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Ed. 12/2013 GCZ Index IN L12004-0_850 Index Fabricaciones
Ed. 12/2013
GCZ
Index
IN
L12004-0_850 Index
Fabricaciones

0.1 TABLE OF REVISIONS

5

0.2 WARNING REGARDING PROPERTY OF THE INFORMATION

6

0.3 UPDATING PROCEDURE

7

0.4 LIST OF ATTACHMENTS

8

INTRODUCTION

9

1.1 USING THE INSTRUCTION MANUAL

10

1.2 PRESERVATION OF THE MANUAL

11

1.3 WHO THE MANUAL IS INTENDED FOR

12

1..1

Customer

12

1..2

Carrier

12

1..

Installer

12

1..4

User

12

1..5

Service engineer

12

GENERAL INFORMATION

13

2.1 EDITING PICTOGRAMS

14

2.2 GLOSSARY

15

2.2.1

Abbreviations

16

2.3 IDENTIFICATION DATA OF THE MANUFACTURER

17

2..1

Identification Data of the Machine

17

2..2

Information Regarding After-sales Assistance

17

GENERAL DESCRIPTION

19

3.1 SPHERICAL VALVE AND APPURTENANCE MAIN DATA

20

3.2 DESCRIPTION OF MAIN PARTS

21

.2.1 General

21

.2.2

Turbine Spherical Valve (SV)

22

.2.2.1

.2.2.2

.2.2.

.2.2.4

.2.2.5

.2.2.6

Valve Body

22

Bushing, Sealing System

22

Valve Rotor And Trunnion

2

SV Anchoring

24

Hydraulic Cylinder

24

Limit Switches And Position Indicator

24

3.3 OPERATING SEQUENCES FOR THE SPHERICAL VALVE MANOEUVRE

25

..1

Working Principles – Movable Seal System Description

28

3.4 RING OPERATING MECHANISM

32

.4.1

Description Of Operation

2

.4.2

General

.4.

Operating Sequences

4

3.5 BY-PASS

35

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italy - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

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GCZ Ed. 12/2013 IN Index Fabricaciones L12004-0_850 Index
GCZ
Ed. 12/2013
IN
Index
Fabricaciones
L12004-0_850 Index

3.6 UPSTREAM PIPE

36

3.7 DISMANTLING JOINT PIPE AND DISMANTLING JOINT BOLT

37

3.8 MAIN FLANGE CONNECTION

38

3.9 PAINT AND SURFACE TREATMENT

39

MAINTENANCE

41

4.1

CONTROL AND ROUTINE MAINTENANCE

42

4.1.1 Maintenance Of The Mechanical Parts

42

4.1.2 Spare Parts (Not Supplied)

44

PLANT LIFE PHASES

45

5.1 HANDLING AND TRANSPORT

46

5.1.1

Handling Of The Spherical Valve

47

5.2 PACKAGING

48

5.2.1 Packaging Of The Spherical Valve

48

5.2.2 Shipping Elements

49

5.3 ERECTION, ASSEMBLY AND INSTALLATION

51

5..1

Valve Positioning

51

5..2

Valve Alignment

52

5..

Bolts And Nuts Flange Tightening

54

5..4

Electrical Limit Switch, Mechanical Position Indicator

55

5..5 By-Pass

56

5..6

Electrical, Hydraulic And Water Circuit

56

5.4 COMMISSIONING, INSPECTION

57

5.5 DEMOLITION AND SCRAPPING

58

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italy - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italy - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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Ed. 12/2013 GCZ Chap. Foreword L12004-0_850 Chap 0 Fabricaciones 0 0.1 TABLE OF REVISIONS REV.
Ed. 12/2013
GCZ
Chap.
Foreword
L12004-0_850
Chap 0
Fabricaciones
0
0.1 TABLE OF REVISIONS
REV.
DESCRIPTION
DRAWN-UP
CONTROLLED
APPROVED
DATE
Eng.
Mrs.
Eng.
0
First Emission
Marco Luca
04/12/13
Annamaria Farina
Irene Merli
Bonaveri

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

5
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Chap. GCZ Ed. 12/2013 Foreword 0 Fabricaciones L12004-0_850 Chap 0 0.2 WARNING REGARDING PROPERTY OF
Chap.
GCZ
Ed. 12/2013
Foreword
0
Fabricaciones
L12004-0_850 Chap 0
0.2 WARNING REGARDING PROPERTY OF THE INFORMATION

• The configuration of the appliances as well as the representation of the set-ups and devises rep- resented in this use manual may differ from those supplied to the machine in the specific set-up realised according to particular requirements or Safety Standards.

• The company, in line with its policy of constantly developing and upgrading the product, reserves the right to make any modifications necessary to improve the essential features; i.e. without fore- warning and under no obligation whatsoever. If this does not modify the safety aspects, the com- pany is not obliged to give notice of said changes in this document, attached to the machine.

• Vortex Hydra S.r.l. also reserves the property rights on this document with explicit prohibition to reproduce it or make it available to third parties without authorisation. Every infraction will be prosecuted by law.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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Ed. 12/2013 GCZ Chap. Foreword L12004-0_850 Chap 0 Fabricaciones 0 0.3 UPDATING PROCEDURE
Ed. 12/2013
GCZ
Chap.
Foreword
L12004-0_850
Chap 0
Fabricaciones
0
0.3 UPDATING PROCEDURE

• This version of the document and/or set-up is only updated when the functional aspects of the machine itself are modified by Vortex Hydra S.r.l. staff.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

7
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Chap. GCZ Ed. 12/2013 Foreword 0 Fabricaciones L12004-0_850 Chap 0 0.4 LIST OF ATTACHMENTS
Chap.
GCZ
Ed. 12/2013
Foreword
0
Fabricaciones
L12004-0_850 Chap 0
0.4 LIST OF ATTACHMENTS

ALL. N°

CODE

DESCRIPTION

1

L12004 - DB GEN

Quality and Data Book

2

L12004 - DB EP

Electrical equipment Data Book

3

-

Drawings as per list par. 5.2.2

4

-

Drawings as per list par. 5.3.6

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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SPHERICAL VALVE DN850 PN36

Ed. 12/2013 “L12004-0_850 Chap 1” Chapter 1
Ed. 12/2013
“L12004-0_850 Chap 1”
Chapter 1

INTRODUCTION

Chap. GCZ Ed. 12/2013 Introduction 1 Fabricaciones L12004-0_850 Chap 1 1.1 USING THE INSTRUCTION MANUAL
Chap.
GCZ
Ed. 12/2013
Introduction
1
Fabricaciones
L12004-0_850 Chap 1
1.1 USING THE INSTRUCTION MANUAL

This manual is an integral part of the machine ad has the purpose of supplying all information necessary for:

• making operators fully aware of safety problems;

• the correct installation of the plant;

• the in-depth knowledge of its functioning and limits;

• its correct use in safe conditions;

• to perform maintenance interventions correctly and safely;

• to disassemble the machines in safe conditions and with respect to the Standards in force to pro- tect the health of the workers and the environment.

The instructions, diagrams and documentation contained in this manual are the property of Vortex Hydra S.r.l. and cannot be reproduced in any way, entirely or partially.

The manual has a module structure: there is a general plant manual (this document) and, at the side of this, a series of technical sheets of the machines supplied. At par. 0.5 it is possible to see the table with all attachments present in the manual.

The different versions of this document are identified by a revision index (see par. 0.4). If a new version should be issued, it will be distributed to the customer the Vortex Hydra S.r.l. documental management procedure, in compliance with the ISO 9001:2008 Standard.

procedure, in compliance with the ISO 9001:2008 Standard. ATTENTION The plant operator is therefore responsible of

ATTENTION The plant operator is therefore responsible of making sure that, if any changes are made to this document by Vortex Hydra S.r.l., the customer is responsible for ensuring that only up-to-date versions of the manual are available at user points.

Those responsible for production and the qualified operators in charge of using the plant are obliged by the Standards in force to read this and all other manuals enclosed with the machine carefully and to make sure that the transporters, users and service engineers read the parts that concern them.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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Ed. 12/2013 GCZ Chap. Introduction L12004-0_850 Chap 1 Fabricaciones 1 1.2 PRESERVATION OF THE MANUAL
Ed. 12/2013
GCZ
Chap.
Introduction
L12004-0_850
Chap 1
Fabricaciones
1
1.2 PRESERVATION OF THE MANUAL

The manual must be handled with care, with clean hands. Do not place it on dirty surfaces. It must be kept in an environment protected from humidity and heat. No parts must be removed, ripped or arbitrarily modified.

No parts must be removed, ripped or arbitrarily modified. ATTENTION The manual is considered an integral

ATTENTION The manual is considered an integral part of the machine; therefore it must be kept until final dismantling of the same.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

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Chap. GCZ Ed. 12/2013 Introduction 1 Fabricaciones L12004-0_850 Chap 1
Chap.
GCZ
Ed. 12/2013
Introduction
1
Fabricaciones
L12004-0_850 Chap 1

1.3

WHO THE MANUAL IS INTENDED FOR

1.3.1

Customer

It is the person or company that has bought goods or services from Vortex Hydra S.r.l.

1.3.2

Carrier

It is a person with a professional qualification with a certain amount of experience concerning safety, who can handle the machine without putting persons, objects and the machine itself at risk.

1.3.3

Installer

It is a person with electrical, mechanical and electronic technical qualifications with a good level of ex- perience concerning safety, who can install the machine perfectly.

1.3.4

User

This is a technically qualified person, suitably trained in safety matters, who is able to ensure the correct use of the machine.

1.3.5

Service engineer

It is a person with technical, electrical, mechanical, electronic professional qualifications and a level of experience concerning safety that authorises him to perform maintenance operations such as not to create risks to persons, objects and the machine itself.

to create risks to persons, objects and the machine itself. ATTENTION Do not employ staff with

ATTENTION Do not employ staff with qualifications different to those indicated.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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SPHERICAL VALVE DN850 PN36

Ed. 12/2013 “L12004-0_850 Chap 2” Chapter 2
Ed. 12/2013
“L12004-0_850 Chap 2”
Chapter 2

GENERAL INFORMATION

Chap. GCZ Ed. 12/2013 General Information 2 Fabricaciones L12004-0_850 Chap 2 2.1 EDITING PICTOGRAMS
Chap.
GCZ
Ed. 12/2013
General Information
2
Fabricaciones
L12004-0_850 Chap 2
2.1 EDITING PICTOGRAMS

ATTENTION The indications preceded by this symbol contain information, prescriptions or procedures, which if not performed The indications preceded by this symbol contain information, prescriptions or procedures, which if not performed correctly, can cause injury, death or long term risks to health of persons and the environment.

CAUTION The indications preceded by this symbol contain procedures or practices, which if not performed correctly, The indications preceded by this symbol contain procedures or practices, which if not performed correctly, can cause serious damage to the machine or the product.

INFORMATION The indications preceded by this symbol contain information regarding any subject of particular importance: failure The indications preceded by this symbol contain information regarding any subject of particular importance: failure to comply can lead to the contractual warranty becoming null and void.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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2.2 Ed. 12/2013 GCZ Chap. General Information L12004-0_850 Chap 2 Fabricaciones 2 GLOSSARY This section

2.2

Ed. 12/2013 GCZ Chap. General Information L12004-0_850 Chap 2 Fabricaciones 2 GLOSSARY
Ed. 12/2013
GCZ
Chap.
General Information
L12004-0_850
Chap 2
Fabricaciones
2
GLOSSARY

This section contains a list of terms not in common usage or with meanings different to normal, and the abbreviations used in the document.

• DANGER ZONE: inside and/or in proximity of the machine where the presence of an exposed person constitutes a risk for safety and the health of the person itself;

• EXPOSED PERSON: any person that is entirely or partly inside a dangerous area;

• OPERATOR: person engaged to install, run, regulate, perform maintenance, clean, repair and transport the machine;

• MAN-MACHINE INTERACTION: any situation in which the operator interacts with the machine in any operational phase and at any time in the life span of the same;

• OPERATOR QUALIFICATION: minimum level of skill that the operator must have in order to perform the operation described;

• NUMBER OF OPERATORS: the number of operators suitable for performing the operation de- scribed optimally and deriving from a careful analysis performed by Vortex Hydra S.r.l. Therefore, the use of a different number of persons could prevent attainment of the expected result or put the safety of the staff involved in danger;

• MACHINE STATE means:

- the functioning mode: automatic start with maintained-action control, stop, etc.;

- the safety conditions present on the machine: guards included, guards excluded, emergency stop pressed, type of isolation of the energy sources, etc;

• RESIDUAL DANGER: danger that it has not been possible to eliminate or reduce sufficiently through the design against which the guards are not (or not totally) effective. The manual gives information regarding its existence and the instructions and events that allow to overcome it;

• SAFETY COMPONENTS: means a component use to assure safe functioning and whose break- down or bad functioning jeopardises the safety and/or health of exposed persons (e.g. lifting equipment, fixed, mobile or adjustable guard etc. electric, electronic, optical, pneumatic, hydraulic device that interlocks a guard etc.).

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

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Chap. GCZ Ed. 12/2013 General Information 2 Fabricaciones L12004-0_850 Chap 2 2.2.1 Abbreviations
Chap.
GCZ
Ed. 12/2013
General Information
2
Fabricaciones
L12004-0_850 Chap 2
2.2.1
Abbreviations

Chap.

Chapter

Par.

Paragraph

Pag.

Page

Tab.

Table

Fig.

Figure

Min.

Minimum

Max

Maximum

Dx

Right

Sx

Left

Rif.

Reference

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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2.3 2.3.1 Ed. 12/2013 GCZ Chap. General Information L12004-0_850 Chap 2 Fabricaciones 2 IDENTIFICATION DATA

2.3

2.3.1

Ed. 12/2013 GCZ Chap. General Information L12004-0_850 Chap 2 Fabricaciones 2 IDENTIFICATION DATA OF THE
Ed. 12/2013
GCZ
Chap.
General Information
L12004-0_850
Chap 2
Fabricaciones
2
IDENTIFICATION DATA OF THE MANUFACTURER

Company name: VORTEX HYDRA S.r.l. Address: Via Argine Volano, 355 - 44034 Fossalta (FE) ITALY Tel. 00 39 (0) 532/879411 Fax 00 39 (0) 532/866766

Identification Data of the Machine

A B C
A
B
C

A - Year of Manufacture: 2013

B - Machine model: SV DN850 PN36

C - Machine Code: M.00755 / M.00756

2.3.2

Information Regarding After-sales Assistance

/ M.00756 2.3.2 Information Regarding After-sales Assistance INFORMATION Remember that modifications of the machine

INFORMATION Remember that modifications of the machine performed by the user, without explicit writ- ten authorisation from Vortex Hydra S.r.l. make the warranty null and void and relieve Vortex Hydra S.r.l. from any liability for damage/injury caused to objects/persons.

This is particularly valid when the above-mentioned modifications are performed on the safety devices, lowering their effectiveness.

The use of non-original spare parts or parts different to those explicitly indicated in this manual and spare parts catalogue, relieve Vortex Hydra from any liability.

It is therefore recommended always to contact Vortex Hydra S.r.l. after-sales centres.

AFTER-SALES SERVICE ADDRESS

AFTER-SALES SERVICE ADDRESS

ITALY

VORTEX HYDRA S.R.L. Via Argine Volano, 355 44034 Fossalta (FE) ITALY Tel. 00 39 (0) 532/879411 Fax 00 39 (0) 532/866766 E-mail: [info@vortexhydra.com]

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

17
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SPHERICAL VALVE DN850 PN36

Ed. 12/2013 “L12004-0_850 Chap ” Chapter 3
Ed. 12/2013
“L12004-0_850 Chap ”
Chapter 3

GENERAL DESCRIPTION

Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  3.1 SPHERICAL VALVE AND
Chap.
GCZ
Ed. 12/2013
General Description
3
Fabricaciones
L12004-0_850 Chap
3.1 SPHERICAL VALVE AND APPURTENANCE MAIN DATA
SPHERICAL VALVE (SV) Quantity (units) 2 Nominal diameter 850 mm Total length 1328 mm Nominal
SPHERICAL VALVE (SV)
Quantity (units)
2
Nominal diameter
850
mm
Total length
1328
mm
Nominal pressure
36
bar
Test pressure
54
bar
Opening time
60
s
Closing time
20
s
Cylinder quantity/unit
1
Cylinder diameter
260
mm
Cylinder stroke
670
mm
Total weight SV
9774.4
kg
 

BY-PASS

Quantity per unit

 

1

Quantity per unit   1

Nominal diameter

50

mm

Nominal pressure

40

bar

Total length

1978

mm

Total weight

147.2 kg

UPSTREAM PIPE

Nominal diameter

850 mm

Total length

645

mm

Total weight

494 kg

diameter 850 mm Total length 645 mm Total weight 494 kg   DISMANTLING JOINT Nominal diameter
 

DISMANTLING JOINT

Nominal diameter

850

mm

Nominal diameter 850 mm

Total length

800

mm

Total weight

566.31

kg

20
20

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

This document is exclusive property of Vortex Hydra s.r.l. Any duplication, distribution or utilisation without written permission will be persecuted.

Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 3.2 DESCRIPTION OF MAIN
Ed. 12/2013
GCZ
Chap.
General Description
L12004-0_850
Chap
Fabricaciones
3
3.2
DESCRIPTION OF MAIN PARTS
3.2.1
General

REFERENCE DRAWINGS

REFERENCE DRAWINGS

NUMBER

273A000

DESCRIPTION

Lay-Out

The layout of GCZ Project is the following: 1 M.00755 M.00756
The layout of GCZ Project is the following:
1
M.00755
M.00756

This valves are used in the hydroelectric power plant as a turbine protection to guarantee the emer- gency shut-off of the pressurized water flow of the penstock. They are placed immediately before the turbines and work automatically to shut-off the water flow in case of any turbine malfunction, lack of power or any specified condition. The shutter is actuated by one hydraulic cylinder moving it from the

“ON” to “OFF” position by rotating of 90° on side trunnions. The valve in the open position has a fluid way which is essentially a straight cylinder so has approximately the same head losses as would occur

in an equivalent length of pipe.

Closure is effected by rotating the shutter 90° degrees, so it stops completely the fluid way. To guarantee the fast closing in lack of power suitable counterweight are installed on the shutter arm. Once shutter

is closed, the perfect water tightness is guaranteed by Main Operation Seal: the downstream mobile

sealing rings that close against the fix rings seal against the fixed part of the shutter (both made of stain- less steel with different grade of hardness). Other mobile ring closure (Maintenance seal) are installed in the upstream side of the shutter and are used only in case of maintenance to the Main Operation downstream seal without the necessity to remove the valve from the site. Both of them are operated by the pressure of the oil derivated from HPU with a dedicated system with piping (out of VH scope). Seats NEVER touch the valve during opening or closing.

A complete description in the following paragraph.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap
Chap.
GCZ
Ed. 12/2013
General Description
3
Fabricaciones
L12004-0_850 Chap

3.2.2

Turbine Spherical Valve (SV)

3.2.2.1

Valve Body

REFERENCE DRAWINGS

NUMBER

DESCRIPTION

273A001

Body valve 1 of 3

273A001

Body valve 2 of 3

273A001

Body valve 3 of 3

273A002

Body valve downstream

The valve body is composed of two parts, both of steel plate welded construction, bolt together with 30 bolts M36x3x360 and 6 bolts M36x3x300. The valve body has a total length of 1328mm, with connection flanges at both ends and complete with welded in stainless steel lining for guiding the movable sealing rings.

3.2.2.2

Bushing, Sealing System

REFERENCE DRAWINGS

NUMBER

DESCRIPTION

273A009

Bushing assembly

273A010

Bushing support

273A011

Flange for bushing support

273A019

Mobile ring

273A005

Fixed ring

Self lubricated bushing DEVA - BM 310x300x120mm. The bushings are closed with a flange and both are fixed with 10 screws M10x50 A2 to the bushing support. The trunnion sealing can be changed, if necessary without dismantling the SV. For changing the sealing, the operating lever must be removed, so the penstock must be dewatered or better the inlet of the valve must not be pressurized. Each SV has two indipendent sealing systems: the maintenance seal on the upstream side and the working seal on the downstream side. Both are metal to metal sealings, hydraulically operated by oil pressure (from the HPU).

22
22

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 3.2.2.3 Valve Rotor And
Ed. 12/2013
GCZ
Chap.
General Description
L12004-0_850
Chap
Fabricaciones
3
3.2.2.3 Valve Rotor And Trunnion

REFERENCE DRAWINGS

REFERENCE DRAWINGS

NUMBER

273A004

273A003

DESCRIPTION

Shutter assembly

Shutter

Solid spherical valve shutter made from welded plate steel, with screwed-on trunnions with each 8 bolts M36x3x680 and 1 maintenance bolt M36x3x430 in the center on lever side, and 8 bolts M36x3x410 and 1 maintenance bolt M36x3x430 on opposite side.

The trunnion is the other key component of the valve, it is made of carbon steel and covered by stain- less steel layer . The rotation is made on self lubricating bearing made of bronze/graphite with limit of specific pressure up to 40 Mpa. The leakage trough the trunnion is prevented by two special seals of hard rubber. When the valve is closed the normal stress is taken by the trunnion bolts that are preloaded to maintain closed the surface between the trunnion itself and the shutter. During the rotation the torsional phase is supported by the small bushings around the trunnion bolts. This system allow an easy assembly phase ad great performances against the strongest loads in normal and emergency operations of opening and closures.

Fig. 2 - Trunnion section

TRUNNION BOLTS

TRUNNION BOLTS BUSHING 2
TRUNNION BOLTS BUSHING
2

TRUNNION BUSHING IN BRONZE GRAPHITE

TRUNNION

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  3.2.2.4 SV Anchoring
Chap.
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Ed. 12/2013
General Description
3
Fabricaciones
L12004-0_850 Chap
3.2.2.4 SV Anchoring

The anchoring consists of two base plates and 4 anchor bolts M30 (2 every base plate). The holes are bigger then the bolts in order to enable SV movement in longitudinal direction, for taking up expansions of upstream pipe. The base frame are fabricated by Vortex.

3.2.2.5 Hydraulic Cylinder

REFERENCE DRAWINGS

REFERENCE DRAWINGS

NUMBER

273A022

273A018

DESCRIPTION

Hydraulic cylinder

Actuator lever

Drive mechanism consists of 1 operating lever and 1 hydraulic cylinder, Ø260mm. Operating lever in welded construction is bolted to the trunnion with 8 bolts M36x3. The cylinder is connected to the valve body and to the hoist stirrup by a pivot with a self lubricated bush- ing, the stirrup is also bolted to the base plate with 6 bolts M30x3.5x370. Manual locking device rod in close position of the shutter can be connected to the valve body for main- tenance purposes.

3.2.2.6 Limit Switches And Position Indicator

The SV is equipped with two electrical limit switch, completely open or completely closed, placed on the valve body, in the flow direction on the left hand side:

 

LIMIT SWITCH POSITION

 

POSITION

DEGREE

STATUS

SYMBOL

Vertical

90°

Close

C

Horizontal

Open

O

On the same side, also a visual position indicator, with a scale C and O, is erected. The SV is also equipped with 4 limit switches, completely open or completely closed, regarding the mobile rings.

 

LIMIT SWITCHES TYPE

DB NUMBER

DB CODE

DESCRIPTION

QUANTITY

52890

FIN-T XCKL515

Telemecanique mechanical limit switch, XCKL515 code

2

260633

INT-T XCK-L110

Telemecanique mechanical limit switch, 240Vac/ 250Vdc-10A, 1NC+1NO, XCK-L110 code

4

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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 3.3 OPERATING SEQUENCES FOR
Ed. 12/2013
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Chap.
General Description
L12004-0_850
Chap
Fabricaciones
3
3.3 OPERATING SEQUENCES FOR THE SPHERICAL VALVE MANOEUVRE
3 3.3 OPERATING SEQUENCES FOR THE SPHERICAL VALVE MANOEUVRE INFORMATION This sequence only gives an indication

INFORMATION This sequence only gives an indication about the correct procedures to follow in order to properly manoeuvre the spherical valve without damage it.

All the indications only refer to the spherical valve and to its devices, when provided, such as hydraulic cylinders, bypass, HPU, oil and electrical circuits, limit switches and control devices: no conditions or interactions with other systems on the upstream or on the down- stream of the valve are taken into account. Furthermore, all the described operations on the valve do not take into account the machines and the devices that may be present on the upstream and on the downstream of the valve.

In this description will be indicated as:

“FULLY OPENED CONFIGURATION” the configuration with water passing through the valve, rotor in opened position and mobile rings not applied.

“FULLY CLOSED CONFIGURATION” the configuration with no water passing through the valve, rotor in closed position, downstream mobile ring applied and upstream mobile ring not applied (but it could be also applied).

“FULLY CLOSED CONFIGURATION FOR MAINTENANCE” the configuration with no water passing through the valve, rotor in closed position, upstream mobile ring applied, blockers (if foreseen) in locked position and downstream mobile ring not applied (but it could be also applied).

CLOSING PROCEDURE – NORMAL CLOSURE This procedure indicates all operations necessary to bring the spherical valve from the “fully opened configuration” to the “fully closed configuration”.

1. Ensure to have the valve in the “fully opened configuration” by checking the signals from the limit switch on the rotor axle and those on the mobile rings. The rotor shall be in its opened position and both the mobile rings shall be in their “not applied” position (in this case also the blockers shall be in their unlocked position);

2. Ensure the valves on the bypass line are in “closed position” and no water is flowing through the line. The limit switch on the needle valve (automated valve) shall give the signal of “closed position”.

3. Give the closing signal for the valve: the “opened” signal from the limit switch on the rotor shall commute into “closed”. At this point the rotor is closed but the valve is not yet sealed and water is still passing through the valve to downstream. Note: in this condition the water is passing through the little gap between rotor and mobile rings and has a high velocity: this situation can lead to a very fast damage of the rings, so it should be maintained only for the shorter time as possible (for instance from the moment when the rotor reaches its closed position and the moment when the mobile ring applies).

4. Give the “closing” signal to the downstream mobile ring: the signal from the limit switch shall com- mute from “not applied” into “applied”: now the valve is in its “fully closed configuration”.

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  CLOSING PROCEDURE – NORMAL
Chap.
GCZ
Ed. 12/2013
General Description
3
Fabricaciones
L12004-0_850 Chap
CLOSING PROCEDURE – NORMAL CLOSURE FOR MAINTENANCE
This procedure indicates all operations necessary to bring the spherical valve from the “fully opened
configuration” to the “fully closed configuration”.

1. Ensure to have the valve in the “fully opened configuration” by checking the signals from the limit switch on the rotor axle and those on the mobile rings. The rotor shall be in its opened position and both the mobile rings shall be in their “not applied” position;

2. Ensure the valve on the bypass line are in “closed position” and no water is flowing through the line. The limit switch on the needle valve (automated valve) shall give the signal of “closed position”.

3. Give the closing signal for the valve: the “opened” signal from the limit switch on the rotor shall commute into “closed”. At this point the rotor is closed but the valve is not yet sealed and water is still passing through the valve to downstream. Note: in this condition the water is passing through the little gap between rotor and mobile rings and has a high velocity: this situation can lead to a very fast damage of the rings, so it should be maintained only for the shorter time as possible (for instance from the moment when the rotor reaches its closed position and the moment when the mobile ring applies).

4. Give the “closing” signal to the upstream mobile ring: the signal from the limit switch shall com- mute from “not applied” into “applied”: now the valve is in its “fully closed configuration for main- tenance”. If the maintenance will not comprehend the downstream side of the valve itself or the rotor itself, it is possible to close also the downstream mobile ring as a further safety: the signal from the limit switch shall commute from “not applied” into “applied”.

5. Engage the blockers on the upstream flange of the valve: set all of them in their locked position, in order to prevent a mistaken opening of the maintenance mobile sealing ring.

6. Engage the mechanical lock on the lever in order to prevent a wrong opening command on the valve.

From this configuration it is possible to start operate on the downstream side of the vale, of the rotor and of the penstock.

CLOSING PROCEDURE – EMERGENCY CLOSURE This procedure indicates all operations necessary to bring the spherical valve from the “fully opened configuration” to the “fully closed configuration” in case of emergency closure. The valve is in “fully opened configuration” and normally working when an emergency occurs. The emer- gency signal must cause the following actions, in the given order:

1. Command the rotor of the valve to close (acting on the cylinder oil feeding).

2. Command the automated valve on the bypass to close (the limit switch must give the “automated valve closed” signal).

3. Once the limit switch on the valve axle gives the signal of “rotor closed”, both, or at least the downstream mobile ring, must be closed (signal from the limit switch shall indicate the ring as applied).

4. The valve is in its “fully closed configuration” and no water is passing through the valve to downstream.

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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 OPENING PROCEDURE – NORMAL
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OPENING PROCEDURE – NORMAL OPENING and NORMAL OPENING AFTER MAINTENANCE
This procedure indicates all operations needed to bring the SV from the “fully closed position” and “fully
closed position for maintenance” to the “fully opened position”.

1. Ensure that all of the blockers are in their unlocked position: in this case the maintenance mobile sealing ring is free to be opened.

2. Ensure that the mechanical block on the lever is not engaged.

3. Since the valve must be opened under balanced load, open the valves on the bypass line so that water can flow through the line. The limit switch on the needle valve (automated valve) shall give the signal of “opened position”.

4. Once the pressure difference between the upstream and the downstream pipe is lower than the 10% of the nominal pressure it is possible to start opening the sealing rings (both upstream and downstream): the limit switches of both the mobile rings must commute from “applied” to “not ap- plied”: this means both rings are opened and the rotor is free to be moved.

5. After both the limit switches of the upstream and downstream mobile sealing rings give the signal of “opened ring” it is possible to open the rotor: the limit switch on the rotor axle shall commute the signal from “closed” to “opened”. The “fully opened configuration” has been reached.

6. Command the bypass automated valve to close (the limit switch must give the “automated valve closed” signal).

switch must give the “automated valve closed” signal). ATTENTION Never manoeuvre one or both the mobile

ATTENTION Never manoeuvre one or both the mobile rings while the rotor is moving or is in opened position! This can damage the mobile rings and their sealing surface.

All manoeuvres on the mobile ring(s) must be made starting from the configuration of “ro- tor closed”!

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  3.3.1 Working Principles –
Chap.
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Fabricaciones
L12004-0_850 Chap
3.3.1 Working Principles – Movable Seal System Description

The seal system adopted in this valves is a double movable seal system, these two features allow the advantages explained in the following.

The single seal is composed by two stainless steel rings of different shapes and different hardness, the first one, the less hard, is fixed on the rotor with stainless steel bolts and it moves solidal with the rotor itself (see Fig. 3).

Fig. - Spherical Valve’s Shutter

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3
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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3
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The second one, the hardest, is positioned inside the body valve, and it’s free to move parallel to the flow, in both directions. It slides over seats collocated in the body of the valve, that are covered with a stainless steel layer. This ring is moved by the application of pressurized oil, taken from the HPU, the operations, ruled by a dedicated circuit, will be deeply described in the following. The shape of this ring is a kind of “T” that allow to have a greater surface in the sides where is needed the pressure application. Fig. 4 - Mobile ring shape

SPECIAL HARD RUBBER SEALS FOR THE PRESSURE SEATS

4
4

T-SHAPE MOBILE RING

Fig. 5 - Mobile ring’s seats stainless steel covered

STAINLESS STEEL COVERING OF THE SEATS

STAINLESS STEEL COVERING OF THE SEATS 5
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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  Fig. 6 - Mobile
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General Description
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Fabricaciones
L12004-0_850 Chap
Fig. 6 - Mobile ring position
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6

When the rotor is perfectly aligned in closed position, the consent to move the mobile ring and close against the fixed one is given by the logic of the circuit (out of Vortex scope of supply). The perfect tight- ness is ensured by the contact between the two stainless steel surfaces of different hardness. The T-shape hardest one imprint a line of contact in the fixed one, allowing the perfect restrain under the water pressure. To prevent the leakage trough the movement rooms of this movable seal, three special hard rubber seals are used. These seals are suitable for oil/water holding, in sliding application against metal, as in this case.

Fig. 7 - Tightening line between mobile and fixed ring

7 TIGHTENING LINE
7
7

TIGHTENING LINE

As has been introduced before, the valve seal system is composed of two different seals, the down- stream service seal and the upstream maintenance seal. The service seal works for the normal opera- tion on the downstream side of the valve, while the maintenance seal works only in case that has to be done maintenance on the service seal itself. This double seal system allows to save time during the maintenance operation on the valve. The closure of the upstream maintenance seal, permits to manage the downstream side without emptying (and later re-filling) the penstock, a manoeuvring that could take from two days to one week (or even more).

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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 Fig. 8 - Double
Ed. 12/2013
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General Description
L12004-0_850
Chap
Fabricaciones
3
Fig. 8 - Double seal system in a spherical valve

MAINTENANCE SEAL SYSTEM

MAINTENANCE SEAL SYSTEM SERVICE SEAL SYSTEM 8
MAINTENANCE SEAL SYSTEM SERVICE SEAL SYSTEM 8

SERVICE SEAL SYSTEM

8
8

The mind of the working procedures is the dedicated circuit, connected to the control panel and to the HPU (out of Vortex scope of supply). Due to safety reasons, the circuit works with oil taken from the HPU.

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  3.4 RING OPERATING MECHANISM
Chap.
GCZ
Ed. 12/2013
General Description
3
Fabricaciones
L12004-0_850 Chap
3.4
RING OPERATING MECHANISM
3.4.1
Description Of Operation

Spherical valve’s hydraulic sealing is insured by rotor upstream and downstream seal rings. Upstream seal ring is normally opened. The closing can be made only with the valve closed, by voluntary maneu- ver. Upstream seal ring function is to lock water circulation when rotor is closed, in order to safely make downstream seal ring maintenance, without empting upstream penstock. Rotor upstream and downstream seal rings, must be opened when the rotor is open or during opening/ closing operations. The sealing can be made only when the rotor is closed.

The sealing can be made only when the rotor is closed. ATTENTION These instructions are very

ATTENTION These instructions are very important, because an interference between valve’s rotor and seal rings could damage the system.

Opening and closing of each seal ring are made by a dedicated circuit, using the oil in pressure taken from the HPU (out of Vortex Scope). The control circuit will be hard-wired on a panel near the valve (out of Vortex Scope). Reference drawings are: “L12004-SI-CID-000 M.00755” (ref. fig. 9) and “L12004-SI-CID-000“L12004-SI-CID-000 M.00756”M.00756” (ref. fig. 10). TheThe componentscomponents areare identifiedidentified onon thethe schemescheme byby meansmeans ofof referencesreferences andand functions.functions.

Fig. 9 - Ring Operating Mechanism for Valve M.00755

9
9
2
2

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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 Fig. 10 - Ring
Ed. 12/2013
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Fig. 10 - Ring Operating Mechanism for Valve M.00756
10
10

3.4.2

General

The solenoid valves that allow to work the rings are electrically actuated and in case of black-out all the system automatically get set for the emergency closure: without electrical power the mobile rings get the opened (not applied) configuration. The reason is that, if the valve is opened, first it must be closed the rotor then can be closed the ring(s).

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  3.4.3 Operating Sequences
Chap.
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Ed. 12/2013
General Description
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Fabricaciones
L12004-0_850 Chap
3.4.3 Operating Sequences

The valve sealing is made by manoeuvring the circuit that applies/not applies the mobile rings.

In the following description it will only be indicated how to apply (seal the valve) or not apply (make the rotor free to be opened) the mobile sealing rings, regardless the real position of the rotor, of the blockers or the real feasibility of the manoeuvre.

of the blockers or the real feasibility of the manoeuvre. ATTENTION Never manoeuvre one or both

ATTENTION Never manoeuvre one or both the mobile rings while the rotor is moving or is in opened position! This can damage the mobile rings and their sealing surface.

All manoeuvres on the mobile ring(s) must be made starting from the configuration of “ro- tor closed”!

OPEN BOTH THE MOBILE RINGS (get them as “not applied”). The configuration shown in the drawings “L12004-SI-CID-000 M.00755” and “L12004-SI-CID-000“L12004-SI-CID-000 M.00756” isis thethe oneone thatthat keepskeeps bothboth thethe mobilemobile ringsrings opened.opened. InIn thisthis configurationconfiguration nonenone ofof thethe ringsrings apap-- plies and the rotor can be moved (if no other signal opposes).

CLOSE BOTH THE MOBILE RINGS (get them as “applied”). In order to close both the mobile rings, the solenoid valves must be energized (items 2 and 1): in this case both the mobile rings will apply on the rotor (the rotor must be closed and the rings will seal the valve).

CLOSE ONLY THE SERVICE RING (DOWNSTREAM RING) (get it as “applied”/”not applied”) In order to close the only service ring (downstream ring) manoeuvre as follows:

1. set the circuit as shown in the drawings “L12004-SI-CID-000“L12004-SI-CID-000 M.00755”M.00755” andand “L12004-SI-CID-000“L12004-SI-CID-000

M.00756”

2. energize the solenoid valve (item 2);

3. energize the solenoid valve (item 1) relative to the downstream ring.

CLOSE ONLY THE MAINTENCE RING (UPSTREAM RING) (get it as “applied”/”not applied”) In order to close the only maintenance ring (upstream ring) manoeuvre as follows:

1. set the circuit as shown in the drawings “L12004-SI-CID-000 M.00755” and “L12004-SI-CID-000

M.00756”

2. energize the solenoid valve (item 2);

3. energize the solenoid valve (item 1) relative to the upstream ring.

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3.5 Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 BY-PASS REFERENCE DRAWINGS

3.5

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BY-PASS

REFERENCE DRAWINGS

REFERENCE DRAWINGS

NUMBER

273A040

DESCRIPTION

By-pass

One by-pass DN50 PN40, situated under 30° clockwise in respect of horizontal line, right hand side in flow direction, consisting of 2 manually operated valves and an hydraulically controlled needle valve.

valves and an hydraulically controlled needle valve. INFORMATION For any other information see the Quality and

INFORMATION For any other information see the Quality and Data Book L12004 - DB GEN.

The manual valve, on upstream side, remain normally always open and will be used for maintenance purpose only. The needle valve has to be open every time for filling up the penstock and equilibrating pressure before opening of the SV and will be closed automatically when the SV is in open position.

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  3.6 UPSTREAM PIPE
Chap.
GCZ
Ed. 12/2013
General Description
3
Fabricaciones
L12004-0_850 Chap
3.6 UPSTREAM PIPE

REFERENCE DRAWINGS

REFERENCE DRAWINGS

NUMBER

273A044

DESCRIPTION

Upstream pipe

Upstream connection pipe welded construction, with one connection flanges for by-pass DN50. A provisional one of 1” GAS for instrumentation, if not necessary can be closed with a plug. The theoretical built in length is 645mm.

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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 3.7 DISMANTLING JOINT PIPE
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3.7 DISMANTLING JOINT PIPE AND DISMANTLING JOINT BOLT

REFERENCE DRAWINGS

REFERENCE DRAWINGS

NUMBER

273A036

273A037

273A025

DESCRIPTION

Dismantling joint assembly

Dismantling joint

Short tie rod

Dismantling joint pipe welded construction. The theoretical built in length of the assembly is 815mm.

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Chap. GCZ Ed. 12/2013 General Description 3 Fabricaciones L12004-0_850 Chap  3.8 MAIN FLANGE CONNECTION
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3.8 MAIN FLANGE CONNECTION

The main flange connection consists of each one set of the following bolts and nuts:

 

BOLTS & NUTS SPECIFICATION

TYPE

QUANTITY

WHERE USED

AXIAL PRELOAD

M36x3 L=360mm

30

SV half-body / SV half-body

 

M36x3 L=300mm

6

M36x3 L=410mm

8

Right trunnion - without lever (in the circumference)

M36x3 L=430mm

1

Right trunnion - without lever (in the centre)

M36x3 L=680mm

8

Left trunnion - with lever (in the circumference)

300kN for all

M36x3 L=430mm

1

Left trunnion - with lever (in the centre)

M36x3 L=300mm

24

SV / Upstream pipe

M36x3 L=300mm

24

SV / Dismantling joint

M24 L=220mm

40

Dismantling joint / Downstream pipe

The axial preload is given by a hydraulic tightener: this grabs the threaded bar and pulls, stretching it, to create the desired axial preload. At this point the bolts are screwed manually up to the stop with the flanges (it is good practice to limit the maximum axial preload at 70/75% of the tie rod’s yield strength). The tightener is a commercial component that is easy to order from a catalogue.

commercial component that is easy to order from a catalogue. INFORMATION Provide an axial preload ensures

INFORMATION Provide an axial preload ensures greater safety and adherence to the calculation note, and is essential when you want a high control of preload provided with tie rods and bolts (as in tightening the trunnion, but in reality also for the flanges subjected to high PN).

The torque wrench (manual or hydro-actuated) does not provide the same accuracy, be- cause it is difficult to determine how much of an optimal torque output is lost to overcome the friction between the bolt and washer, washer and flange and between the screw and the nut.

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Ed. 12/2013 GCZ Chap. General Description L12004-0_850 Chap  Fabricaciones 3 3.9 PAINT AND SURFACE
Ed. 12/2013
GCZ
Chap.
General Description
L12004-0_850
Chap
Fabricaciones
3
3.9 PAINT AND SURFACE TREATMENT

PAINTING OF AIR CONTACT STATIONARY PIECES:

• Surface preset: Sa 2 1/2

• Background painting: 1 layer of Inorganic Zinc primer, dry thickness 60 ��mm

• Final painting: 2 layers of bi-component epoxy paint, dry thickness 150 ��mm

• Total min. dry film thickness: 210 �m

• Final colour: RAL 5005 (Blue)

PAINTING OF AIR CONTACT MOVABLE PIECES:

• Surface preset: Sa 2 1/2

• Background painting: 1 layer of Inorganic Zinc primer, dry thickness 60 �m

• Final painting: 2 layers of bi-component epoxy paint, dry thickness 150 �m

• Total min. dry film thickness: 210 �m

• Final colour: RAL 2013 (Yellow)

PAINTING OF WATER CONTACT PIECES:

• Surface preset: Sa 2 1/2

• Background painting: 1 layer of Inorganic Zinc primer, dry thickness 60 �m

• Final painting: 2 layers of coal tar epoxy paint, dry thickness 250 �m

• Total min. dry film thickness: 310 �m

• Final colour: Black

TEMPORARY PROTECTION OF MACHINED SURFACES:

• Surface preset: cleaned with proper solvent

• Background painting: 1 layer of varnished diluted (Rust Veto 342, Tectyl 506 or equivalent), dry thickness 40 �m

CHAMFERS FOR WELDING:

• Surface preset: cleaned with proper solvent

• Background painting: 1 layer of epoxy iron bi-component oxide (Interplate 27 or equivalent), dry thickness 20 �m

• Final colour: Oxide Red

CONCRETE CONTACT:

• Surface preset: mechanical cleaning

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SPHERICAL VALVE DN850 PN36

Ed. 12/2013 “L12004-0_850 Chap 4” Chapter 4
Ed. 12/2013
“L12004-0_850 Chap 4”
Chapter 4

MAINTENANCE

Chap. GCZ Ed. 12/2013 Maintenance 4 Fabricaciones L12004-0_850 Chap 4
Chap.
GCZ
Ed. 12/2013
Maintenance
4
Fabricaciones
L12004-0_850 Chap 4

4.1

CONTROL AND ROUTINE MAINTENANCE

These instructions have been drawn-up with the intention of being a guide for performing preventive and programmed maintenance in order to keep all appliances perfectly efficient.

4.1.1

Maintenance Of The Mechanical Parts

DIMENSIONS AND WEIGHTS OF VALVE MAIN PARTS

DESCRIPTION

DIMENSIONS (MM)

WEIGHT (KG)

Body valve

1328 x 1540 x H. 1740

9774.4

Shutter

1150 x 962 x H. 950

1072.5

Fixed ring

Ø865 - L=19

10.5

Bushing support

Ø375 - L=160

40.35

Flange for bushing support

Ø460 - L=47

21.1

Mobile ring

Ø995 - L=131,5

106.7

Right trunnion

Ø300 - L=239

112.3

Left trunnion (cylinder side)

Ø300 - L=257

119.8

Actuator lever

300 x 250 x 1275

227.8

Cylinder support

360 x 240 x H. 185

20

Hydraulic cylinder

Bore Ø260 - Rod Ø80 - Stroke 670

390.9

Upstream pipe

Ø1150 - L=645

494

Central counterweight

900

x 900 x 80

534.1

Lateral counterweight

900

x 900 x 70

443

Dismantling joint

Ø1150 - L=800

566.3

By-pass

Ø50 - centre to centre distance L=1978 H=400

147.2

MAINTENANCE CHECKS

TYPE OF CHECK

FREQUENCY

Check that the painting cycle of the mechanical structures is in good state. Restore the paint in deteriorated areas after careful cleaning.

Once a year

When the valves remain inactive for a long period of time, a check of the correct functioning of the manoeuvre and sealing parts is recommended, performing the closure manoeuvres completely.

Every three months

Check that the seals have kept the regulation for the correct closure of the valve. If necessary it is sufficient to perform a new regulation by acting on the adjusting screws.

Every three months

Check that all flangings and the O-ring gaskets do not have leaks.

Every three months

Check that the hydraulic connections to the manoeuvre cylinder do not have oil leaks.

Every three months

Check valve internal surface regarding erosion and cavitation. (see photo 1)

Once a year

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Ed. 12/2013 GCZ Chap. Maintenance L12004-0_850 Chap 4 Fabricaciones 4 INFORMATION In case of erosion
Ed. 12/2013
GCZ
Chap.
Maintenance
L12004-0_850
Chap 4
Fabricaciones
4
INFORMATION
In case of erosion and cavitation point it must be record with extension and location. If
possible photos must be taken as part of this report.

All mechanical couplings between rotating moving parts relative to one with respect to the other, are equipped with self-lubricating bushes that therefore do not require periodic greasing.

1
1

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Chap. GCZ Ed. 12/2013 Maintenance 4 Fabricaciones L12004-0_850 Chap 4 4.1.2 Spare Parts (Not Supplied)
Chap.
GCZ
Ed. 12/2013
Maintenance
4
Fabricaciones
L12004-0_850 Chap 4
4.1.2 Spare Parts (Not Supplied)
 

SPARE PARTS LIST

DB NUMBER

DB CODE

DESCRIPTION

QUANTITY

262276

273A019

Mobile ring

n° 2

262261

273A005

Fixed ring

n° 2

 

CARCO PRP 02A06

CARCO Seal, CARCO PRP series, PRP 02A06-9010-A-32-N code, dim. 873/9011/9.5

 

262332

873/901/9.5

n° 4

 

CARCO PRP 02A06

CARCO Seal, CARCO PRP series, PRP 02A06-9950-A-32-N code, dim. 967/995/9.5

 

262331

967/995/9.5

n° 2

 

BOCC DEVA.BM 362/9P 300X310X120

DEVA.BM 362/9P self-lubricating bushing,

 

262270

300x310x120

n° 2

259760

CARCOTEX UG

CARCO Seal, CARCOTEX/UG/S820I

n° 4

300/330/20

300/330/20

240219

OR 4

OR Seal, Ø4, NBR 70

mt 8

239797

OR 8

OR Seal, Ø8, NBR 70

mt 10

239798

OR 10

OR Seal, Ø10, NBR 70

mt 20

259763

O-RING 3 INT.38

ANGST+PFISTER O-Ring seal, Ø3, int.38, ORM 0380-30 code

n° 2

259762

O-RING 3 INT.14

ANGST+PFISTER O-Ring seal, Ø3, int.14, ORM 0140-30 code

n° 4

262223

O-RING 6 INT.18

O-Ring seal, Ø6, int.18

n° 6

262781

273A022-RICAMBI

Spare parts for hydraulic cylinder

n° 1

Spare parts for hydraulic cylinder n° 1 INFORMATION The use of non-original Vortex Hydra spare

INFORMATION The use of non-original Vortex Hydra spare parts is not recommended. Their use will make any warranty become null and void.

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SPHERICAL VALVE DN850 PN36

Ed. 12/2013 “L12004-0_850 Chap 5” Chapter 5
Ed. 12/2013
“L12004-0_850 Chap 5”
Chapter 5

PLANT LIFE PHASES

Chap. GCZ Ed. 12/2013 Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5 5.1 HANDLING AND
Chap.
GCZ
Ed. 12/2013
Plant Life Phases
5
Fabricaciones
L12004-0_850 Chap 5
5.1 HANDLING AND TRANSPORT

The plant is designed to be transported to the place of final installation. Once transported to the site of installation, the appliances are set-up and connected to the energy sources (electric, hydraulic), that are included in the supply (electrical panel). The handling and transport operations must be performed with great care, only by specialised qualified staff, managing and co-ordinating the operations in a way to guarantee safety of the persons and no damage to the valves.

Check suitability of the lifting and transport means of the machines, of the handling path and the access routes to the deposit position. Coordinate the persons present on site in a way to guarantee the safety of unloading and handling operations. Check that the place where the machines are to be deposited is adequate to house the appliances and suitable for positioning and storage. In particular, check the overall width, height and depth, as well as the conditions of the floor and ground.

Once installation has been performed in the place of production, no other handling or transport opera- tions are envisioned.

If the appliance must be replaced during the life span of the machine, the operator can commission the operation to Vortex Hydra S.r.l. or perform autonomously taking on the fees and responsibility of disas- sembly, handling and any other operation necessary.

Any modification to the plant that is not performed directly by Vortex Hydra S.r.l., i.e. any replacement of components or their modification, must be considered as a substantial modification to the plant itself, with the warranty and all responsibility of Vortex Hydra S.r.l. regarding machine functioning and the safety of the operators consequently becoming null and void.

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Ed. 12/2013 GCZ Chap. Plant Life Phases L12004-0 Chap 5_850 Fabricaciones 5 5.1.1 Handling Of
Ed. 12/2013
GCZ
Chap.
Plant Life Phases
L12004-0 Chap
5_850
Fabricaciones
5
5.1.1 Handling Of The Spherical Valve

For a correct and safety handling of the spherical valve, use the dedicated plates identified in yellow (see fig.1)

1
1
use the dedicated plates identified in yellow (see fig.1) 1 ATTENTION For a correct and safe

ATTENTION For a correct and safe handling, it is very important to use all the plates simultaneously.

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Chap. GCZ Ed. 12/2013 Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5
Chap.
GCZ
Ed. 12/2013
Plant Life Phases
5
Fabricaciones
L12004-0_850 Chap 5

5.2

PACKAGING

The plant is designed to be transported inside one or more containers, crates or lorries. The appliances are fastened inside using ropes (steel or other materials).

5.2.1

Packaging Of The Spherical Valve

To move the case with body valve inside, use the dedicated devices provided for this purpose.

The spherical valve could arrive at destination partially disassembled: the main body with arms blocked in the safety position by a mechanical retainer and the rest (the remaining parts of the arms, the counter- weights, the cylinders and the base) packaged inside one or more cases.

cylinders and the base) packaged inside one or more cases. ATTENTION Before removing the packaging or

ATTENTION Before removing the packaging or safety blocks from the machines, make sure that they are stable. During transport the machines may have moved and be in an unstable position. It is extremely dangerous to unpack the machines before this control because it could move, fall or tip over causing injury to persons or damage to the machines themselves.

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Ed. 12/2013 GCZ Chap. Plant Life Phases L12004-0 Chap 5_850 Fabricaciones 5 5.2.2 Shipping Elements
Ed. 12/2013
GCZ
Chap.
Plant Life Phases
L12004-0 Chap
5_850
Fabricaciones
5
5.2.2 Shipping Elements
2
2
3 Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel.
3
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Chap. GCZ Ed. 12/2013 Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5
Chap.
GCZ
Ed. 12/2013
Plant Life Phases
5
Fabricaciones
L12004-0_850 Chap 5

POS.

DWG.

DESCRIPTION

Q.TY

WEIGHT KG.

 

1 273B000

Body Valve Assembly

2

9774.4

 

2 273A022

Hydraulic Cylinder Øi 260 x 80 x 670

2

390.9

 

3 273A044

Upstream Assembly

2

571.1

 

4 273A036

Dismantling Joint Assembly

2

1484.2

 

5 273A040

By-Pass DN50 PN40

2

147.2

 

6 273A047

Valve’s Embedded Elements

2

121.7

 

7 273A057

Locking Bar Assembly

2

8.7

 

8 273A053

Counterweight

2

4341.5

 

9 273A045

Valve’s Embedded Elements

4

87.6

 

10 273A021

Cylinder Support

2

20

 

11 273A046

Cylinder Support

2

18

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Ed. 12/2013 GCZ Chap. Plant Life Phases L12004-0 Chap 5_850 Fabricaciones 5
Ed. 12/2013
GCZ
Chap.
Plant Life Phases
L12004-0 Chap
5_850
Fabricaciones
5

5.3

ERECTION, ASSEMBLY AND INSTALLATION

Once the appliances are received at the final installation site, the operations can start.

The installation activity envisions:

• the set-up of the appliances;

• the check of assembly alignments;

• the definitive fixing.

It is not possible to generalise these operations as they greatly depend on site conditions: they are ac- tivities that must be evaluated case by case. The presence of several suppliers on site, the access routes for handling the machines, the presence of construction restraints, the amount of labour available, greatly affect installation. So much so that every site can be considered as a unique combination of the above-mentioned factors.

For these reasons it is necessary that all installation activities are performed by expert staff trained in industrial assemblies, under the careful supervision of Vortex Hydra S.r.l. It is not recommended to per- form these activities without advising Vortex Hydra S.r.l.

Once the mechanical assembly has been concluded, proceed with electrical, hydraulic wiring and water connections.

ATTENTION Before removing any safety retainers from the mobile parts, check that the appliance is

ATTENTION Before removing any safety retainers from the mobile parts, check that the appliance is safe, on a stable surface and fixed well, in a way to prevent injury/damage to persons/objects.

5.3.1

Valve Positioning

The following assembling procedure, is based upon the assumption that the axes of the existing pipes and of the foundations give the points of reference needed to correctly execute the site erection. Otherwise if one or both of the references would not be available, it would be necessary to identify them though the stretch of signalling drawstrings. Be careful, when the valve is ready to be unloaded from the truck, follow these instructions (recommended):

1) Unload the two spherical valves 2) IMPORTANT: The valve must be placed on the means of transporting, so that it arrives on site already predisposed for the discharge and lined up to the main pipe as represented in the scheme 3) Set an inclined frame in suitably calculated to hold the valve weight during unload 4) Arrange proper lubrication 5) With the help of hydraulic jacks the valve must slide on metal beams, laided in cement, lubrificated with grease.

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Chap. GCZ Ed. 12/2013 Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5 5.3.2 Valve Alignment
Chap.
GCZ
Ed. 12/2013
Plant Life Phases
5
Fabricaciones
L12004-0_850 Chap 5
5.3.2 Valve Alignment

Before connecting the valve to the conduits it is necessary to prepare the anchorages to the civil works. The first operation is to predispose the basement and regulate it through the 8 bolts M30 (4 for valve basement and 4 for cylinder basement).

4 N.10 M30
4
N.10 M30

Then the valve is positioned on the base structure without fixing completely the 4 screws TE M30. During this operation also 4 washers have to be lodged into the 4 buttonholes on valve and cylinder basement. Then it is possible to proceed to the regulation of valve position according to the measures found with reference to the civil works and existing piping. When the valve is in the right position the nuts of the 4+4 stirrups of basement have to be welded the 4 screws TE M30 must be tighten in order to fix the body valve. Then it is necessary to fix temporary some flange bolts, without tighten they, to keep aligned the valve to the upstream and downstream pipe, and checking that the o-ring seals are in correct position into the seats. At this point, it is possible to proceed with the upper concrete casting on the basement.

to proceed with the upper concrete casting on the basement. ATTENTION It is very important that

ATTENTION It is very important that the screws result in the middle of the slots of the valve base struc- ture, to grant them the possibility to follow the expansion of the pipe with little longitudinal movements.

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Ed. 12/2013 GCZ Chap. Plant Life Phases L12004-0 Chap 5_850 Fabricaciones 5
Ed. 12/2013
GCZ
Chap.
Plant Life Phases
L12004-0 Chap
5_850
Fabricaciones
5

After the valve position is fixed, the hydraulic cylinder (ref. to drawing 273A022) can be placed, adjusted and connected to the system. First of all, the anchoring baseplate of the cylinder (ref. to drawing 273A047) must be put in place and adjusted in order to have the foreseen positioning referred to the valve trunnion axis: after this first ad- justment it can be embedded into the first stage of concrete. After the first stage got dry, it is possible to put in place the hydraulic cylinder and connect it to the base- plate and to the valve lever: it is important to check that the signs on the trunnions indicating the rotor fully closed position are aligned when the hydraulic cylinder is in its closed configuration (low position of the valve counterweight lever, minimum length of the cylinder). If the signs are not aligned, the floor anchoring of the cylinder must be adjusted in order to get the alignment: this operation is fundamental in order to guarantee the valve sealing by the mobile rings. Only when this issue is correctly done it will be possible to mount the counterweight ballast on the lever. The ballast plates (ref. to drawing 273A033) can be mounted once the main plate (ref. to drawing 273A032) is fixed on the lever: by means of a crane, the main plate is put in position between the lever arms and than fixed. On the main plate can now be mounted the threaded rods and, one by one, the other plates. Once all the plates are mounted the nuts can be tightened. Make the last check on the signs on the trunnion and move the lever, using the hydraulic cylinder, in order to open and close the valve : it is important to check that the cylinder can run the entire stroke to check that the extreme lower positions of the lever correspond to fully closed rotor position (signs on the trunnion aligned) and that the extreme higher position correspond to fully opened rotor position. After these checks, it is possible to place the second stage concrete on the cylinder foundation and to place and adjust the locking system, both embedded elements (ref. to drawings 273A045 and 273A047), and locking eye: this latter must be placed and adjusted referring to the position of the eye placed under the main ballast plate and the manual locking pin must be easy to insert and pulled out. Now it is possible to fix the locking system by casting the concrete.

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Chap. GCZ Ed. 12/2013 Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5
Chap.
GCZ
Ed. 12/2013
Plant Life Phases
5
Fabricaciones
L12004-0_850 Chap 5
Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5 INFORMATION During the assembling of the valve rotor

INFORMATION During the assembling of the valve rotor into the valve body, the alignment marks on trun- nions and body must coincide: their alignment indicates the correct “fully closed” position for the rotor. (see fig. 5).

Also during the assembling of the counterweight lever and of the hydraulic cylinder the alignment marks on trunnions and body must coincide: their alignment indicates the cor- rect “fully closed” position for the hydraulic cylinder and the lever: basing on this configu- ration it can be made the positioning, the alignment and the adjustment of the cylinder(s), of the locking pin(s) of the lever and of their connection on the basement.

ROTOR IN CLOSED POSITION

5
5
ROTOR IN CLOSED POSITION 5

5.3.3 Bolts And Nuts Flange Tightening

When all the operations above described have been done, it is possible to tighten completely the bolts of the flanges. During the tightening operations it is essential to make sure that all the cord rings remain correctly positioned. Insert all the bolts on the flanges and tighten them completely as per table in par. 3.9.

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Ed. 12/2013 GCZ Chap. Plant Life Phases L12004-0 Chap 5_850 Fabricaciones 5 5.3.4 Electrical Limit
Ed. 12/2013
GCZ
Chap.
Plant Life Phases
L12004-0 Chap
5_850
Fabricaciones
5
5.3.4 Electrical Limit Switch, Mechanical Position Indicator

Check the electrical limit switch that signal the opened and closed position of the valve, placed on the left side in the same direction of the flow.

6
6

Check also the limit switches that signal the opened and closed position of the mobile rings. Check also the fixing of the graduated plate to the valve body on the cylinder side with screws in the provided holes, and the indicated needle with screws on the external diameter of the level.

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Chap. GCZ Ed. 12/2013 Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5 5.3.5 By-Pass
Chap.
GCZ
Ed. 12/2013
Plant Life Phases
5
Fabricaciones
L12004-0_850 Chap 5
5.3.5 By-Pass
It is necessary to control only the tighten of the bolts. 7 BY-PASS
It is necessary to control only the tighten of the bolts.
7
BY-PASS
to control only the tighten of the bolts. 7 BY-PASS 5.3.6 Electrical, Hydraulic And Water Circuit

5.3.6 Electrical, Hydraulic And Water Circuit

The electrical and instrumentation items must be in position before the welding joints are done, to avoid damage.

For everything about the connections for equipment of this paragraph, the referring drawing are:

VORTEX NUMBER

DESCRIPTION

L12004-SI-CID-000 M.00755

Oil scheme for mobile rings M.00755

L12004-SI-CID-000 M.00756

Oil scheme for mobile rings M.00756

L12004-CBM-M.00755

Terminal connection plan M.00755

L12004-CBM-M.00756

Terminal connection plan M.00756

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Ed. 12/2013 GCZ Chap. Plant Life Phases L12004-0 Chap 5_850 Fabricaciones 5 5.4 COMMISSIONING, INSPECTION
Ed. 12/2013
GCZ
Chap.
Plant Life Phases
L12004-0 Chap
5_850
Fabricaciones
5
5.4 COMMISSIONING, INSPECTION

When installation has been concluded, commission and inspect the plant. As for assembly and installa- tion, these operations are also extremely delicate and must be carried out exclusively by qualified staff under the supervision of Vortex Hydra S.r.l.

INFORMATION All responsibility is declined for interventions not authorised by Vortex Hydra S.r.l. staff All responsibility is declined for interventions not authorised by Vortex Hydra S.r.l. staff

ATTENTION Before starting the appliance, carefully delimit (using fences) the areas at risk affected by the Before starting the appliance, carefully delimit (using fences) the areas at risk affected by the radius of action of large mobile parts (e.g. counter-weights and relative levers), in order to prevent injury/damage to persons/objects.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com

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This document is exclusive property of Vortex Hydra s.r.l. Any duplication, distribution or utilisation without written permission will be persecuted.

Chap. GCZ Ed. 12/2013 Plant Life Phases 5 Fabricaciones L12004-0_850 Chap 5 5.5 DEMOLITION AND
Chap.
GCZ
Ed. 12/2013
Plant Life Phases
5
Fabricaciones
L12004-0_850 Chap 5
5.5 DEMOLITION AND SCRAPPING

Always contact Vortex Hydra S.r.l. Italia when the plant must be replaced or disassembled. At that time it will be possible to analyse the possibility of selling the plant second-hand, without disassembling and scrapping it. If it is decided to proceed with demolition, it will be necessary to prepare a detailed man- agement plan of the operations, considering the risks, carefully planning the activities and identifying the work areas.

planning the activities and identifying the work areas. ATTENTION Demolishing an existing plant is as difficult

ATTENTION Demolishing an existing plant is as difficult and complex as building a new one. It must be remembered that the machinery can contain hydraulic oil, electrical material and metal and plastic parts. It is the duty of the management of the new building to consult and find operators authorised to demolish and scrap the plant.

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411

Vortex Hydra s.r.l. - Via Argine Volano 355 44034 Fossalta (Ferrara) Italia - Tel. +39.0532.879.411 - Fax +39.0532.866.766 - e-mail: info@vortexhydra.com
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This document is exclusive property of Vortex Hydra s.r.l. Any duplication, distribution or utilisation without written permission will be persecuted.