F

Installation,Operation and Manual Maintenance for Wafer-type BUTTERFLY YALVES

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Installation, Operation and Maintenance Manual for Wafer-type Butterfly Valves

1 . 0 ST O R AG E
On leccipt. check that thc valves and accessories erre intact. Ensure that the valve is in a 'crack-open' position so that the clastomer seatis not under compression.and at the same tirne the disc does not protrude outside r,alve bodv. End protectors (stickers) on either side of the valr.e should be kept in tact and be removed onlv at the time of installation. Direct exposureto sunlight can deterioratethe elastomer. The valves should be stored in a covered area. If covered area is not available. an!. \.rv,ater proof coverin-s material should be spread or.erthe valves and the r,alvesshould be kept on a wooden pallet at least6" above the sround level. Do not applv tar. paint. grease or an_vother material inside the l alve or on the shaft as this rvould impair the perfcrrmanceof the valve. While transporting the valve from stora-se area to installation site. it should not be dra-egedon the ground.

2.0 CONSTRUCTION
AIL Wafer type butterfly valvesare of compactdesignanJ light weight. The rubber lined butterfly valvesprovide tight shuroff. 'I'hedisc seats on to an integrally mouldedelastomer in the body.The disc is operated by a shaft driven internally. The typical valve constructionis shown belo'*,.

VYEATHER SEAL ACETALBEARING s@. sETscREw BODY TOP SHAFT DISC DISC BEARING BODYLINING BOTTOM SIIAFT CIRINC RETAININGPIN

IMPORTANT These valves do not require a separateflange gasket while mounting on to the pipeline. The elastomerseat itself projects outside the body so as to form a gasket.When the companion flangeson eithersidearetightened, the elastomer getscompressed provides and requiredsealing. AIL wafer type Butterfly valvescanbe categorised into four types dependingon the type of application.This manual covers the following types :

a. b. c. d.

Slimseal - usedfor generalpurpose. - usedin chemicaland corrosiveservices Chemseal Cleanseal for food & hygienic services - for air conditioning& refrigerationindustry Aquaseal

3.0 INSTALLATION
a. Handlethe valve with appropriatelifting equipment.Use lifting lugs/eyebolts only for handling. Prop up the valve temporarily Keep the valve in nearly closed position while if necessary. installing. b. Do not userope or chain throughvalve port. Use the bolt relief holesat the top of the body for passingthe rope or chain. of the companionflange faces c. Carefullycheckthe cleanliness and cleanif necessary. d. Centrethe valve suchthat the shaft is in a centreposition.Do not usevalve asjack to pull the pipe into alignment. e. Fit the flange bolting on both sidesand tighten. No gasketis required separately. f. Ensurethe valve interiors and adjacentpiping are cleanedprior to tighteningthe joints. g. Tightenthe bolts, working diagonally to the requiredtorque, using a torquewrench. are not transferredon to the h. Ensurethat the pipline stresses valve as this can result in leakageacrossthe seator difficulty in operation. i. In new pipelineswhen weld neck companionflangesare used, centre each flange bore to the valve bore and run the bolts through.Tack weld the pipes to the flanges and remove the boltingsto take out the valve; then finish weld the flangesto pipe so that the elastomer seatis not damaged by the welding. j As no separate gasketis requiredbetweenthe flanges,flat face flanges are recommended.In case of valves with EPDM, Hypalon.Siliconeor Aqua nitrile, it must be ensuredthat the flange faces are totally free from grease/oil which will swell the elastomers.

3.1 Do's & Dont's INSTRUCTIONS INSTALLATION

--l ,71 Correct Installation
(a) lvlating pipe flanges shouldbe kept well apan to allorvfreeaccess for the valve.The disk shouldbe slightlyoff its seatbur not protrudingto damage the disk.

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Incorrect Installation
(a) Mating flanges are too closeto allow access for the valve and the disk in the wrongposition.

(b) Disk in thesame position ( s l i g h t l y o p e n . lw h e n flangebolts are inserted will ensure that no distonionofthe seattakes placeon final tightening.

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(b) Disk againis in thewrong position(closed)andthis will firstly distortthe seat on installation and seconriiy causeexcessive torquein initial operation.

(c) Beforeevenlvtightening theflangeboltssee thatthe valve is centralised and thenifpossible, fully open with care to ensurethe d i - s kd o e s n o t f o u l t h e intemalboreof the pipe.

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rc)If the valve is not centralised betweenthe pipeflanges this adjoining w i l l r e s u l ti n e x c e s s i v e to thedisk torque. damage andeventual leakage

3.2

Sequence of Flange Tightening

The sequence to be followed for bolts tightening while installation of valve is shown below. .:.

;; =--'.\ ,z-r'i , \: : -, . '..'\/ ./

'J,--<v ':--. .):>/t/ - /.-^-.

Insert :1bolts near to neck area and tighten the bolts as per the gir,enin the figure evenly and nor fully tightened. sequence Check the valve is being concentricto the pipeline and ensure smoothoperationof valve. If further bolts are to be tightened.follow the similar sequence i.e. tightenthe bolts diagonallyand not fully tightened. Now tighten all the bolts diagonally till the clamping faces of flangejust touchthe body metal end faces.Over tighteningis not necessary and to be avoided. Thesevalves are suitable for installation betweenpipe flanges listedbelow: I. BS 4504- PNIO/DINNDIO 2. BS 4504- PNI6/DIN NDI6 3 . A N S I 8 1 6 . 1- C l a s s1 2 5 l ANSI B16.5- Class150 4. BSl0 - TableD 5. BSl0 - Table E 6. IS 6418Tables 6 to 9 '7. IS 6392Tablesl0 to 20

3.3 Lined Pipes and Heavy Walled pipes should have a

Minimum inside diameterwell clear of Dimension"ZN" (Refer Figure shown Below) in Disc fullopen positaon.

Dimerrsions & sizesin mm

Valrc.;i:e

-50 65 27
.t7

80 100 l2-s 1 5 0 200 250 300 350 .100 450 500 5(X)
6l

"Z\"

- lirrnn. of pr(,trudinsdiSc

83 t07 136 r 8 5 231 280 325 376

176 573

When installingthe valve between existingpipe flanges.the flangesare requiredto be spreadsufficiently while placingthe valve betweenthem to preventany damageto the sealingend face which actsas the gasket. Pipe line is expectedto proviciefor this flexibility.

4.0 VALVE MOUNTING

AIL Butterfly valves are bi-directional and can be mounted in verticalor horizontalor angularpipelineswith shaftin any position. Slurry Service The valve is to be mountedon horizontal pipeline with shaft in the horizontalposition with lower disc edgeopeningin the down streamside for best results.

5.0 START-UP
After installation,the pipeline shouldbe cleanedby compressed air or by flushing with water,keepingthe valve fully open.The use of temporary filters on the upstream side of the disc is recommended to avoid any damagecausedby the transportation of abrasiveparticles. Ensure that the pipeline stresses are not transferredto the valve as this can distort the seatingand result in leakagearound the seator higher torque.

6.0 HYDRAULIC TEST OF THE INSTALLATION

AIL Butterfly valvesareindividually pressure testedin our factory. If a hydraulic test of the piping installationis ro be underraken, make sure that the valve disc is in the open position and check thatthevalve materialinstalledis compatiblewith the testmedium. Testpressure be limited to the maximum ratedpressure.

7.0 OPERATION
7.1 Manually operatedvalves
(i) AIL Butterfly valvesupto 12" canbe operated by wrenchand sizesabove 12" aresuppliedwith gearunit. GearUnit can be fitted for any size on spqcific requestat the time of ordering.

(ii) VALVES WITH FC LEVERAND LATCHARRANGEMENT: The generalconstructiondetailsof FC lever and latch fitted on to valve is shown below.
FC LI\JER t_.{TcH \O'TCHED I\DICATOR

I
Press the latch upward to releasethe latch from notched indicator.At pressed condition operatethe valve.If the pressing is not done fully while operation,latch will ger damaged by the notchedindicator. (iii)VALVES WITH FC LEVER HEAD ARRANGEMENT: The generalconstruction detailsof FC leverfitted on to valve is shown below.
Ht\DLE FC LE\ER IIE.\D

NOTCHED I\DIC,,lTOR \OSE

Pressthe handledown to release the lever headfrom notched indicator.At pressed condition operatethe valve.If the pressing is not done fully while operation,lever head nose will get damagedby the notched indicator. (iv) GEARED VALVES : All gearboxeshavean indicatingpointer on the gear box which shows the angularmovementof the disc as well as the open/closed positions.They also have a positive stop in both the open and closedpositions. When closing the valve,the handwheel shouldbe turnedonly up to that position wherethe indicatingpointermatches with the letters"CLOSE" on the gearbox case.This by itself will ensureproper sealing.There is no need to "slam" the hand

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nor wheel till it jams this practice is neither necessary recommended. Similaris the casewhen openingthe valve. 7.2 Electrically operated valves Electrical actuatorsare fltted to the gear unit or directly mounted. instruction For operationaldetailsconsultthe manufacturer's wiring diagram. manual and the appropriate are given asindicatedin the Ensurethat electricalconnections wiring diagramfor the specificactuator. Before making a test run move the disc to an intermediary positionby meansof the hand wheel. Startthe motor and seeif the rvorkine direction is correct.

7.3 LIMITSWITCHSETTING
The actuator limit switch is setin the facttlry.However.for valves preset rvithextension spindle. actuator is approximately andshould be resetat site. The presettingcan also be modified if required oncethe valvehasbeenput into service. unit Do not disturb the mechanicalstopsin the quarterturn -eear which are factory set.

8.0 MAINTENANCE
free and requireno ln normal use,thesevalves are tnaintenance 'fit & forget' valves. attention. They are literally 8.1 Seat Leak If the disc is If thereis a leak acrossthe seat.checkdisc surf-ace. it can be replacedas detailedbelou' : damaged, 8.2 Dismantling and Re-Assembly Generallythereis no needto dismantleour valve:;.However,if it is desired, the valve can be dismantledand reassembled. To dismantlethe valve, proceedas follows.

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8.2.1(a)

50-300 mm SL|MSEAL, CHEMSEAL & CLEANSEAL BUTTERFLY VALVES

The construction of this group is shownin the following diagram:

WEATIIER. SEAL ACtsTALBEARING SOC.SETSCTEW BODY TOP SIIAFT DISIC DITICBEARTNG BODYIINING BOTTOMSIIAFT ORING R.ETAININGPIN

Dismantling
l. Removethe gearunit or actuatorif fitted. The wrenchmay be left in position on wrench operated valves. Removethe socketset screw and pull out top shaft. Removethe bottom shaft-retaining pin. Insert a long drift through rhe rop shaft hole and drift out the bottom shaft. Pull out the disc.

2. 3. 4.

5.

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Re-Assembly
1. Cleanbody, shafts,disc etc. a light application NB: After cleaningand prior to assembly, of all mating components to all surfaces of siliconegrease (No grease to be used,which may other is recommended be harmful to certain kinds of elastomers). 'O'ring on bottom shaft shouldbe replacedwith new. steeldisc fitted valves,fix For 50mm to 200mm stainless new PTFE bearing into disc if the bearing has sufferedany damage. Pushdisc into bore of body in fully openposition andensure positionof squarehole in disc towardstop platform end of body. Fit top & bottom shaft, and ensuretop shaft cross hole to the disc position. position is perpendicualr holes in body and bottom shaft & fit Align corresponding pin. new bottom shaft-retaining hole in body Align groove in top shaft with corresponding and tighten new socketset screwtill it touchesthe shaft& unscrew ll2 tum to ensureit doesnot Jam' the shaft. Fix weathersealon top of valve. clockwiserotationfor andensure Fit operatingmechanism closeoperation. "Lever alongthe pipeline" the positionof disc in the valve. "across "disc open", and the pipeline" will mean, will mean, "disc closed". Check this feature while making 'disc to shaft' connection.If the disc orientationwith lever is wrong, the disc canbe rotatedthrouqh 90" to correct the fault, after dismantlins.

2. 3.

4.

5.
6.

7.

8. 9.

10. Checkthe disc/wrenchorientationis correct.Lever indicates

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(b)

350-600mm SLIMSEAL ButterftyVatves

The construciton of this group is shownin the following diagram.:

BODY soc. SETSCREW BODYBEARING BODYLINING TOP SIIAFT DIIIC DISC BEARING BOTTOM SIIAFT RETAININGPIN PLUG NUT BOTTOM @VERPI.AIE

Dismantling
l. 2. 3. 4. 5. 6. Removethe gearunit or actuatorif fitted. Remove the socket set screw and pull out top shaft Remove the screwsand remove bottom cover plate, lock plate, plug & ring nut. Remove the bottom shaft-retainingpin. Insert a long drift through the top shaft hole and drift out the bottom shaft. Pull out the disc.

Re-Assembly
l. Cleanbody, shafts,disc etc. NB: After cleaningandprior to assembly, a light application of silicone grease to all surfaces of all mating components

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2.

3. 4. 5.

6. 1. 8. 9.

(No other greaseto be used.r.r'hich is recommended may be harmful to certainkinds of elastomers). Pushdisc into boreof body in fully openpositionandensure positionof square hole in disc towardstop platform end of body. Fit top & bottom shaft. and ensure top shaft cross hole positionis perpendicular to the disc position. Align corresponding holes in body and bottom shaft & fit pin. new retaining Align groove in top shaft with corresponding hole in body and tighten new socketset screwtill it touchesthe shaft& unscrewl/2 turn. Fix lock plate with gasketor 'o' ring to bottom platform of body. Lock the bottom shafl with plug and ring nut adjusting suitablyto avoid seatleak. Fix the bottom cover plate '*'ith 'o' ring or -qasket to the platform of body. Fit operatingmechanism and ensure clockwiserotationfor closeoperation.

8.2.3(c)

AquasealButterflyValves 50-300mm

Theconstruction of this model is sho'*.n in the followins diasram:

t4

2.

-3. 4. 5.

6. l. 8. 9. 8.2.3 (c)

(No other greaseto be used.which may is recommended be harmful to certainkinds of elastomers). Pushdisc into boreof body in fully openpositionandensure positionof square hole in disc towardstop platform end of body. Fit top & bottom shaft. and ensuretop shaft cross hole positionis perpendicular to the disc position. Align corresponding holes in body and bottom shaft & fit pin. new retaining Align groove in top shaft w.ithcorresponding hole in body and tighten new socketset screwtill it touchesthe shaft& unscrew l/2 turn. Fix lock plate with gasketor 'o' ring to bottom platform of body. Lock the bottom shafi with plu-eand rin-enut adjusting suitably'to avoid seatleak. Fix the bottom cover plate with 'o' rin-eor ,gasket to the platform of body. Fit operatingmechanism andensure clockwiserotationfor closeoperation. 50-300mm Aquaseal Butterfly Valves

Theconstruction of this model is shownin the following diagram:

ROSS HOI-E WTmSilL AmlBImc rcPSffi MDY AODY UNC

Dts BOTTOMSffi omG HMGPN

TMDHOT

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Dismantling l. 2. Removeoperating mechanism complete Removebottom shaft-retaining pin & puli bottom shaftby using tappedhole at the bottom. Pull out top shaft & acetalbearingby using crosshole. After removing two shaftsthe disc can be pushedout from
the bod1.'.

3. 4.

Re-Assembly
l. Cleanbody'. shafts. disc etc. NB: Atier cleaningandprior to assembly. a light application of silicone-qrease to all surfaces of all mating components (No other greaseto be used.which may is recommended be harmful to certainkinds of elastomers). 'O' ring on bottom shaft & acetal bearing fbr top shafi shouldbe replacedwith new. Pushdisc into boreof bodyin fully openpositionandensure position of squarehole in disc towardstop platform end of body. Pushthe bottom shaft into body and disc shaftholes. Ali_en corresponding holes in body and bottom shaft & fit nerr retainingpin. Pushthe top shaftthrou-sh body shafthole to locarein disc. Fix new acetalbearingat the top of body till it touchesthe top shaft shoulder. Fix weathersealon the top of valve. Fix operatingmechanism andensure clockwiserotationfor closeoperation. indicatesthe positionof disc in the valve. "Lever alongthe pipeline" will mean,"disc open",and "acrossthe pipeline" will mean."discclosed".Checkthis feature while makins

) -)-

4. 5. 6. 7. 8. 9.

1 0 . Check the disc / wrench orientationis correct. Lever

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'disc to shaft' connection.If the disc orientationwith lever is wrong, the disc can be rotated through 900to correct the fault. AFTER ASSEMBLING ANY SLIMSEAL, CHEMSEAL, CLEANSEAL OR AQUASEAL VALVE, THE FOLLOWING PRECAUTIONSTO BE FOLLOWED TO ENSURE TROUBLE FREE PERFORMANCE. GENERAL PRECAUTIONS this should be done with l. If any further cleaning is necessary diluted detergentfollowed by water and should not be with a hydrocarbonor similar solvent. adjust the 2. Check completeoperationof valve and if necessary 'open' and'shut' positionsofgearboxes and actuators to ensure correct operation. testthe valve beforeputting it back to work' If in doubt 3. Pressure please referBS : 5155latestamendment. the about testprocedure, to sunlightor ozonefor extended 4. Do not exposeelastomerseats periods(In caseof black nitrile liner, its contactwith ozoneshould be totally avoided). 5. Foreignmaterial in the butterfly valve can damageelastomerseat when operated.Ensure valve interiors and adjacent piping are thoroughlycleanedprior to installation. 6. Ensure the valves are not subjectedto pressuresabove rated pressures of the valves(Black nitrile - 16 bar; White nitrile - 14 bar; Hypalon/Viton- 12bar EPDM, Silicone - 6 bar: Aquaseal10bar). 7. Ensure end faces are suitably protected by end protectors to preventdamageto disc and body lining while in storage. this should 8. If pipelinesarebeingpurgedprior to commissioning, position. Care to be open the fully valves in be done with the the test not exceed takento ensurethat the purging pressuredoes pressure of the valve.

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