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ARMATURENWERK

HTENSLEBEN GmbH
INSTRUCTION MANUAL
Butterfly Valve with Handle
AWH Armaturenwerk Htensleben GmbH
Schulstrae 5 / 6
D-39393 Htensleben
Germany
Phone: +49 - (0) 3 94 05 / 92 0
Fax: +49 - (0) 3 94 05 / 92 111
http:// www.awh.de
e.mail: awh-edelstahl@t-online.de
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PVT 900
Instruction Manual
Copyright
This document, or parts thereof, may not be reproduced or
divulged to any third party without express permission of AWH.
Violation will incur prosecution.
All Rights Reserved.
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1 Intended Use
AWH Butterfly valves have been designed and manufactured
for process pipework of hygienic standard with the aim of
shutting off liquid flow in trade and industrial applications (food
industry, chemical industry, pharmaceutical industry, and
minimum-germ processes).
Fluids intended to be handled include water, steam, foodstuffs,
liquids of the chemical and the pharmaceutical industries which
are subject to a hygiene standard.
The butterfly valve is manually operated through a handle.
For the Technical Data Sheet please refer to the Butterfly
valve product pages in the Web. Alternatively, relevant data
can be obtained from AWH Armaturenwerk Htensleben
GmbH. After quoting the AWH reference.
The Intended Use also meets the conditions and requirements
specified by the manufacturer for operation, maintenance and
repair.
This is a technical manual designed to meet the needs of
qualified process engineers.
Definition highly similar to that given in DIN EN-60204-1::
Specialist
A person who, in the light of his/her technical and practical
knowledge and experience as well as expertise with respect to
relevant standards, can judge assigned work and realise
potential risks and hazards that may exist.
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1.1 Materials in Contact with the Product
Refer to Fig. 1-1
Flange (Item 5); 1.4301 / 1.4307 / 1.4404 / 1.4435
Disc (Item 6): 1.4301 / 1.4404
Packing (Item 7) Selected to suit operating conditions
Packing material:
EPDM Max. short-time sterilisation temperature: 130C
VMQ Max. short-time sterilisation temperature: 130C
FPM Max. short-time sterilisation temperature: 140C
The butterfly valve and packing, must be chosen, giving careful
consideration to the environment, (i.e. product, temp. and flow)
requirements.
Surfaces
Outer surface: Bright metal / polished
Inner faces in contact with product: Ra < 1.6 m
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1.2 Exploded View, Outline Drawings, and Dimensions
Fig. 1-1 Exploded view
1 Handle
2 Socket-head cap screw
3 Plug
4 Bolts and nuts
5 Flange
6 Disc
7 Packing
8 Bushing
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Typical connecting configurations for the butterfly valve are shown
below. Any mounting position can be chosen.
For dimensions refer to the Tables.
The operating range with provision for locking is 90 for the OPEN and
the SHUT positions.
For the Technical Data please refer to the Butterfly valve product
pages in the Web. Alternatively, they can be obtained from AWH
Armaturenwerk Htensleben GmbH.
Fig. 1-2 Connection configurations
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Further connecting options are available, e.g. inch-system
configuration, with clamp connection, flange-mounted
configuration, and with aseptic connection as per DIN 11864.
Dimensions DN 25 DN 32 DN 40 DN 50 DN 65
d
1
26.0 32.0 38.0 50.0 66.0
d
2
87.0 92.0 97.0 110.0 127.0
L
1
64.0 64.0 72.0 72.0 76.0
L
2
40.0 42.0 50.0 50.0 50.0
L
3
84.0 92.0 102.0 106.0 114.0
L
4
107.0 107.0 137.0 137.0 137.0
L
5
90.0 92.0 94.0 101.0 110.0
L
6
90.0 90.0 100.0 100.0 100.0
E Rd 52 x 1/6 Rd 58 x 1/6 Rd 65 x 1/6 Rd 78 x 1/6 Rd 95 x 1/6
Dimensions DN 80 DN 100 DN 125 DN 150 DN 200
d
1
81.0 100.0 125.0 150.0 200.0
d
2
142.0 162.0 200.0 230.0 306.0
L
1
100.0 104.0 112.0 124.0
L
2
60.0 64.0 112.0 124.0
L
3
134.0 152.0 180.0 198.0
L
4
167.0 167.0 248.0 248.0 276.0
L
5
123.0 134.0 168.0 183.0 200.0
L
6
136.0 136.0 168.0 178.0 112.0
E Rd 110 x Rd 130 x Rd 160 x Rd 190 x
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2 Contents
2.1 Contents
1 Intended Use 3
1.1 Materials in Contact with the Product 4
1.2 Exploded View, Outline Drawings, and Dimensions 5
2 Contents 8
2.1 Contents 8
2.2 List of Figures 8
3 Safety / Hazards 9
3.1 Informative Signs / Explanatory Notes 9
3.2 Identification of the Butterfly Valve 9
3.3 Safety Standards and Codes 10
3.4 Safety Inspections and Tests 10
4 Warning Notices 11
5 Transport and Packaging 12
6 Installation of Butterfly Valve 13
6.1 Installing the Butterfly Valve with
- Male/ Male connection
- Female nut & liner connection 13
6.2 Installing the Butterfly Valve with
- welding ends
- between flanges connection 14
7 Assembly / Dismantling 15
7.1 Removal from the System 15
7.2 Assembly with Packing Renewal 16
8 Maintenance / Cleaning 18
9 Malfunction, Cause, Rectification 19
10 Dismantling / Disposal 20
11 Index 21
2.2 List of Figures
Fig. 1-1 Exploded view 5
Fig. 1-2 Connection configurations 6
Fig. 7-1 Assembly / Dismantling 15
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3 Safety / Hazards
3.1 Informative Signs / Explanatory Notes
Warnings
are shown in a frame and identified by a STOP sign.
Danger notices
are shown in a frame and identified by a DANGER warning
triangle.
Important reminders
are shown in a frame and identified by a Hand.
3.2 Identification of the Butterfly Valve
Type No.
Information provided in this Instruction Manual only applies to
the butterfly valve type as indicated on the title page.
To enable us to respond to your questions properly it is
essential that details as below, are given correctly:
- Nominal diameter (DN);
- Packing material;
- Casing material;
- Connection type (DIN 11851; DIN 11864; welding, etc.)
- Handle;
- Accessories (check-back indication, etc.).
Unless such information is provided your queries cannot be
properly and quickly handled.
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3.3 Safety Standards and Codes
The butterfly valve is manufactured to conform with the German
versions of the following standards and codes:
1. DIN 3230;
2. DIN EN 10204;
3. Druckbehlterverordnung (Pressure Vessel Code).
3.4 Safety Inspections and Tests
Conducted by the manufacturer in manufacturers workshops
(Refer to Data Sheet).
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4 Warning Notices
Butterfly valves, length and quality of piping must meet the
specific requirements.
Installation and fitting work to be carried out by qualified
personnel.
Operation and maintenance at fluid temperatures greater than
80C may involve a burn or scalding hazard.
Care must be exercised to ensure that only fluids indicated on
the Data Sheet are used.
Compliance with the specifications in the Data Sheet is of
critical importance.
To unlock the locking mechanism pull the handle in the
direction of the centreline.
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5 Transport and Packaging
Butterfly valves manufactured by AWH Armaturenwerk
Htensleben GmbH are thoroughly inspected and carefully
packaged prior to dispatch. Damage may still occur, due to
circumstances beyond our control.
Unpacking:
- Remove the caps from the pipe connections (if
provided).
- Remove the remainders of packing materials.
Incoming inspection:
Check against the delivery note to make sure the equipment
supplied is complete.
In case of damage
Inspect the consignment for damage (visual inspection).
In case of defects
If the consignment has incurred damage in transit:
Contact the final carrier immediately.
Retain the packing material(s) (to enable the carrier to
inspect as necessary, and/or to permit the equipment to be
packed again for return to the consignor).
Packaging for return to consignor
Use the original packing materials if available.
Otherwise, call in a packaging contractor employing skilled
personnel.
In case of queries relating to packaging and precautions to be
taken for transport, please consult AWH Armaturenwerk
Htensleben GmbH.
Seaworthy packaging
For shipment to overseas destinations, the butterfly valves will
be sealed in plastic.
Outdoor storage
Outdoor storage is not acceptable.
In case of seaworthy packaging, the desiccant is designed for
storage periods of less than three months.
Storage in confined spaces
Storage conditions
- Temperature 20C to 30C
Relative humidity < 60%
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6 Installation of Butterfly Valve
Install the butterfly valve while taking into account the design
configuration of the pipework concerned and the coupling
requirenend of the valve.
Face-to-face dimensions are clear from the outline drawings.
Care should be exercised to ensure that clearances and space
are as required for operation and maintenance.
Also, make sure that flanged joints and pipe joints are not
leaky.
Due care is essential during installation to rule out tensile and
compressive stresses on completion.
6.1 Installing the Butterfly Valve with
- Male/ Male connection
- Female nut & liner connection
Care should be exercised when installing the butterfly valve to
make sure that the connecting adapters and the slotted nut
conform to an identical standard (e.g. DIN 11851 or
DIN 11864).
Prior to assembly, inspect the sealing ring on the threaded
nipple for damage and check to be sure it is properly fitted;
renew if necessary.
Also, care must be exercised not to damage the thread.
The butterfly valve is mounted by means of the slotted nut using
a C spanner.
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6.2 Installing the Butterfly Valve with
- welding ends
- between flanges connection
Welding specifications
The valve is welded into piping to DIN 11850.
Welding process: TIG or orbital
Weld type: Square butt weld to DIN 8532
Pre-welding condition
Dismantle the valve prior to welding (Refer to Assembly /
Dismantling).
Weld preparation
Square the pipe ends.
Remove burrs from cut faces.
Align the casing welding ends with the piping in both radial
and axial directions.
The welding ends must be in flat-to-flat contact, and be welded
without any gap.
Filler metals
Base metal Suitable filler metal
1.4301/ 1.4307 1.4302; 1.4316; 1.4551
1.4404 1.4430; 1.4455; 1.4576
1.4435 1.4430; 1.4440
Welding
Connect forming gas prior to welding.
- Apply 3 or 4 tack welds prior to welding.
Postweld treatment
- No inside postweld treatment is required. The surface finish
of accessible zones can be improved by grinding.
- Outside postweld treatment can be performed by pickling,
brushing, grinding, and polishing.
Cleaning
Clean all welded components prior to assembly.
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7 Assembly / Dismantling
Fig. 7-1 Assembly / Dismantling
7.1 Removal from the System
To remove the butterfly valve from the system proceed as
detailed below:
1. Depressurise the piping.
2. Drain the piping.
3. Remove the plug (Item 3).
4. Undo the screw (Item 2).
5. Withdraw the handle assembly (Item1) in the direction of the
centreline.
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6. Undo the bolts and nuts (Item 4).
7. Disconnect the flanges (Item 5).
8. Remove the disc (Item 6) with packing (Item 7) and
bushings (Item 8) from the flange.
9. Withdraw the bushings (Item 8) from the stems of the disc,
and then pull the short stem of the disc (Item 6) from the
bore of the packing (Item 7) and then the long stem.
7.2 Assembly with Packing Renewal
Refer to Fig. 7-1
1. Inspect the packing for damage.
2. Clean the space where the packing was installed, and
inspect for damage as may have been incurred.
3. Clean the disc (Item 6) including the stems and grease the
packing (Item 7) in the stem-accommodating holes, using
an approved lubricant grade.
4. Insert the long stem of the disc (Item 6) into the hole in the
packing (Item 7).
5. Compress the packing (Item 7) and pull it over the short
stem.
Exercise care and caution to avoid damage.
While fitting the packing the disc must not be seated.
6. Push the bushings (Item 8) over the stems of the disc
(Item 6).
7. Position the disc (Item 6) with the packing fitted, in the bore
provided in the flange (Item 5).
8. Position the mating flange, exercising care not to damage
the packing (Item 7), and bolt the flanges together
9. While bolting the flanges together, check the disc stem in
the transverse hole and realign if necessary. Tighten the
hex bolts and hex nuts in sequence opposite from each
other.
10. Position the disc (Item 6) in the SHUT position.
11. Fit the handle assembly (Item 1) on the square end.
12. Turn the handle such that the through-hole points in the
direction of the aligned disc. To mount the handle assembly
insert and tighten the socket cap screw (Item 2).
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13. Fit the plug (Item 3).
14. Perform a function test by turning (90 deg) into the OPEN
and the SHUT positions several times, making sure that the
handle is fully engaged in the particular position.
Perform a leakage test under service required.
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8 Maintenance / Cleaning
Prior to starting cleaning, maintenance and repair work, check
to make sure that the following steps are taken to de-energise
and depressurise as applicable.
1. De-energise higher-level equipment / machine / unit .
2. Deselect the fluid
- Check to make sure the butterfly valve is depressurised.
- Remember that for fluid temperatures above 80C a
cooling-down period must be allowed before starting work.
Failure to comply with the above will jeopardise personnels life
and limb!
Clean the valve in the as-installed condition by rinsing the faces
in contact with the fluid (CIP cleaning).
Cleaning fluids: 3% Nitric acid
3% Caustic-soda solution
Temperature: 80C max.
Care must be exercised to ensure that:
- clean and chlorine-free water is used as a diluent;
- caution: when measuring avoid excessive concentration of
the cleaning agent;
- the valve is finally rinsed with ample water once cleaning is
completed.
Make sure that cleaning agents are stored in compliance with
relevant safety codes.
Care should be exercised when handling cleaning agents to
ensure that the safety instructions given on the Data Sheet
issued by the cleaning-agents manufacturer are followed.
Wearing rubber gloves and safety goggles is an essential
requirement to be met when performing cleaning work.
Caution must be used not to touch the butterfly valve or the
piping when hot fluids are being processed or while the
sterilisation process is in progress.
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9 Malfunction, Cause, Rectification
If the proposed rectification fails to cure the problem, please
contact a specialist contractor or AWH Armaturenwerk
Htensleben GmbH.
Problem Cause Rectification
Valve fails to operate Disc distorted due to pressure
surge.
Packing at fault.
Stem seizure.
Renew disc.
Renew packing.
Leaky valve Packing at fault or worn. Renew packing.
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10 Dismantling / Disposal
The butterfly valve mainly consists of stainless steel. (except for
the electrical equipment). For disposal, relevant local
environmental regulations must be complied with.
No. electrical equipment with manual valve.
Contaminated fluids as well as residue chemical of cleaners
must be disposed of while complying with relevant local
environmental regulations.
Care must be exercised to avoid contact with harmful fluids.
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11 Index
Assembly 15
Assembly with packing renewal 16
Cleaning 18
Contents 8
Damage 12
De-energise system 18
Defects 12
DIN EN-60204-1 3
Dismantling 15, 20
Disposal 20
Explanatory notes 9
Exploded view, Dimensions 5
Filler metals 14
German standards and codes 10
Hazards 9
Identification of shutoff valves 9
Incoming inspection 12
Informative signs 9
Installation of shutoff valve 13
Intended use 3
List of figures 8
Maintenance 18
Malfunction 19
Materials in contact with the product 4
Note 6, 7, 13
Packaging 12
Packaging for return to consignor 12
Problem solving 19
Rectification 19
Removal from the system 15
Safety 9
Safety standards 10
Safety testing 10
Specialist 3
Transport and packaging 12
Warning 18
Warning notices 11
Weld preparation 14
Welding specifications 14