DUCTILE IRON FLANGE GATE VALVES DN40 DN00, PN.0-.6 MPa Approved by: Production Director - mgr inŝ. Jan Jurasz Ductile Iron Flanged Gate - Valves - Instruction Manual Opracował P.Maślanka 6.0.2008 Sprawdził J.Karpiński 6.0.2008 Zatwierdził A.śyrek 6.0.2008 MANUFACTURED AND DESIGNED BY METALPOL WĘGIERSKA GÓRKA DTR 0 / TR / 2008 Sheet: of 8
TABLE OF CONTENTS. TECHNICAL DESCRIPTION..... Product name and main features....2. Intended use of a product..... Construction and principle of operation...4.4. Tightness class...7.5. Materials...7.6. Technical verification and approval...7.7. Applicable norms and regulations...7 2. DESIGN VARIATIONS...8 2.. Face-to-face dimensions...9 2.2. Types of driving mechanism...0 2.. Type of valve gate/wedge...2 2.4. Marking of gate valves...2. ASSEMBLY AND OPERATION..... Transport and storage....2. Assembly...4.. Operation and maintenance...4 4. MANUFACTURER S GUARANTEE...8 LIST OF TABLES Table : Flow speed, pressure and temperature range of gate valves... Table 2: Dimensions of gate valves...5 Table : Handwheel diameter and number of turns to open/close valve...5 Table 4: Gate valve opening and closing torque...6 Table 5: Dimensions of gate valves driven by electrical motor...2 Table 6: O-ring and spanner sizes for use with gate valves...6 TABLE OF FIGURES Figure : Gate valve cross-sectional drawing...4 Figure 2: Gate valves with electrical motor according to ISO 520... DTR 0 / TR / 2008 Sheet: 2 of 8
. TECHNICAL DESCRIPTION.. Product name and main features This manual contains information concerning flange ductile iron gate valve with the following features: Smooth waterway construction with full port diameter waterway. no recesses to trap debris or obstruct flow Rubber-encapsulated ductile iron wedge design ensures drop tight seal every time with low stem torque. Stem that does not rise Internal stem thread Soft sealing of the stem in the stuffing box Backflow sealing when gate valve is fully open Manual or electromechanical gate valve action.2. Intended use of a product Ductile iron flange gate valves as described in section. Intended use of a product are designed to deliver chemically neutral clean consumption water, free from sand, gravel, metallic particles or other impurities, at nominal working pressure of 6bar, at maximum water temperature of 4 K (70 C). Ductile iron flange gate valves can be installed in either vertical or horizontal configuration in underground or surface pipelines. Table : Flow speed, pressure and temperature range of gate valves DN Maximum working pressure PN Maximum pressure for external tightness Maximum gate valve pressure Maximum water flow speed Maximum operating temperature [mm] bar [m/s] C 0 5 40-00 70 6 24 8 4 DTR 0 / TR / 2008 Sheet: of 8
.. Construction and principle of operation Gate valve s outer shell consists of valve bonnet and body that are bolted together. The sealing is provided by an o-ring or a special profile gasket. Valve s body is a tee whose opposite outlets (waterway) are circular and the upper outlet has oval shape. The opposite outlets have flanges for connection to a pipeline and the oval outlet has a flange for connection to the bonnet. A a B C f DN d D H L x i K FTF - F4 (F5) Figure : Gate valve cross-sectional drawing valve body 2 valve bonnet resilient wedge 4 threaded sleeve 5 stem 6 stem nut 8 o-ring (profile gasket) 9, 0,, o-rings 2 protective cap DTR 0 / TR / 2008 Sheet: 4 of 8
Table 2: Dimensions of gate valves FTF Weight (kg)* DN F5 F4 D K d C f L i a D k A B H F5 F4 Series Series Series Series 40 240 40 50 0 84 9 9 4 4 200 0 22 290 0 9, 50 250 50 65 25 99 9 9 4 4 200 04 4 20 2,7 2, 65 270 70 85 45 6 9 9 4 7 250 2 46 70 6, 5, 80 280 80 200 60 2 9 9 8 7 250 22 66 90 8,7 8 00 00 90 220 80 56 9 9 8 9 5 4 86 450 25,7 2 25 25 200 250 20 84 9 9 8 9 5 52 26 50,6 50 50 20 285 240 2 9 2 8 9 5 80 248 575 42 9 200 400 20 40 295 266 20 2 2 9 400 78 296 582 58 5 250 450 250 405 55 9 22 28 2 24 400 94 56 778 92,5 80,5 00 500 270 455 40 70 24,5 4 28 2 24 400 220 420 878 2,7 8 * weight without handwheel Table: Handwheel diameter and number of turns to open/close valve DN D K Tr LH operating nut stem thread pitch of turns to open/close valve [mm] [mm] [mm] [mm] [mm] [/n] 40 200 20 x 4 4 4 50 200 20 x 4 4 5,5 65 250 24 x 5 7 68 4 80 250 24 x 5 7 8 7 00 5 26 x 5 9 0 2 25 5 28 x 5 9 0 26 50 5 28 x 5 9 55 200 5 28 x 5 9 205 4 250 400 2 x 6 24 255 42,5 00 400 2 x 6 24 05 5 DTR 0 / TR / 2008 Sheet: 5 of 8
Table 4: Gate valve opening and closing torque opening and closing torque (Nm) DN nominal torque maximum torque 40 5 70 50 5 70 65 50 00 80 50 00 00 6 26 25 6 26 50 6 26 200 6 26 250 80 200 00 80 200 Internal diameter of main waterway, sometimes known as the valve nominal diameter, is normalised and denoted by DN. The dimensions of valve body and connecting flanges are also normalised. The oval outlet consists of a chamber that contains the resilient rubber encapsulated wedge that either opens or closes the valve. The wedge is specially shaped to match the recess that divides the waterway. The chamber on its sides has wedge guides that force and stabilise wedge s sliding motion and also protect the wedge from excessive vibration transferred from the flowing water. Valve bonnet is of spherical shape with a tubular gland at the top. There is a metal sleeve in the gland. The sleeve stabilises the stem s position and minimises operating torque. All mentioned elements are sealed by o-rings. The sleeve also contains a debris collector ring that protects the stem and other valve elements from dust and dirt. The stem is made of monolithic stainless steel and has a thrust flange that stabilises the stem s longitudinal position. Section of the stem that is placed inside valve body under the flange has a trapezoidal thread that matches the thread on bronze nut embedded in the rubber encapsulated wedge. Section of the stem above valve bonnet is terminated with a square head which can be use for installation a handwheel or a square operating nut. Under and above the stem s flange there are brass washers that reduce operating torque between the flange, gland and sleeve and provide backflow sealing allowing replacement of o-rings and the sleeve under pressure. Rotary motion of the handwheel is transferred to the stem and converted by the wedge nut to linear motion of the wedge. Turning the handwheel clockwise closes the valve while turning it counter-clockwise opens the gate valve. The directions to open/close the valve are marked on the handwheel. In gate valves designed for underground operation, closing and opening is done by a special T spanner. In this design the stem is extended to ground surface and protected by housing. The stem s head and valve bonnet are inside a street cap. Stem DTR 0 / TR / 2008 Sheet: 6 of 8
extension, street cap and valve housing are separate parts and can be delivered on customer request. i NOTE! On customer s request gate valve may be produced with optional mechanism that allows closing of the gate valve by counter-clockwise turning of the handwheel..4. Tightness class Gate valves as described herein ( Table and room temperature of 20) have been categorised as class A devices according to EN-2266- Tab.A5. All class A gate valves during a leak test cannot develop a visible leak bigger than 00. x DN mm /s Nominal pressures and test pressures are given in Table : Flow speed, pressure and temperature range of gate valves.5. Materials ELEMENTS OF GATE VALVES MATERIAL. valve body, valve bonnet, wedge ductile (or grey) cast iron 2. handwheel cast iron. stem Stainless steel 4. stem nut, threaded sleeve, sliding ring Brass 5. bolted parts Galvanised carbon steel 6. wedge lining, o-rings, debris collector ring hard rubber 7. Protective coating Furnace-hardened epoxy powder paint i NOTE! Material types and requirements are given in Spare parts list, which is a constituent of design documentation for each product..6. Technical verification and approval.7. Applicable norms and regulations NORM DESIGNATION DESCRIPTION. PN-EN 9 : 200 Industrial valves. Marking of metallic valves 2. PN-EN 558-: 200 Industrial valves. Face-to-face and centre-to-face dimensions of metal valves for use in flanged pipe systems. Part : PN-designated valves. PN-EN 68- Elastomeric seals. Rubber DTR 0 / TR / 2008 Sheet: 7 of 8
4. PN-EN 76-2: 200 Valves. Terminology. Part 2: Definition of components of valves 5. PN-EN 074- : 2002 Valves for water supply. Fitness for purpose requirements and appropriate verification tests. Part : General requirements 6. PN-EN 074-2 : 2002 Valves for water supply. Fitness for purpose requirements and appropriate verification tests. Part 2: Isolating valves 7. PN-EN 092-2 : 999 Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Part 2: Cast iron flanges 8. PN-EN 7 : 200 Industrial valves. Cast iron gate valves 9. PN-EN 56 : 2000 Founding. Spheroidal graphite cast irons 0. EN 2266- : 200 Industrial valves. Testing of valves. Part : Pressure tests, test procedures and acceptance criteria. Mandatory requirements. EN 2266-2 : 200 Industrial valves. Testing of valves. Part 2: Tests, test procedures and acceptance criteria. Supplementary requirements 2. PN-ISO 520 :994 Industrial valves. Multi-turn valve actuator attachments. PN-ISO 8062:997 Castings. System of dimensional tolerances and machining allowances 4. PN-92/M-7400 Industrial valves. General requirements and testing 5. PN-8/M-74002 Industrial valves. Painting and identification makrking. 6. PN-90/M-7092 Fluid systems. Sealing devices. O-rings. Specification and tests 7. PN-9/H-87026 Cast copper alloys. Grades. 8. PN-6/M-74085 Industrial valves. Key for gate valves and hydrants 9. PN-6/M-74084 Industrial valves. Cast iron covers for gate valves and hydrants 20. PN-M-74202:996 Industrial valves. Spindle ends for manual control. Dimensions 2. PN-M-7420 :996 Industrial valves. Handwheels 22. DIN-202 cz. Industrial flange valves. Face-to-face and centre-toface dimensions of flange valves. 2. DESIGN VARIATIONS In order to meet the market requirements, gate valves are manufactured in several variations depending on length, working pressure, type of driving mechanism and additional accessories. Basic design, materials used in construction, intended use, compliance with requirements remain unchanged for all variations. DTR 0 / TR / 2008 Sheet: 8 of 8
2.. Face-to-face dimensions a) Gate valves with face-to-face dimensions in 4 series according to EN 558- or in F4 series according to DIN 202 part denoted by a catalogue number. Example: Gate valve DN80, catalogue number UG/Sf b) Gate valves with face-to-face dimensions in 5 series according to EN 558- or in F5 series according to DIN 202 part denoted by a catalogue number 2. Example: Gate valve DN80, catalogue number 2 UG/Sf DTR 0 / TR / 2008 Sheet: 9 of 8
2.2. Types of driving mechanism a) Gate valves with face-to-face dimensions in 4 or 5 series driven by a handwheel for installation in surface (above ground) pipelines or gate valves with face-to-face dimensions in 4 or 5 series driven by a T spanner without a special indicator in marking. Example: Gate valve DN80, catalogue number UG/Sf, gate valve DN80, catalogue number 2 UG/Sf b) Gate valves with face-to-face dimensions in 4 or 5 series driven by an electrical motor according to ISO 529 with a /986 indicator in catalogue number. Example: Gate valve DN80, catalogue number UG/Sf/986 i NOTE! Type of handwheel shall be specified in an order Gate valves DN200-00 with electrical motor are available on request DTR 0 / TR / 2008 Sheet: 0 of 8
Figure 2: Gate valves with electrical motor according to ISO 520 2 valve body 5 valve stem 6 thrust washers 9 - sleeve 7, 8 OR 20 motor base 2 guide key groove DTR 0 / TR / 2008 Sheet: of 8
Table 5: Dimensions of gate valves driven by electrical motor DN 40 50 65 80 00 25 50 200 250 00 Flange size F0 Flange type B ISO 520 E DIN 20 Flange outer diameter (mm) Bolt distance (mm) Bolt diameter / no of bolts (M x i) Stem diameter (mm) 25 02 0 x 4 20f8 F4 - - 75 40 6 x 4 0f8 Groove b x h x l (mm) 6 x 6 x 50 8 x 7 x 6 2.. Type of valve gate/wedge a) Gate valves with face-to-face dimensions in 4 or 5 series with a /4 indicator in catalogue number. Example: Gate valve DN80, catalogue number UG/Sf/4 b) Gate valves with face-to-face dimensions in 4 or 5 series with rising stem with a /008 indicator in catalogue number. Example: Gate valve DN80, catalogue number UG/Sf/008, gate valve DN80, catalogue number 2 UG/Sf/008 i NOTE! CATALOGUE DESIGNATIONS HAVE THE FOLLOWING MEANING: UG gate valve wedge is rubber lined. Sf parts subjected to pressure are made of spheroidal graphite iron Design variations shown above are suitable for operating with working pressure of PN.0.6 MPa. Nominal pressure of a gate valve must be stated in customer order. Catalogue symbols/numbers do not provide any indication of working pressure. 2.4. Marking of gate valves Marking of gate valves is done according to the following norms: EN-9, EN-074-, PN-8/M-74002. DTR 0 / TR / 2008 Sheet: 2 of 8
All markings are permanently engraved on both sides of gate valve body. Marking shall include the following information: Inner diameter of main waterway in millimetres Material type according to PN-EN 56 PN nominal working pressure in bars Manufacturer s logo Year of production Number of applicable norm Below is an example of marking on a DN 80 gate valve made of ductile iron class EN- GJS 500-7 according to EN 56 designed for working pressure of PN 6 bars, produced in 2008. FRONT SIDE BACK SIDE DN80 EN-GJS 500-7 PN6 2008 EN 074-2. ASSEMBLY AND OPERATION.. Transport and storage Gate Valve is delivered with all openings fully sealed and the wedge in its lowest position. Gate valve is protected from dust and particles that could soil its internal parts. Transport and storage should be done in a manner that does not present a risk of permanent damage to external or internal protective coating or soiling of internal parts with dust or any sharp particles. Soiling may lead to damage or loss of tightness. Valve must not be subjected to chemicals that could pollute water passing the waterway. Valves must not be stacked as this could lead to damage to protective coating, the handwheel or deformation of the stem, which could, in turn, lead to loss of tightness. If stacking is necessary, valves must be properly protected by suitable cardboard or Styrofoam packing. Valves must be properly fastened during road transport to prevent displacement and possible damage. If transported individually using a traverse (in case of very heavy valves), valve can only be lifted by the oval chamber. Valves must not be lifted or moved by handwheel, bonnet, motor base, stem head or any connection flange holes. DTR 0 / TR / 2008 Sheet: of 8
.2. Assembly Gate valves described herein can be installed in above ground or underground pipelines (horizontal or vertical). Gate valves DN250-00 are recommended for installation in horizontal pipelines in an upright position only. Gate valves shall be installed in such a way that they are not subject to shearing forces in the pipeline. Pipeline designer should indicate proper installation configuration. When installed in an underground pipeline it is recommended that gate valve rests on a concrete foundation, this applies especially to gate valves of bigger sizes. When installed in above ground pipelines, gate valve should rest on a support or concrete foundation. Prior to installation, it is recommended to wrap valve body with wide insulating tape to provide better protection against corrosive properties of the surrounding soil. All sealing caps must be removed prior to installation. Valve must be carefully inspected for any debris or dirt in its parts, and if necessary, rinsed with water. ANY DEBRIS, DIRT OR SHARP PARTICLES ON ANY GATE VALVE PARTS MAY CAUSE LOSS OF TIGHTNESS OR IRREVERSIBLE DAMAGE TO SEALING SURFACES During priming, gate valve must be fully open. Air must be vacated from gate valve before normal operation. In order to vacate air, stem sleeve must be loosened until small leak develops. When this occurs the sleeve must be tightened. Tools necessary for this operation are not part of standard delivery. Sizes of tools necessary for operation and maintenance of gate valves DN40-00 are given in 0 Table 6: O-ring and spanner sizes for use with gate valves.. Operation and maintenance Gate valves described herein do not require any maintenance. Worn o-rings in valve gland can be replaced under pressure without the necessity to cut off water supply. In order to replace the o-rings, the following steps must be taken.. fully open the gate valve 2. remove the handwheel. remove the threaded sleeve 4. replace the o-rings and debris collector ring 5. verify the condition of upper thrust washers and replace, if necessary 6. coat the sleeve with thread grease 7. screw the sleeve in until resistance is felt DTR 0 / TR / 2008 Sheet: 4 of 8
i NOTE! during the replacement of o-rings a small leak from the gland may develop. Dimensions of all o-rings for gate valves DN40-00 are give in 0 Table 6: O- ring and spanner sizes for use with gate valves DTR 0 / TR / 2008 Sheet: 5 of 8
If there is loss of tightness around the valve wedge the following steps must be taken:. cut off water supply 2. fully open the gate valve. undo all bolts fixing valve bonnet to valve body 4. withdraw the internal unit and inspect all sealing surfaces 5. if there is damage to valve wedge it must be replaced 6. if there is damage to wedge recess in valve body, it must be replaced 7. re-assemble the valve (in reverse order) 8. re-apply additional insulation before burying i NOTE! The manufacturer shall not be liable for damage to gate valves caused by improper transport, handling, installation or operation in violation of recommendations and procedures contained herein. Table 6: O-ring and spanner sizes for use with gate valves DN O - ring S type spann er (mm) D x d (mm) pcs. 40 20,2 x 28,2 x 5,2 x 22,5 x 2 5, x 2,4 6 50 20,2 x 28,2 x 5,2 x 22,5 x 2 5, x 2,4 6 65 24,2 x 2,2 x 8,2 x 27 x 8,2 x 4 DTR 0 / TR / 2008 Sheet: 6 of 8
80 24,2 x 2,2 x 8,2 x 27 x 8,2 x 4 00 26,2 x 4,2 x 4,2 x 29 x 20,2 x 4 25 28,2 x 6,2 x 44,2 x,2 x 22,2 x 46 50 28,2 x 6,2 x 44,2 x,2 x 22,2 x 46 200 28,2 x 6,2 x 44,2 x,2 x 22,2 x 46 250 2,2 x 44,2 x 52,2 x 5 x 26,2 x 55 00 2,2 x 44,2 x 52,2 x 5 x 26,2 x 55 DTR 0 / TR / 2008 Sheet: 7 of 8
4. PROCEEDING DURING REMOVE GATE VALVE Never it was found that any part of gate valve produced by METALPOL WĘGIERSKA GÓRKA, has negative influence for environment, people and animals. This fact is confirmed by Higienic Atest issued by PZH in Warsaw. None part of gate valve in chemical analysis don t hold substance from list of Substances of Very High Concern (SVHC). In case remove of gate valve, each part of gate valve is subject to recycling and as raw material it may be making use of other manufacturing process. 5. MANUFACTURER S GUARANTEE The manufacturer guarantees that the products manufactured by it will be of the kind and quality described in its specification and will be free of defects in workmanship and material. In the event any product supplied hereunder fails to comply with this warranty, the manufacturer will correct such non-conformity by repair or, at its option, by replacement of the defective part or parts within 24 months from the date of purchase or 2 months from the date of installation, provided the product has been stored, installed, operated and maintained in accordance with industry standard practices and recommendations contained herein. Detailed provisions of manufacturer s guarantee are available in manufacturer s Guarantee conditions constituting attachment to pricelist. DTR 0 / TR / 2008 Sheet: 8 of 8