MAPAG Butterfly valve - Type BK For cryogenic applications Installation, Maintenance and Operating Instructions 2 BK 70 en 8/2010
2 2 BK 70 en Content 1 Method of operation... 3 2 Cleaning and maintenance... 3 2.12.Replacement of the sealing elements... 4 2.2.1 Replacement of the sealing elements on bodys with welding ends... 4 2.3.2 Replacement of the sealing elements in the monoflange configuration, where the sealing ring is attached directly to the body... 5 2.4 Replacement of mechanical parts on the actuator side... 5 2.5 Replacement of mechanical parts on the cover side... 6 2.6.1 Replacement of mechanical parts on the cover side >PN16... 6 3 Qualifications... 7 3.1 ATEX... 7 Read these instructions first! These instructions provide information about safe handling and operation of the valve. If you require additional assistance, please contact the manufacturer or manufacturer s representative. Addresses and phone numbers are printed on the back cover Save these instructions! Subject to change without notice. All trademarks are property of their respective owners.
2 BK 70 en 3 1 Method of operation The purpose of MAPAG Type BK butterfly valves is to shut off pipes and to regulate the flow of products in both directions. Type BK butterfly valves are provided with double O-ring. It can be used for liquids or gases between - 273 C and + 200 C, depending on the medium and the configuration of your system. Information about the exact application area for your Type BK butterfly valve can be found in the documentation compiled for your order. The butterfly valve has been designed to have doubleoffset bearings in order to guarantee that the sealing elements have a long useful life. There is practically no friction when it closes. Type BK butterfly valves have a neck extension to enable them to be insulated for their planned use in low temperature ranges. This extension guarantees that the gland packing which provides external sealing is accessible even when the valve is insulated. The low temperatures are not transferred to the actuator either. MAPAG Type BK butterfly valves can be operated with all types of actuator (manual, electric, pneumatic or hydraulic). There is a mark on the actuator shaft as well as one on the O-ring side of the body. The valve is closed when the two marks are in line with each other (Fig. 1). Fig. 1 306 Bolt 302 Sealing ring 301 Sealing ring 320 PTFE profile O-ring Position of the installed shut-off disc 321 Copper profile O-ring 2 Cleaning and maintenance Type BK butterfly valves require typically no maintenance. Check the butterfly valve regularly to make sure it is not leaking. You should replace the sealing elements (320, 321) after two years at the latest (Fig. 2). When you are doing this, make sure you also check the condition of the other seals, i.e. the O-ring (107), the O-ring (471) and the packing (451). Do not forget to check the sealing rings (301, 302), too. In some versions of the Type BK butterfly valve the sealing ring (302) is screwed directly to the body. The sealing ring (301) ring is not included in this case. Fig. 2 Checking that the butterfly valve does not leak In order to avoid long shutdowns due to maintenance, please order the sealing elements (320, 321) in good time (Fig. 2 and 3). If the medium carries contaminants that may have an adverse effect on the tightness of the butterfly valve you will need to clean the sealing surface of the shut-off disc on a regular basis. Contamination can damage the sealing surface of the disc or the sealing elements. Do not use any agents to remove residues that might attack the sealing surface or the sealing elements. Use water, soap suds or other liquid solvents and a soft, lintfree cloth instead. CAUTION: Do not under any circumstances use files or sandpaper. Do not use any cleaning agents that might cause undesirable chemical reactions with the residues of the medium or might attack the sealing elements. If you outsource the butterfly valve cleaning operation, it is essential that you pay attention to the dangers of the medium being used as well as to any residues that may be present inside the valve cavities.
4 2 BK 70 en 2.1 Replacement of the sealing elements Please proceed as follows when you want to replace the sealing elements (Fig. 4: 320, 321) on the butterfly valve: Fig. 5 Opening the shut-off disc 2.1.1 Replacement of the sealing elements on bodys with welding ends Fig. 3 Sealing element - configuration 1 (Type BK, triple bearing construction, weld-end) 1. Remove the butterfly valve when it is in the closed position. Instructions how to remove the valve can be found in section 1 of the manual 'General instruction manual for heavy-duty valves (section 1)', 2B70. For maintenance purposes the weld-end valve has to be cut off from the pipe using suitable equipment. 2. Secure the butterfly valve in position, so that it cannot move or tip over. Fig. 6 Welding ends 306 Bolt 302 Sealing ring 301 Sealing ring 320 PTFE profile O-ring 321 Copper profile O-ring Fig. 4 Sealing element - configuration 2 (K592) 3. Open the shut-off disc by moving it to the left, so that it is in the 180 position and the sealing ring is exposed. If you turn the shut-off disc by moving it to the right or by turning it beyond the 180 position, the sealing elements will be damaged (Fig. 5). The shut-off disc must not hit against the body. Now secure the shut-off disc for example with wooden wedges in order to eliminate the danger of crushing. Make sure that you do not damage the sealing area of the shut-off disc while you are doing this. 4. The remaining operations you need to carry out in order to remove the sealing elements depend on the configuration (Fig. 3; configuration 1; Fig. 4: configuration 2) and - if relevant - the version of your butterfly valve (Fig. 6 and 8). You will find the instructions for bodies with welding ends in section 2.1.1. and for the monoflange configuration, in which the sealing ring (302) is screwed directly to the body, can be found in section 2.1.2. Fig. 7 Changing the sealing elements Remove the bolts (Fig. 7: 313). You can now pull the following parts off one after the other and replace them if necessary: 1. the retaining ring (310), 2. the sealing ring (301) and 3. the elastic sealing element (323). Then remove the bolts (203). You can now pull the following parts off one after the other and replace them if necessary: 4. the clamping ring (202) and 5. the sealing element (322). Installation is carried out by completing the same operations in the opposite order. Check that the butterfly valve is tight before fitting it again. Information about the installation operations can be found in part 1 of the instruction manual 2B70.
2 BK 70 en 5 2.1.2 Replacement of the sealing elements in the monoflange configuration, where the sealing ring is attached directly to the body Gland packing (451) Bearing (425) Lengthing joint (102) Actuator shaft (401) Fig. 8 Monoflange configuration Remove the bolt (Fig. 4: 306) You can now pull the following parts off one after the other and replace them if necessary: 1. the sealing ring (302), 2. the copper profile sealing element (321), 3. the sealing ring (301) and 4. the PTFE profile sealing element (320). Installation is carried out by completing the same operations in the opposite order. Check that the butterfly valve is tight before fitting it again. Information about the installation operations can be found in part 1 of the instruction manual. 2.2 Replacement of mechanical parts on the actuator side Proceed as follows to replace mechanical parts on the actuator side: 1. Start off by removing the bracket (Fig. 9: 501) and then pull the coupling (504) down (Fig. 9). 2. Open the shut-off disc by moving it to the left, so that it is in the 180 position and the sealing ring is exposed (Fig. 5). If you turn the shut-off disc by moving it to the right or by turning it beyond the 180 position, the sealing elements will be damaged. The shut-off disc must not hit against the body. Now secure the shut-off disc - for example with wooden wedges - in order to eliminate the danger of crushing. Make sure that you do not damage the sealing area of the shut-off disc while you are doing this. Nut (104) Bolts (412) O-ring (107) Bearing bushing (411) Bearing (424) Trust bearing (404) Fig. 10 Mechanical parts on the actuator side 4. Undo the nut (Fig. 10; 104). You can now pull the lengthing joint (102) off over the actuator shaft (401). The following parts are now accessible and can be replaced if necessary: - the gland packing (451) - the bearing (425) and - the O-ring (107). Coupling (504) Bracket (501) Nut (455) Washer (456) Disc spring (457) Gland (450) Stud bolt (458) Fig. 9 Screw connection of the gland 3. Undo and remove the nut (455), the washer (456) and the disc spring (457) and pull the gland (450) out (Fig 9). Fig. 11 Removal of the locking plate and the nut 5. Bend the locking plate (Fig 11: 447) downwards. Undo the nut (445) now and remove both of them. Then pull the actuator shaft (Fig. 10: 401) out. 6. Undo the bolts (FIg. 10:412). The bearing bushing (411) can now be pulled out of the body and the bearing (424) and the thrust bearing (404) can be replaced.
6 2 BK 70 en Installation is carried out as follows: 7. Insert the actuator shaft (401) through the body into the shut-off disc (Fig. 12). Push the thrust bearing (404) and then the bearing bushing (411) with the bearing (424) already fitted onto the actuator shaft (401). Tighten the bearing bushing (411) with the bolts (412). Check whether the actuator shaft moves freely by turning it backwards and forwards repeatedly. Make sure that the thrust bearing (404) has been fitted properly. The rest of the installation process is carried out by completing the same operations as before, except in the opposite order. Please do not tighten the nut (455) to the locking bolt (458) until it reaches the stop, because the disc spring (457) will be damaged if you do (Fig. 9). The tighter you screw on the nut (455), the higher the resistance on the actuator shaft (401). When you attach the coupling (504), make sure that the two red points are aligned in accordance with the shut-off disc. Check that the butterfly valve is tight before fitting it again. Information about the installation operations can be found in part 1 of the instruction manual 2B70. 2.3 Replacement of mechanical parts on the cover side Proceed as follows to replace mechanical parts on the cover side: 1. Open the shut-off disc by moving it to the left, so that it is in the 180 position and the sealing ring is exposed (Fig. 5). If you turn the shut-off disc the wrong way or turn it further than the 180 position, the sealing elements will be damaged. The shut-off disc must not hit against the body. Now secure the shutoff disc for example with wooden wedges in order to eliminate the danger of crushing. Make sure that you do not damage the sealing area of the shut-off disc while you are doing this. 2. Remove the bolts (413) from the opposite side of the butterfly valve from the actuator. 3. Force the pivot (403) from the body using both threads. 4. You can now pull out the O-ring (471) and the thrust bearing (420) and replace them if necessary. Installation is carried out by completing the same operations in the opposite order. Check that the butterfly valve is tight before fitting it again. Information about the installation operations can be found in part 1 of the instruction manual 2B70. Actuator shaft (401) Fig. 12 Bolts (412) Bearing bushing (411) Bearing (424) Trust bearing (404) Mechanical parts on the actuator side Fig. 13 Mechanical parts on the bottom shaft side, lower pressure classes 2.3.1 Replacement of mechanical parts on the cover side >PN16 Proceed as follows to replace mechanical parts on the cover side: 1. Open the shut-off disc by moving it to the left, so that it is in the 180 position and the sealing ring is exposed. If you turn the shut-off disc the wrong way or turn it further than the 180 position, the sealing elements will be damaged. The shut-off disc must not hit against the body. Now secure the shutoff disc - for example with wooden wedges - in order to eliminate the danger of crushing. Make sure that you do not damage the sealing area of the shut-off disc while you are doing this. 2. Remove the stud bolts (413) and nuts (414) from the opposite side of the butterfly valve from the actuator.
2 BK 70 en 7 3. Force the pivot (403) from the body using both threads. 4. You can now pull out the O-ring (471), sealing (472) and the thrust bearing (420) and replace them if necessary. Installation is carried out by completing the same operations in the opposite order. Check that the butterfly valve is tight before fitting it again. Information about the installation operations can be found in section 1 of the instruction manual 2B70. 3 Qualifications 3.1 ATEX If ATEX is stated in the nameplate for the individual valve the ATEX requirements are also valid for that valve. In this case the valve is ATEX certified and the maintenance and service of the valve is allowed to be done only by qualified METSO-personnel or by ATEX qualified Service people. See separate METSO instructions for ATEX requirements or contact Metso Sales and Service for more information. Fig. 14 Mechanical parts on the bottom shaft side, higher pressure classes
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