These installation and maintenance instructions must be read in full and completely understood before the installation!

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1 NEOTECHA These installation and maintenance instructions must be read in full and completely understood before the installation! 1. General information on the installation and maintenance instructions These installation and maintenance instructions contain the information necessary for safe and correct installation and operation of the valve in the prescribed manner. If any difficulties are encountered during installation or operation which cannot be solved with the aid of the installation and maintenance instructions, please contact the supplier/manufacturer for more information. These installation and maintenance instructions comply with the relevant applicable EN safety standards. When installing the fitting, the operator or the person responsible for the design of the installation must ensure that applicable national regulations are complied with. The manufacturer reserves all rights to make technical changes and improvements at any time. The use of these installation and maintenance instructions assumes that the user is qualified to Qualified Personnel level. Operating staff must be given appropriate training in the operating and maintenance instructions. 2. Safety Please also read through these notes carefully Meaning of the symbols Contents 1 General information on the installation and maintenance instructions 1 2 Safety 1 3 Transport/Storage 2 4 Features 3 5 Identification 3 6 Installation 3 7 Commissioning 4 8 Notes on dangers during installation, operation and maintenance 5 9 Operation 5 10 Servicing 5 11 Cause and remedy of operating faults 5 12 Decommissioning 6 13 Disposal 6 14 Customer service 6 15 Validity of the Installation and Maintenance Instructions 6 This symbol in the operating instructions indicates dangers General potential danger due to: a) failure to observe the instructions b) improper use c) insufficiently qualified personnel 2.3. Correct Use Area of application SG Sight glasses equipped with 2 large borosilicate sight glasses and drip nozzle are valves which facilitate the observation of highly corrosive, hot liquids and gases over a range from the smallest quantity to large volume flows. The SG is suitable for vertical and horizontal mounting. Ball check valves with integral sight glass are valves which facilitate a controlled retention or isolation of highly corrosive, hot liquids and gases. A special feature of the is the gas tight seal. The soft elastomer seal inserted in the body guarantees a perfect shut off for gases. The interchangeable soft seal can be supplied in various elastomers as far as Perfluorelastomer. The is suitable for vertical and horizontal mounting. When mounted horizontally, the volume flow must be high enough to press the ball into the seat via the guides. SG / All product-wetted components are manufactured in PFA and PTFE materials. The materials used for components subject to pressure are GGG40.3, polyester coated and borosilicate glass Method of Operation SG The medium can flow through without restriction in the working direction (direction of arrow) and drip onto the drip nozzle. In the opposite direction, it is not possible to observe the smallest quantity. The medium can flow through without restriction in the working direction (direction of arrow). In the opposite direction, the ball closes the passage, as soon as sufficient pressure has built up under the ball and pressed it into the ball seat. Emerson reserves the right to change the contents without notice NEOJV-0019-EN-1307

2 Performance Data Pressure range : 16bar - 20Pa Temperature range : see table Nominal diameters : DIN PN16 DN 25 ANSI 150lbs 1 DN40 1 1/2 DN50 2 DN80 3 Test pressure : 1.5 x PN = 24bar Ball Check Valve Flow values DN Kv Cv Kv in m 3 / hr Water Δp = 1 bar Cv in USG / min Water Δp = 1 bar Pressure-Temperature diagram bar 20Pa Usage Restrictions The product-wetted components must be classified as resistant to the product to be conveyed. Refer to appropriate literature or consult the manufacturer or distributor for advice Modification Prohibition Mechanical modifications to the valves or the use of other manufacturers parts for repair purposes are not permissible. Safety is not guaranteed if this requirement is disregarded. Repair work must only be carried out by the manufacturer s trained personnel Warning about foreseeable misuse Valves and their accessories must not be misused as climbing aids Duty to comply with the instructions for operation, maintenance and servicing These operating instructions are part of the delivery package and must be kept clean and made accessible to the user Sources of Danger Chemical external The valve bodies are made from Spheroguss GGG40.3 coated with a 2-part polyester paint. The coating can be attacked externally by strong solvents, leading to corrosion of the body. If damage of this nature occurs, the effects on the environment should be investigated and the damage to the coating made good Mechanical Excessive oscillation and vibration should be avoided, to prevent the bolts loosening Electrical If static charges can lead to explosions, the valve must be earthed by means of the earthing accessory. Alternative: Use valves with electrically conductive linings. Please contact your supplier! Thermal Due to the range of operating temperatures between -40 C and +200 C, surface temperatures from -40 to +200 C can be present on the valve bodies. Suitable precautions should be taken to protect against burns due to high or freezing temperatures. Insulated gloves must be worn during installation and service work. In case of fire, the mechanical strength of the PFA coatings is no longer guaranteed above 200 C. Emerson reserves the right to change the contents without notice page 2

3 2.5. Requirements for the Operator This means people who are familiar with the erection, installation, commissioning, operation and maintenance of the product and have appropriate qualifications relating to their activities and functions, such as e.g.: - instruction in and duty to comply with all installation-related, regional and internal works regulations and requirements - training or instruction in accordance with the Safety Standards for personal care and use of appropriate safety equipment and protective workgear, like e.g. personal protection equipment (insulated gloves or similar), suitable for the operating conditions. Furthermore, these people must have read and understood these instructions. 3. Transport/Storage The valve is supplied with protective covers. Do not remove the protective covers until immediately prior to installation. They protect the PFA surface from dust and mechanical influences Transport - transport temperature -20 C to +65 C - protect against external force (impact, shock, vibration) - do not damage the coating Sight glass 3.2. Storage - storage temperature -20 C to +65 C, dry and dust-free. - a drying agent or heating is required in damp storage areas to protect against condensation Handling prior to installation - do not remove the protective covers until immediately prior to installation - protect against the effects of weather, such as dampness (or else use a drying agent) - proper treatment prevents damage 4. Features Flange drillings : DIN 2501 PN16 or ANSI B16.5 Class 150 Face-to-face dimension : DIN 3202/T1/F1 and F17 Bolted joint : Hexagon bolts steel 8.8 galvanized * variants Sight glass Blank cover : PTFE solid ball as standard PTFE hollow ball, floating, for overflow safety device PTFE ball with steel core for exhaust backwash : Borosilicate glass : Steel cover with virgin PTFE liner Parts list Item Description Material 1 Body GGG 40.3 polyester coated PFA lined 2 Cover GGG 40.3 polyester coated 3 Sight glass Borosilicate glass DIN Seal IT Hexagon bolt Steel 8.8 galvanized 6 Hexagon nut Steel 8.8 galvanized Dimensions and weights DN 3 Weight mm inches øa B E L 2 H øf øg S ød TK 3 Nxd 3 kg x / x x x ) Face-to face dimension according to DIN 3202/T1/F1 and F17 3) Flange drillings according to ANSI B16.5 Class 150 on request Emerson reserves the right to change the contents without notice page 3

4 Standard version: Flange PN 16 DIN 2501 Face-to-face dimension DIN 3202/T1/F1 and F17 without soft seal PTFE solid ball Bolts in steel 8.8, nuts in steel 8, items 8/9 Parts list Item Description Material 1 Body GGG 40.3 polyester coated PFA lined 2 Cover GGG 40.3 polyester coated 3 Sight glass Borosilicate glass DIN a 2) Cover plate Steel KBL HII with PTFE liner 3b Cover Steel 37 with PTFE liner 4 Seal IT Ball guide PTFE/glass 6 Solid ball Virgin PTFE 6a Hollow ball Virgin PTFE 6b Steel core ball Virgin PTFE/steel 7a 3) Soft seat Perfluorelastomer (Kalrez ) 7b 3) Soft seat FPM (Viton ) up to 140 C 7c 3) Soft seat EPDM max. temp. 120 C 8 Hexagon bolt Steel 8.8 galvanized 8a Hexagon bolt Stainless steel A Hexagon nut Steel 8. galvanized 9a Hexagon nut Stainless steel A4 2) Cover plate, Item 3a, in steel K.Bl.H II can be supplied with certificate to DIN B (if glass is not permissible, for example). 3) If soft seal, Item 7, is required, please quote material a, b or c. Registered trade mark of E.I. Dupont de Nemours SA Ball check valve Glass cover Dimensions and weights DN 3 Weight mm inches øa B E L 2 H øf øg øk S ød TK 3 Nxd 3 kg x / x x x ) Face-to face dimension according to DIN 3202/T1/F1 and F17 3) Flange drillings according to ANSI B16.5 Class 150 on request 4.1. Installation position The valve can be installed from a horizontal to a vertical position Sealing Soft seal and solid ball, installed vertically, provide a gas-tight shut off. Without a soft seal, a pressure difference from 1.5 to 3 bar is required to achieve a drip tight shut off, depending on the installation position. Blank cover 5. Identification CE identification on the valve in accordance with Pressure Equipment Directive 97/23/EC > DN25 Additional identification on the valve in accordance with DIN 19, such as: Rating plate without CE mark Manufacturer Country of manufacture Rating plate with CE mark Serial number Equipment type CE-mark with 4-digit number of notified body Year of manufacture Additional identification on the valve in accordance with DIN 19, such as: DN, PN, manufacturer s logos of the Neotecha AG company. The identification of the valve body material is cast onto the valve. Emerson reserves the right to change the contents without notice page 4

5 6. Installation 6.1. Installation Preparation for installation The dimensions of the valves have been chosen so that the sight glasses / ball check valves can be clamped between all current DIN and ANSI flanges. It should be noted here that valves designed for a specific flange standard no longer fit other flanges. The flanges must meet the following requirements: - Cleaned and undamaged mating surface. - The mating sections in the pipeline must be to the same connection standard as the valve which is to be installed. - The appropriate flange bolt hole arrangements in the various flange standards and diameters allow the valve to be centered by passing the flange bolts through the holes in the flanges. - The flange bolts must be centrally aligned in the holes in the valve flanges. Flange packings are not required with flanges with flat sealing surfaces. Additional packings may possibly be required with rubberized flanges Installation position The valve can be installed from a horizontal to a vertical position. (With the ball check valve, the ball is guided by 4 ribs) 6.2. Installation in the pipeline With sight glasses / ball check valves, the flow direction has to be right. SG In the working direction (direction of arrow), the medium flows over the drip nozzle, which allows the medium flowing through to be closely observed. The medium can flow through without restriction in the working direction (direction of arrow). In the opposite direction, the ball closes the passage, as soon as sufficient pressure has built up under the ball and pressed it into the ball seat. The flow direction must be observed at the time of installation! A sight glass / ball check valve is not a crowbar! Please do not use it to force the flanges apart, as this would lead to damage to the PFA coating and seat. To avoid damage to the PFA coating, the protective covers should only be removed immediately prior to installation. It is not advisable to use the valve for positioning pipelines in new systems. Sparks which occur during spot welding can damage the seat. Use adjusting pieces instead. Final welding of the flange with the valve in position will lead to severe damage to the valve seat due to the high temperature. Always use all flange bolts, even on low pressure systems. The valve should never be pressurized if one of the flange bolts is missing Step-by-step installation 1. Remove the plastic protective covers. 2. Check the mounting flanges (damage, soiling). 3. Check that the distance between flanges matches the face-to-face dimension of the ball check valve. Before installing the valve, spread the flanges apart sufficiently using a suitable tool. 4. Check that the direction of flow of the valve matches that of the pipeline system. 5. Slide the valve between the opened flanges. 6. Now insert the flange bolts through the adjusting holes. 7. Tighten the flange bolts hand-tight as the tool holding the flanges apart is gradually removed. Make sure that the flanges remain correctly aligned. 8. Tighten all flange bolts in opposite pair sequence. Refer to following table for tightening torques. Recommended tightening torques (Nm) of bolted connections for installing isolation valves Recommended torques DN Bolts Torque mm inches Nm x M /2 4 x M x M x M Emerson reserves the right to change the contents without notice page 5

6 Final checks - checking the operation of the valve - cleaning and flushing the pipeline before the first closure. 7. Commissioning 7.1 General commissioning Before commissioning, the information relating to material, pressure and temperature should be checked against the installation diagram of the pipeline system. Any debris left in the pipeline and valves (dirt, welding beads, etc.) will inevitably lead to leakage. Before each commissioning of a new system or re-commissioning of a system after repair or modification, it must be ensured that: - all installation and assembly work has been completed in accordance with the regulations! - commissioning is only undertaken by Qualified Personnel - the valve is in the correct operating position. - new protective equipment is installed or existing protective equipment repaired. 8. Notes on dangers during installation, operation and maintenance Safe operation of the valve is only guaranteed if it has been correctly installed, commissioned and maintained by qualified personnel (see Qualified Personnel ), taking into account the warning information of these installation and maintenance instructions. In addition, compliance with the general installation and safety regulations for the pipeline or plant construction, together with the correct use of tools and protective equipment, must be ensured. The installation and maintenance instructions must be strictly followed when any work is carried out on the valve or when handling the valve. Non-observance can result in injuries or damage to property. 9. Operation This valve must not be operated. 10. Servicing No routine maintenance or lubrication is required. However, for systems with high temperatures, an inspection for leakage at the flanges should be carried out shortly after installation. The different coefficients of expansion and temperature expansions can cause settlement of the PFA. Tightening the bolts once again will rectify this problem. This process may possibly have to be repeated several times. 13. Disposal Hand in the correctly cleaned valve to the scrap material recycling plant. Badly cleaned valves can cause severe burning of the hands and other parts of the body. If the valve is passed on to a third party, the manufacturer does not guarantee the safety of the equipment. 14. Customer service For further information or technical advice, please contact: Neotecha A.G. Etzelstrasse CH-8634 Hombrechtikon / Switzerland Telephone: +41 (0) Fax: +41 (0) Validity of the Installation and Maintenance Instructions These installation and maintenance instructions are valid from until the next revision. 11. Cause and remedy of operating faults If the valve function or operating action is faulty, a check should be made to ensure that the assembly and installation work has been carried out and completed in accordance with the installation and maintenance instructions. The information relating to material, pressure, temperature and direction of flow should be compared with the installation diagram of the pipeline system. Furthermore, a check should be made on whether the installation conditions correspond to the technical data given in the data sheet or on the rating plate. The safety regulations must always be observed when troubleshooting. 12. Decommissioning Removal of the valve for repair or servicing is often carried out carelessly, as the valve has to be repaired or replaced in any case. However, it is recommended that the valve be removed with care, without damaging the PFA, so that the possible cause of damage can be determined after removal. Attention! Check that the pipe is depressurized and drained. With corrosive, inflammable, aggressive or toxic media, flush out and ventilate the pipeline system. 1. Only allow assembly work to be carried out by qualified personnel (see Section 2.5). 2. Loosen all flange bolts and withdraw them until the valve can be removed. 3. Spread the flanges apart using a suitable tool and withdraw the valve. Emerson reserves the right to change the contents without notice page 6

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