BW7A Butterfly Valves

Installation and Maintenance

Instructions

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1 4 IM-P220-04
2200150
CH Issue 1
 INSTALLATION AND
MAINTENANCE INSTRUCTIONS
CONTENTS SECTION.

General 1

Additional Recommendations 1.2

Installation 2

Post Installation Proceedures 2.2

Effect of Flange Weld Types on the Butterfly Valve 2.3

Valve Inspection and Maintenance 3

Removal from Pipe work 3.2

Overhaul and Reassembly (Valve) 3.3 / 3.4

Correct Assembly of Valve (Valve) 3.5

Actuator Orientation 4

Mounting of actuators to the valve 5

Air Supply 6

Solenoid Valve 7

Actuator Maintenance 8

Component Diagrams 9

SPIRAX SARCO LTD

Charlton House
CHELTENHAM GL53 8ER
telephone (0242) 521361
telex 43123
fax (0242) 573342

All correspondence should be sent to the above

addressIn the unlikely event that products need to
be returned then these should be forwarded, clearly
labelled and identified to our Returns Investigation
Dept., Runnings Road, Kingsditch Trading Estate,
Cheltenham, Glos, GL51 9NX.
2200150 Scottish Office (041) 427 4071 1
Printed in U.K. © Copyright 1993
SECTION 1 GENERAL
1.1.1 The BW7A series Butterfly valves are designed for use on
water systems.

1.1.2 The butterfly valves should be stored in a cool and well

ventilated, preferably air-conditioned, warehouse. Do not
remove the protective coverings.

1.1.3 During long-term storage, open and shut the valves once
every three months. In addition, apply rust-prevention oil on
the plated parts, such as position indicators, worm shafts,
bolts and nuts periodically, approximately once every six
months.

1.1.4 After the valves are unpacked, avoid any point or spot loads
on critical parts before use.

1.2 Additional Recommendations

1.2.1 Before installation, check that the material type of the seat
ring and disc meets the required specifications

1.2.2 When handling butterfly valves, pick them up by the neck

(the upper stem housing) with a nylon sling.

1.2.3 Install valves in a pipeline only after the flange weld zones
have cooled down. Flanges should never be welded with a
butterfly valve installed between them.

1.2.4 Sharp edges, gashes, or flash on the piping flanges should

be filed off to prevent damage to the valve seat ring (Fig 1). The
pitch circle of flange bolt holes should be exactly concentric Fig. 3
with the piping bore.

1.2.5 The flange surfaces should be cleaned with compressed air

then wiped with a solvent-soaked cloth. (Fig. 2) The pipeline 1.2.8 A short piece of pipe should be inserted between the butterfly
should also be cleaned by compressed air or steam blower valve and a check valve, bend, or pump, to prevent interfer
before installing the valve. ence with disc operation. (Fig.4)

1.2.9 No gasket is required between the butterfly valve and the

piping flanges. (Fig.4)

1.2.10 Seat rings should be kept free from solvent. No oily

substances except those made of NBR or Viton should come
in contact with the seat ring.

1.2.11 Pipes whose walls are lined with resin should have the lining
continuously extended up to the flange surface and the lining
flared to cover the surface. The inside diameter as
measured on the resin lining should be equal to or more than
the rated size of the butterfly valve.

1.2.12 Special attention should be paid to the orientation of the

butterfly valve when it is installed downstream from a bend.
(Figs. 5 through 7)

Fig. 1

1.2.6 The valve should be aligned exactly with the pipeline.

1.2.7 Before final tightening of flange bolts, make sure that the
valve disc is not obstructed by the walls of the pipe when
opened and closed. (Fig. 3)

Fig. 2 Fig. 4
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Installation of a Butterfly Valve Adjacent to a bend

Where practicable, the butterfly valve should

be installed upstream from a bend.
✓

Fig. 5

✓ ✗

Fig. 6
If a downstream installation is unavailable, the valve stem should
have parallel orientation with the axis of the upstream piping.
Fig. 7
Installation of a butterfly valve downstream from a bend with the stem
not parallel to the axis of the upstream pipeline is not acceptable for the
following reasons:-
(1) differences in fluid velocity (pressure) on both sides of the disc may
cause it to vibrate, and
(2) in some cases, may cause erosion of the disc on the side having
higher fluid velocity.

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SECTION 2 INSTALLATION
2.1.1 After aligning the pipes, put two bolts into the bottom two
flange holes for temporary support of the butterfly valve while
it is being placed into position. (Fig. 8)

2.1.2 Put two jacking bolts between the pipe flange as shown in
the illustrations. By adjusting the jacking bolts and the two
flange bolts, maintain the gap between the flanges at about 3
to 5 mm beyond its final position. Drop the butterfly valve
into position. During this operation, care should be taken to
keep the surfaces of the joints free from dents, scratches,
etc. (Fig.9)

Fig. 9

Fig. 8 Fig. 10

2.1.3 Before the butterfly valve has been lowered completely onto
the bottom flange bolts, place another two bolts immediately
below the upper lugs of the valve. Then ease the valve down
until the lugs rest on the bolts. (Figs. 8 & 10)

2.1.4 Remove the jacking bolts and install all remaining bolts.
Partially tighten all bolts then align the valve. Once valve
alignment is checked, tighten all bolts until the pipe flanges
touch the metal surfaces of the valve. Take care to apply
equal load to all bolts around the flange.

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2.2 Post Installation Procedures

2.2.1 Pipelines should be flushed and cleaned after installation of

valves.

2.2.2 Inspect and check for any leaks in the piping flanges, valve
glands, or bottom cover by hydrostatic or pneumatic testing .

2.2.3 If any leaks are found retighten bolts carefully, making sure
that the distribution of load to all bolts is uniform.

2.2.4 The butterfly valve should not be closed to hold a test

pressure exceeding the rated pressure of the valve. If such
testing is required, the valve should be removed and
temporarily replaced by a blank flange.

2.2.5 During long-term shutdown of a pipeline the butterfly valve

should be operated periodically at least once every two
weeks.

2.2.6 The Butterfly valve should not be operated with the disk at
30o or less for long periods. If this type of service is required,
please consult our Technical Sales Department for specialist
advice.

2.3 Effect of Flange Weld Types on the

Butterfly Valve
The inner wall of the pipe may sometimes interfere with valve
disc operation depending upon the type of flange weld. The
following instructions and table show two types of flange weld
and applications of BW7A valves to these flanges.

Weld Type A Weld Type B

Typing Weld Type A Weld Type B Cast Iron Cement-Lined Minimum pipe bores allowing
of pipe Pipes for Pipes made use of ISOA valves with weld
Std Gas SCH40 SCH60 SCH80 Std Gas SCH40 SCH60 SCH80 water works by NKK type A (mm)
Valve size Pipe Pipe
50 ● ● ● ● ● ● ● ● ● ● 35
65 ● ● ● ● ● ● ● ● ● ● 52
80 ● ● ● ● ● ● ● ● ● ● 71
100 ● ● ● ● ● ● ● ● ● ● 92
125 ● ● ● ● ● ● ● ● ● ● 119
150 ● ● ● X ● ● ● ● ● ● 145
200 ● ● ● X ● ● ● ● ● ● 194
250 ● ● X X ● ● ● ● ● ● 246

NOTE: (1) : ● applicable:

(2) Possible change in bores due to sagging of pipes and allowable manufacturing tolerances in pipe diameter and thickness are taken
into consideration in the above table.
(3) Arc welded carbon steel pipes, JIS G3457, lined with rubber accepts BW7A valves of all sizes.

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SECTION 3 INSPECTION and
MAINTENANCE
3.1.1 Inspect the disc and seat ring for any corrosion or wear once
a year.

3.1.2 If any abnormality is noticed during the operation, it may be

that foreign matter is clogging the valve, or the seat ring is
damaged. Remove the valve from the system for inspection.
(Fig 11).

3.1.3 Rust-prevention and lubrication procedures are outlined in

the table below:-

Fig. 11

Plated parts anti-rust oil Wd-40 or equivalent

(indicator, bolts, nuts and worm shaft)
Shafts and shaft sealings Molykote 111Dow Corning
Grease
Gears Shell Alvania No 2
Disc edge Silicon Grease Molykote 111 Dow Corning

Removal
3.2.1 Before removing a butterfly valve from a pipeline, first check
that system pressure has been completely released. The
system should also be completely drained before opening up
a piping joint.

3.2.2 Shut the valve before loosening the flange bolts. Remove the
bolts, leaving the bottom two in place. Open the flanges by
means of jacking bolts, then remove the valve (Fig. 11).

Overhaul and Re-assembly

Overhaul and re-assemble for inspection or repair in accordance with
the following procedures:

3.3.1 Isolate the actuator electrically and pnuematically. Ensure

valve is closed

3.3.2 Remove the four bolts (33) which join the valve body and
the actuator.

3.3.3 Grip the body in a vice and extract the actuator from the
valve. The upper stem (3) will remain in position (Fig.12).

3.3.4 Remove the machine screws (8) with a screw driver.

1 3.3.5 Grip the upper stem (3) in the vice and take out the valve
body (1). (Fig.13)

34 3.3.6 Remove the two bolts , and take out the bottom cover
(6) and gasket (14). (Fig. 14)

35 3.3.7 Now insert one of the bottom cover bolts into the
threaded hole at the bottom end of the lower stem and turn
it a few times. Remove the lower stem by pulling out the bolt
(4). (Fig.15)

3.3.8 Hold the disc (2) in both hands and push it out from the seat
ring (12). (Fig 16).

3.3.9 Insert a screw driver between the seat ring (12) and the
valve body (1). (Fig. 17).

3.3.10 Insert your fingers into the gap between the body (1) and
the seat ring (12) and take it out (Fig 18).

Fig. 12

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 Upper stem (3)

Gasket (14)

Bottom
cover (6)

Fig. 13

Spring
Bolt
Fig. 14

Lower stem (4)

Seat ring (12)

Bottom cover bolt
Disc (2)

Fig. 15 Fig. 16

Body (1)

Seat ring (12)

Fig. 17 Fig. 18

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Proper Assembly of the Valve

3.4.1 Before assembly, clean each component carefully with

solvent, and check for damages or defects.

3.4.2 Replace the dust seal (Blow-out proof) and gaskets with
new ones at each overhaul, even if they appear intact.

3.4.3 The lower stem (4) may be put temporarily in place to help
align the seat ring (12). Remove after alignment.

3.4.4 Put the seat ring (12) into the body (1) Bottom first. Make
sure that the holes of the two components match exactly
(Fig. 19).

3.4.5 To position the seat ring (12) to fit into the body (1), push
the upper part of seat ring downward so that it curves like
the letter “U”. Take care to keep the secondary seal ring (11)
inplace (Figs. 19 and 20).

Body (1)
Fig. 19

Secondary
seal ring (11)

Seat ring (12)

Apply grease
to the stem
Fig. 20

Disc (2)

Fig. 21

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3.4.6 Check that the top and bottom holes of the seat ring
completely match those of the body.

3.4.7 Apply silicone oil to the top and bottom ends of the disc (2)
and place it into the bore of the seat ring (12) (Fig.21).

Apply grease to
the stem

Lower stem (4)

Fig. 22

3.4.8 Apply grease to the lower stem (4) and put it in place taking
care not to do damage to the bottom of the seat ring (12)

Body (1)

Gasket (14)

Bottom cover (6)

Spring washer

Bolt

Fig. 23 Machine
screw (8)

(Fig 22).
Dust seal (5)
3.4.9 After the lower stem is fitted into the disc (2), place the (Blow-out proof)
gasket (14) and bottom cover (6) on the bottom end of the
body (1) and tighten them with the bolts and spring
washers (Fig.23).

3.4.10 Looking down from the top of the body (1), check that the
holes of the seat ring (12) and disc (2) are properly aligned Upper stem (3)
with the valve.

3.4.11 Apply grease to the upper stem (3) and lower it down to fit
into the disk, (2), aligning the flats. Insert the upper stem until
the dust seal (5) is flush with the flange of the body, then (5)
tighten down the two machine screws (8). (Fig. 24).

Disc (2)

Fig. 24

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SECTION 4 ACTUATOR SECTION 5 MOUNTING A
ORIENTATION PNEUMATIC ACTUATOR ON A
BUTTERFLY VALVE
4.1 Orientation 5.1.1 Ensure valve is in fully closed position.
BVAT actuators are normally installed with their major axis parallel to
the pipeline. However, the actuator can be positioned above, below, or
alongside the valve without affecting it's operation. 5.1.2 Mount Stop Plate and Actuator over valve spindle (Fig 25)
The circumferential pinion gear allows re-orientation of the extended
output shaft and housing to accommodate installation where physical 5.1.3 Tighten the actuator flange using the bolts (33) and spring
obstructions might otherwise prove prohibitive. washers (34). (Fig 25)

4.1.1 1. Determine mode of operation of the valve 5.1.4 Operate the actuator to open and shut the valve to ensure full
(normally open or normally closed). 90° movement.
2. Determine direction of mounting of actuator (in line or
cross line).

34

33

Fig. 25

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SECTION 6 AIR SUPPLY SECTION 7 SOLENOID VALVE
6.1. Air Supply 7.2. Selection
BVAT actuators are factory lubricated hence a lubricated air supply is BVAT actuators can be fitted with solenoid valves It is important that the
not required. The air must however be dry and clean. correct solenoid valve is chosen to suit the voltage applied.
Any other non corrosive gas can be utilised as the operating medium The table below lists the options available.
as can light hydraulic oil.
Table of Solenoid options
6.2. Supply Pressure
Operating Pressure - 6 barg Model Voltage
MV11 240/220 Vac
6.3. Supply connections - No solenoid
BVAT - Connect air supply to port marked "A" (Fig 26) MV12 110 Vac
Connection size - G¼ MV13 24 Vac
BVAT actuator stroke direction can be reversed. To achieve this,
remove gear/rack piston assembly, rotate 180° and re-install. This will MV14 24 dc
reverse the direction of rotation of the output shaft.

6.4. Supply connections - solenoid 7.2. Solenoid valve - Electrical supply

Solenoid valves have IP65 plugs suitable for 7mm O/D cable
All models of BVAT actuators can be fitted with an integral electrical
solenoid valve. See Section 7 for details Power consumption
For BVAT actuators the air supply connection is on the mounting block.
Connection size ¼" BSP. The exhaust is through a 1/8" BSP male MV11 to MV14 = 4.5W
connection on top of the solenoid.

6.5. Air Consumption

The following table shows the amount of air consumed per 90° stroke
in litres.

Air to port Model

25 40 100 200 500 1100
A 0.1 0.16 0.35 0.8 1.9 4.2
B 0.11 0.22 0.49 1.0 2.5 5.4

Fig. 26

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SECTION 8 ACTUATOR MAINTENANCE
22½° - 45°

Caution: The actuator must be isolated both pneumatically and

electrically before any maintenance is carried out.

8.1 General
Periodic checks should be performed to ensure all fasteners remain
tight. All actuators are supplied with sufficient lubrication for their
normal working life. If required, recommended lubrication for all actua-
tors is Gulf Sovereign LC Grease.
Depending upon the conditions under which the actuator is operating
i.e. extended duty, non compatible operating medium or abnormal
operating conditions, periodic replacement of internal 'O' rings is
recommended. Kits containing all the necessary 'O' rings are available
from Spirax Sarco.
8.2 Actuator Disassembly
8.2.1 Disconnect actuator air and electrical supplies.
8.2.2 Remove actuator and mounting bracket from valve.
Caution:
All valves can trap pressurised media in the cavity. Isolate the
piping system in which the valve is mounted then relieve any
pressure in the valve body.
8.2.3 Remove the actuator bracket from the actuator to begin repair
(note mounting position of bracket for easy reassembly). See fig
5.
8.2.4 Remove solenoid (if fitted) by removing bolts. Use care to retain
'O' ring seals.
8.2.5 Each end cap (19) is fitted no to the body (17) with a machined
sleeve fit. Remove all screws (29) from both end caps. After the
screws are removed gently prise off each end cap, being careful
not to damage the end cap 'O' rings.
Caution:
Uniformly loosen all end screws on each end cap two or three
turns at a time, in sequence, to relieve pre-load of the springs use
caution when removing end caps.
8.2.6 The two pistons (18) can be removed by rotating the actuator
shaft, driving the piston assemblies outward until the gear rack
and pinion have disengaged.
8.2.7 Remove retainer ring (27) and the washer (28) from the shaft.
8.2.8 Remove the shaft (pinion gear) out through the bottom of the
body.
8.2.9 New 'O' rings can be fitted if all actuator surfaces are clean and
free from grit and scratches. If the inside walls of the body are
scored the actuator will leak after rebuilding. Shallow marks
barely detectable to touch are acceptable.
8.2.10Lubricate the actuator thoroughly with grease. Apply a light film
of grease to the 'O' rings.
Fig 27
position with the piston assemblies situated at the body ends.
(Normal position is that which provides the proper output shaft
orientation - See Fig 27)
8.3.6 Gently push each piston into the actuator body. Turn the top
shaft extension clockwise. Do not allow the pistons to rotate. At
the proper point of engagement between the centre gear and the
piston assemblies, both pistons will move towards the centre of
the body when the shaft is turned clockwise.
8.3.7 Once the centre gear and pistons are properly engaged ensure
that smooth movement and 90° operation can occur without
moving the pistons out of the actuator body. This is important!!
8.3.8 Replace the actuator and caps (19) taking care to properly fit the
sealing 'O' rings.
8.3.9 Replace the washer (28) over the top extension.
8.3.10Install the shaft clip (27) into the mating groove on the top shaft
extension.
8.4 Spring Replacement
8.4.1 When replacing springs in a BVAT actuator ensure the springs
are replaced in the end cap in the indentical position from which
they were removed
Important:
Ensure they are positioned as shown in Fig 28
8.4.2 Place springs in the end cap pocket using the alignment nibs
cast into each cap.
8.4.3 With the springs pointing up and the end cap on a solid surface,
place the actuator body over the springs and end cap.
8.4.4 Force the body down and begin by engaging 2 body bolts
by hand through the end cap. Take each bolt up in small and
equal turns. Once the end cap is temporarily secured to the body
turn the actuator over to its normal position and uniformly take
up the end cap bolts.

8.3 Actuator Reassembly

8.3.1 Replace the top bearing (22) and bottom bearing (20)
8.3.2 Replace the centre gear through the bottom of the actuator
body.
The bottom hole in the actuator body is a larger inside diameter
than the top hole.
8.3.3 Very carefully align the pistons square to the body. Up to BVA200T BVA500T & 1100T
8.3.4 Align the centre gear so that the teeth will "pick up" the piston Fig 28
assembly's rack teeth when turning the top extension clockwise.
Important
Proper 90° rotation can only be assured if the centre gear teeth
begin to mesh with the piston assemblys teeth at the "Proper 19
Tooth" between these meshing pairs. 21
8.3.5 To ensure proper meshing of the teeth, rotate the centre gear
22½ - 45° (one or two teeth) counter clockwise from its natural 18
24
18
23 23
24 17
21 27
28
19

29
22

25
19
18 21
23 18
24
24
21
19 26
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 Uniformly load all springs to prevent any from buckling.
8.4.5 Replace springs in other end cap in a similar manner.

SECTION 9 COMPONENTS
NOTCHED Handlever

Parts List

No. Name of Part Qty

1 Body 1
2 Disc 1*
3 Upper stem 1
4 Lower stem 1
5 Dust seal 1
(Blow-out proof)
6 Bottom cover 1 32
8
7 Spring pin 1
8 Machine screw 2
5
11 Secondary seal ring 2*
12 Seat ring 1*
14 Gasket 1*
15 Bolt 2
16 Spring washer 2
17 Actuator body 1 7
18 Piston 2
19 End cap 2
20 Bottom bearing 1 3
21 Springs ?
22 Top bearing 1
23 'O' ring 2*
24 'O' ring 2*
25 'O' ring 1*
26 'O' ring 1*
27 Retainer ring 1
28 Washer 1
29 Screws 8
32 Cam flange 1
33 Bolt 4
34 Washer 4 34

33
* Available as spares

12
Part No's 17 to 29 are
shown on page 12.
11

2 1

14

6
16

15

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