................................................................................9 

Preparing installation .............................................................................................................................9

Connecting the equipment ...................................................................................................................10

Retrofitting and adjusting a stroke limiter ..............................................................................................12

Operation ..........................................................................................................................................13

Activities during operation....................................................................................................................13

After operation .................................................................................................................................13

Changing the settings..........................................................................................................................14

Removing external dirt deposits............................................................................................................15

Maintaining the equipment...................................................................................................................15

Servicing the equipment and installing spare parts ................................................................................15

Troubleshooting ...............................................................................................................................16

Eliminating leaks .................................................................................................................................17

Putting the equipment out of operation ..........................................................................................18

Removing harmful substances..............................................................................................................18

Removing the equipment .....................................................................................................................19

Re-using equipment after storage.........................................................................................................19

Disposing of the equipment..................................................................................................................20

Technical data..................................................................................................................................21

Dimensions and weights ......................................................................................................................21

Flow characteristics.............................................................................................................................22

Pressure & temperature ratings............................................................................................................22

Manufacturer's Declaration.............................................................................................................23

Preface

This installation & operating manual will help you

use the shut-off valve GAV 56F safely and efficiently

for its intended purpose.

This valve will be called equipment in this

document.

This installation & operating manual is intended for

anyone commissioning, using, operating, servicing,

cleaning or disposing of this equipment and, in

particular, for professional after-sales service

technicians, qualified personnel and authorised and

trained staff.

All of these persons must read and understand the

content of this installation & operating manual.

Following the instructions given in this installation &

operating manual helps avoiding danger and

increases the reliability and service life of the

equipment. Please note that in addition to the

instructions given in this installation & operating

manual you must also observe all locally applicable

rules and regulations concerning the prevention of

accidents as well as approved safety guidelines for

good professional practice.

Availability

Keep this installation & operating manual together

with the plant documentation for future reference.

Make sure that this installation & operating manual

is available to the operator.

The installation & operating manual is part of the

equipment. Please hand over this installation &

operating manual when selling the equipment or

passing it on.

Text layout

Certain text elements of this installation & operating

manual feature a specific typographic design. You

can easily distinguish the following text elements:

Standard text

Cross-reference

Listing

Sub-items in listings

Steps for action.

Here you will find additional useful

information and tips serving to assist you

in using the equipment to its fullest

potential.

Safety

Usage for the intended purpose

The following shut-off valves are installed in pipes:

GAV 56F

The equipment is designed for shutting off neutral

gases, steam, vapours and liquids in pipelines.

Equipment of size DN 15 to DN 100 can also be

used for throttling the flowrate.

The equipment must only be used within the

allowable pressure and temperature limits and only

if the chemical and corrosive influences on the

equipment are taken into account.

Correct use includes compliance with the

instructions given in this installation & operating

manual, in particular obedience to all safety

instructions.

Any other use of the equipment is considered to be

improper.

Note that the equipment is also used incorrectly if

the materials of the equipment are not suitable for

the fluid.

Basic safety notes

Risk of severe injuries

The equipment is under pressure during

operation and may be hot. Before carrying out

any work on the equipment make sure that the

following requirements are met:

The pipes must be depressurized (0 bar).

The fluid must be completely removed from

the pipes and the equipment.

During work on the equipment the

installation must be switched off and

protected against unauthorised or

unintended activation.

The pipes and the equipment must have

cooled down to room temperature (approx.

20 °C).

If the equipment is used in contaminated areas

there is a risk of severe injuries or death caused

by harmful substances in or on the equipment.

Before working on the equipment make sure

that it is completely decontaminated. Always

wear the protective clothing prescribed for

contaminated areas when working on the

equipment.

The equipment must only be used with fluids

that do not attack the material and the gaskets

and sealings of the equipment. Otherwise leaks

may occur and hot or toxic fluid could escape.

The equipment and its component parts must

only be mounted or removed by qualified

personnel. A qualified person must be

acquainted with and experienced in the

following:

Making pipe connections.

Selecting suitable lifting gear and

understanding the rules for its safe use.

Working with dangerous (contaminated, hot

or pressurized) fluids.

Risk of minor injuries

Sharp edges on internals present the danger of

cuts to hands. Always wear industrial gloves

when servicing the equipment.

If the support of the equipment during

installation is insufficient the equipment might

fall down, thereby causing bruises or injuries.

Make sure the equipment is safely held in place

during installation and cannot fall down. Wear

protective safety footwear.

Risk of property damage or malfunctions

Malfunctions will occur if the equipment is

installed in a wrong position or with the flow

arrow pointing in the opposite direction of the

fluid flow. This may result in damage to the

equipment or the installation. Make sure that

the flow arrow on the equipment body matches

the indicated direction of the fluid flow in the

pipe.

If the material is unsuitable for the fluid,

increased wear may occur and fluid may

escape. Make sure that the material is suitable

for the fluid used in your installation.

The equipment may get damaged by pressure

impulses, even if the admissible nominal

pressure PN is not exceeded.

Make sure that the equipment is not subject to

pressure impulses or heavily pulsating flow.

Typographic features of warning

notes Description

DANGER

Notes with the heading DANGER warn

against imminent dangerous situations that

can lead to death or serious injuries.

Scope of supply and equipment

specification

Scope of supply

Our equipment is delivered packed and ready for

assembly.

WARNING

Notes with the heading WARNING warn

against possibly dangerous situations that

could lead to death or serious injuries.

CAUTION

Notes with the heading CAUTION warn

against dangerous situations that could

lead to minor or moderate injuries.

Typographic features of

information on environmental &

property damage

Attention!

This note warns against situations that

may lead to environmental and/or property

damage.

Equipment specification

No. Designation

1 Handwheel

2 Grease nipple and locking screw

3 Stem

4 Cover

5 Gasket

6 Body

7 Flow arrow

No. Designation

8 Name plate

9 Seat ring (up to DN 50)

10 Valve plug

11 Bellows

12 Gland packing

13 Stuffing box screw

Equipment of size DN 15 up to DN 100

feature a throttling plug.

Equipment fitted with a throttling plug

allows regulation of the flowrate.

Equipment of size DN 125 up to DN 150

feature a disk-type plug.

Equipment fitted with a this type of plug

can only be used for shutting off the

pipeline.

This installation manual shows equipment

with throttling plug.

A stroke limiter is available as optional extra.

End connections

The equipment is available with the following end

connections:

Flanges

Name plate

The following items are indicated on the name

plate:

Manufacturer

Type designation

CE marking

The CE marking depends on the

classification according to the Pressure

Equipment Directive (PED). Not all types of

equipment will therefore bear a CE

marking.

The following items are indicated on the equipment

body:

Nominal size

Pressure rating

Material

Batch code

Direction of flow

PED (Pressure Equipment Directive)

The equipment fulfills the requirements of the

Pressure Equipment Directive PED 97/23/EC and

can be used for the following fluids:

Fluids of group 1

Fluids of group 2

The following types of equipment are excluded from

the scope of the PED according to Article 3.3 and

must not bear a CE marking.

DN 15

DN 20

DN 25

The following types of equipment have a CE

marking on the name plate:

DN 32

DN 40

DN 50

DN 65

DN 80

DN 100

DN 125

DN 150

ATEX

Please observe the following notes if the

equipment is to be used in explosion-risk areas:

The equipment can be used in zones

(surrounding atmosphere acc. to Directive

1999/92/EC) 0, 1, 2, 20, 21 and 22 (ATEX

Directive 94/9/EC).

The equipment does not have its own potential

source of ignition and is therefore not subject to the

ATEX Directive 94/9/EC.

The equipment is not Ex marked.

Purpose and function

Purpose

The equipment is designed for shutting off

pipelines.

In addition, equipment DN 15 up to DN 100 can

also throttle the flowrate.

Function

The equipment is designed for shutting off

pipelines. For this purpose equipment types DN 125

and DN 150 are fitted with a disk-type plug.

Equipment of size DN 15 up to DN 100 can also

throttle the flowrate. For this purpose the equipment

is fitted with a throttling plug.

By turning the handwheel the stem is lifted or

lowered continuously. As a consequence, the plug

connected to the stem increases or decreases the

flow area.

You can lock the handwheel in the desired position.

The bellows seals off the valve stem.

Even if the bellows seal leaks, the stuffing box will

prevent any fluid from escaping. The stuffing-box

packing is slightly tightened when delivered.

Storing and transporting the

equipment

Attention!

Equipment can be damaged if stored or

transported improperly.

Close all openings with the sealing

plugs or covers supplied with the

equipment or use similar sealing

covers.

Protect the equipment against

moisture and corrosive atmospheres.

Please contact the manufacturer if the

specified transport and/or storage

requirements cannot be met.

Storing the equipment

Please observe the following items when storing

the equipment:

Do not store the equipment for more than 12

months.

Use the supplied sealing plugs or other suitable

seal caps in order to seal off all openings of the

equipment.

Protect the sealing surfaces and contact areas

against mechanical damage.

Protect the equipment and all components

against hard shocks and impacts.

Store the equipment only in closed rooms that

meet the following environmental conditions:

Air humidity below 50 %, not condensing

Indoor air: clean, salt-free and non-corrosive

Temperature 5–40 °C.

Make sure that all these requirements are

always met when storing the equipment.

Please contact the manufacturer if you cannot

comply with the recommended storage

conditions.

Transporting the equipment

Meet the requirements for storage also when

transporting the equipment.

Prior to transport seal off connections with

sealing plugs.

If you do not have the sealing plugs

supplied with the equipment use

appropriate seal caps to seal off the

connections.

For short distances (only a few metres) you can

transport the equipment unpacked.

When transporting the equipment over larger

distances use the original packaging.

If you do not have the original packaging use a

box that protects the equipment adequately

against corrosion and physical damage.

For a short period of time the equipment

may be transported even if the

temperature is below 0 °C, provided that

the equipment is completely empty and

dry.

Mounting and connecting the

equipment

Preparing installation

Take the equipment out of the transport

packaging.

Check the equipment for transport damage.

Contact the manufacturer if you detect any kind

of shipping damage.

When supplied by the factory, the connections may

be sealed off with sealing plugs.

Remove sealing plugs before mounting the

equipment.

Keep the sealing plugs and the packing for

further use.

DANGER

Personnel working on pipes are exposed to

safety risks and may suffer severe injuries,

poisoning or even loss of life.

Make sure that no hot or hazardous

fluid is in the equipment or the pipes.

Make sure that the pipes upstream

and downstream of the equipment are

depressurised.

Make sure that the installation is

switched off and protected against

unauthorised or unintended activation.

Make sure that the equipment and the

pipes have cooled down to room

temperatures.

Wear protective clothing that is

suitable for the fluid and, if necessary,

wear protective gear.

For more information on suitable safety clothing and

safety gear refer to the safety data sheet of the fluid

in question.

Drain pipes until they are empty.

Switch the installation off and protect it against

unauthorised or unintended re-activation.

Connecting the equipment

DANGER

Incorrectly connected equipment can

cause fatal accidents or severe injuries.

Make sure that only qualified skilled

personnel connect the equipment to

pipes.

Make sure that the flow arrow on the

equipment body matches the direction

of flow in the pipe.

Specialist personnel must be highly qualified and

fully experienced in making pipe connections for the

respective type of end connection.

Attention!

Equipment will be damaged if the end

connections are undersized.

Make sure that the connections are

strong and rigid enough to support the

weight of the equipment and to

withstand the forces that occur during

operation.

Make sure that the pipe system of the plant is

clean.

Make sure that the equipment is free from

foreign matter.

Attention!

Damage due to steam leakage may occur

if the equipment is installed with the

handwheel upside down.

Install the equipment with the

handwheel on top.

Furthermore, if the equipment is installed with the

handwheel upside down, dirt can accumulate in the

bellows.

When mounting the equipment make sure that

the handwheel is on top!

Make sure that the flow arrow matches the

direction of the fluid flow in the pipe.

Contact the manufacturer if you want to mount

the equipment in a different position of

installation.

Connect the equipment to the pipes.

Make sure that the equipment is safely mounted

and that all connections are made correctly.

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