LSSN Butterfly Valve Installation Operation Maintenance Licence Number: 5326 www.challengervalves.com.au 1
Index 1. INTRODUCTION 1.1 Design Features 3 1.2 Flange and Pipe Compatibility 4 1.3 Operating Restrictions 4 1.4 Product Storage 4 1.5 Product Marking 5 2. INSTALLATION INFORMATION 2.1 Installation Instructions 5 2.2 Manual Operator Installation 8 3. MAINTENANCE AND REPAIR 9 4. ASSEMBLY /DISASSEMBLY INSTRUCTIONS 9 5. TECHNICAL 5.1 Dimensions and Weights 10 5.2 Torque 11 5.3 CV Valves - Sizing 11 5.4 Trouble Shooting 12 5.5 Warranty 12 2
1. INTRODUCTION 1.1 DESIGN FEATURES Designed for use in AGA type 1 applications Emergency or appliance isolation valves. Available in lugged design only Wafer not available for AGA gas application. Flange holes comply with AS2129 E & ANSI Class 125/150 dimensions. The face-to-face dimensions are designed to comply with ISO5752, BS5155. Through-shaft design. Disc-to-seat interface provides bubble-tight shut-off with reduced torque and extended service life. Factory tested to 110% of full rated pressure in both directions before shipping. STEM RETAINING SYSTEM The stem is securely contained in the body by means of a retaining washer and circlip situated on top of the shaft and fixed into a groove in the body. For maintenance, with only a small hand tool, the circlip can be removed, the shaft then withdrawn, and the valve easily dismantled. STEM BUSHING Heavy duty Acetal bushing aligns and supports the stem and absorbs side thrust STEM SEAL Double - U cupseal design is self-adjusting and gives positive sealing in both directions to prevent external substances from entering the stem area. STEM & DISC DRIVE CONNECTION "Challenger features all the benefits of a high strength one piece through stem design. The disc drive connection is achieved by using a close tolerance Double D arrangement. One piece high strength stem design No disc retaining screws or pins 3
SEAT "Challenger valves are designed with a unique seat locking feature and a full encapsulating liner providing seat retention features which virtually guarantee elimination of any seat movement during both seating and unseating operations. CHALLENGER VALVES HAVE PRIMARY AND SECONDARY SEALING FEATURES The primary seal is obtained by an interference fit of the unique moulded seat flat with the disc hub with the seat firmly retained within the body recess. Sealing capabilities do not rely on external flanging. The secondary seals are achieved by having an interference fit between the stem diameter and the seat hole, plus further added pressure from the moulded "O rings. These three sealing actions are unique in the design to achieve higher pressure ratings and virtually guarantee the prevention of any line media from escaping into the body/shaft area. 1.2 FLANGE AND PIPE COMPATIBILITY Challenger Butterfly Valves are designed to fit between the following piping flanges: AS2129 Table E Lugged Pattern ANSI 125 Cast iron flanges ANSI 150 Steel flanges Note: When installing valves in schedule 80 piping, make sure the valve is properly centered between the pipe flanges to prevent disc edge damage since the clearance between the disc O.D. and the pipe I.D. is reduced. If there is a compatibility question, compare the minimum pipe I.D. 1.3 OPERATING RESTRICTIONS Pressure Range: 1050kpa for AGA applications Temperature Range: 18 C to 100 C 1.4 PRODUCT STORAGE The valves should be stored with the disc in the partially open position. The valves should be stored indoors in a clean, dry, well-ventilated place away from corrosive materials and protected from excessive dust and dirt. The valves should be stored on a rack or pallet off the floor and arranged to prevent damage during handling. Keep valves out of direct sunlight and in a cool location to prolong elastomer life. Valves should be protected to prevent damage to the flange faces, disc sealing edge and operator. 4
1.5 PRODUCT MARKING All Challenger Butterfly Valves are equipped with an identification tag attached to the valve neck. This tag provides the model number, max pressure rating, valve materials and unique serial number. The valve neck also provides the size of the valve. 2. INSTALLATION INFORMATION Challenger butterfly valves are designed for use between the faces of AS2129 E & ANSI 125 and 150 pound flat, raised face, slip-on or weld-neck flanges at the pressure indicated on the nameplate. Flange gaskets should not be used. Consideration should be given to the proper piping alignment prior to the installation of any cast iron lug bodied valve. All Challenger butterfly valves are bi-directional with the ability to control flow equally in either direction. 2.1 INSTALLATION INSTRUCTIONS Step 1. Check to make sure that the pipe flange and valve sealing faces are clean and free from any debris (pipe scale, welding slag, etc.). Step 2. Check the valve nameplate to ensure that the pressure and valve materials are correct for the application. WARNING! Butterfly valves should never be installed where service conditions could exceed the valve ratings. Failure to heed warning may result in personal injury or property damage. Step 3. The seat sealing face on the butterfly valves is wider than the valve body providing a leak proof seal when compressed between pipe flanges. Therefore, no flange gaskets are required when installing any butterfly valve. Step 4. To prevent damage to the disc sealing edge before installation, position the disc in the partially open position (Figure 1) so that the disc is still contained within the valve body. FIGURE 1. VALVE IN PARTIALLY OPEN POSITION 5
INSTALLATION INSTRUCTIONS Step 5. Spread the pipe flanges apart allowing the valve to be supplied easily in between the flanges. Step 6. Centre the valve between the flanges and loosely install all flange bolts. (Consult table 1 for the correct flange bolt size and quantity) TABLE 1. FLANGE BOLTING Size mm 50 65 80 100 125 150 AS2129 E M16 X 2.0 M16 X 2.0 M 16 X 2.0 M 16 X 2.0 M16 X 2.0 M20 X 2.5 PCD 114 127 146 178 210 235 No. Holes 4 4 4 8 8 8 ASA125/150 UNC 5/8 UNC 5/8 UNC 5/8 UNC 5/8 UNC 3/4 UNC 3/4 PCD 120.5 139.5 152.5 190.5 216 241.5 No. Holes 4 4 4 8 8 8 Step 7. Slowly open the valve to the full open position (see figure 2) and back to the partially open position ensuring that the disc moves freely without any obstruction. If no obstruction is encountered, return the valve to full open position and hand tighten all flange bolts using the bolt tightening sequence shown in figure 3. FIGURE 2. VALVE IN FULL OPEN POSITION FIGURE 3. BOLTING SEQUENCE 6 1 9 11 4 8 7 3 12 2 5 10 Step 8. Rotate the disc from the fully open position to the fully closed position and make sure that the valve is properly centred and the disc edge does not make contact with the pipe ID. Return the disc to the full open position and tighten the flange bolts following the bolt tightening sequence shown in Figure 3. Do not fully tighten each flange bolt all at once. Tighten each bolt incrementally. several times. Continually cycle the valve from fully open to fully closed to ensure that there is proper disc clearance. 6
Step 9. Bolts on flanges are not to be tightened to the extent where the flange is in contact with the body of the valve. The unique O-Ring sealing design allows positive sealing without the over tightening of the bolts. Over tightening of the bolts results in excessive valve torques restricting operation of the valve and potentially damaging the rubber seal. A gap should be visible after the bolts are tightened (see figure 4) (Refer to Table 2 for recommended bolt tensions). FIGURE 4. O-RING SEALING DESIGN Flange Face Upon flange loading the Double Moulded O-Ring surface area has been calculated to provide sufficient compression to firmly lock and secure liner into mechanical dovetail joint, ensuring effective sealing and reduced torques. Required Gap between Liner & Flange TABLE 2. RECOMMENDED BOLT TENSIONS Valve Size Torque Ft-Ibs 50 30 65 30 80 35 100 40 125 45 150 50 The torque figures contained within this table are based on maximum pressure differentials listed for the product as noted, using standard discs, stems, body and materials of construction at ambient temperatures. Torque figures have reasonable safety factors for normal service, but for valves poorly handled, stored, installed or In service for extended periods of time, may have a dramatic effect on actual torque ratings, additionally for severe or special applications consult Challenger Valves and Actuators. 7
2.2 MANUAL OPERATOR INSTALLATION LEVER HANDLE MOUNTING PROCEDURE Step 1. First, start by loosely assembling the notch plate on the valve top plate. The notch plate should be installed with the notches in the first quadrant of the valve top plate with the stop tabs at the 12 o clock and 3 o clock position. The notch plate should be installed with the stop tabs pointing upward (Figure 5). Step 2. Next, install the handle so that the lever fully engages in the notches when the lever is released and tighten the handle set screw. Step 3. Compress the handle lever and position the disc so that the valve is in the fully closed position. Align the last notch on the notch plate at the 3 o clock position with the handle lever and tighten the notch plate screws. Step 4. Compress the handle lever and position the disc so that the valve is in the fully open position and release the lever. The lever should line-up with the first notch on the notch plate at the 12 o clock position. FIGURE 5. NOTCH PLATE INSTALLATION POSITION 8
3. MAINTENANCE AND REPAIR Challenger butterfly valves are designed for extended service with minimal wear and servicing. No regular lubrication is required. Prior to any replacement or repair, the valve must be removed from the line following these precautions: The pipeline on either side of the valve must be depressurized and drained. Ensure that the disc is in the partially open or full closed position before removing the valve from the line. DO NOT remove a lever operator from the valve while the line is still pressurized. 4. ASSEMBLY/DISASSEMBLY INSTRUCTIONS The Challenger butterfly valves have field replaceable parts. Once the valve is removed from the line, inspect the parts for wear. If valve parts show wear, replacement is necessary. Contact your local distributor for a replacement parts. DISASSEMBLY 1. Close the valve to the almost closed position and remove from pipeline. 2. Remove the operator (notch plate, lever, gearbox unit or actuator). 3. Remove internal circlip (Part No.8) 4. Pull the stem (Part No.4) out through the top of the ISO top mounting flange 5. The disc is then remove by pushing the disc (Part No.3) out side the liner (Part No.2) 6. Remove the liner by collapsing and pushing out the valve body ASSEMBLY 1. Insert the liner by collapsing and pushing into valve body 2. Ensure the smaller hole in the liner, is align with the bottom hole in the valve body 3. Insert shaft seal (Part No.5) and thrust bearing (Part No.6) into the neck 4. Lubricate the disc and stem with a silicone base grease 5. Push the disc into the liner with the internally flatten side hole at the bottom 6. Align the top hole with the matching hole in the liner 7. Insert the shaft (Part No.4) small end first, and push through the disc until fully home. 8. Replace washer (Part No.7) and circlip (Part No.8) 9. Replace valve operator 8 7 6 5 4 1 2 3 9
5. TECHNICAL D B A E F H G J C 5.1 VALVE DIMENSIONS MOUNTING DIMENSIONS AND WEIGHTS 50 65 80 100 125 150 Size MM 50 65 80 100 125 150 A 100 100 100 100 100 100 B 14 14 14 19.1 19.1 22 C 42.9 46 46 52.3 55.6 55.6 D 9.5 9.5 9.5 12.7 12.7 15.9 E 32 32 32 32 32 32 ISO 5211 F07 F07 F07 F07 F07 F07 PCD 70 70 70 70 70 70 Bolting X4 M8 M8 M8 M8 M8 M8 Shaft ISO 11 11 11 14 14 17 Lugged KGs 4.5 5.5 6 9 12 13 F 140 152 159 178 191 203 G 53 68 82 103 129 152 H 30.6 50 69 89 115.6 151.5 J 94 112 128 158 190 210 FLANGE DRILLING AND TAPPING INFORMATION Size MM 50 65 80 100 125 150 AS2129 E M16 X 2.0 M16 X 2.0 M16 X 2.0 M16 X 2.0 M16 X 2.0 M20 X 2.5 PCD 114 127 146 178 210 235 No. Holes 4 4 4 8 8 8 ASA125/150 UNC 5/8 UNC 5/8 UNC 5/8 UNC 5/8 UNC 3/4 UNC 3/4 PCD 120.5 139.5 152.5 190.5 216 541.5 No. Holes 4 4 4 8 8 8 10
5.2 TORQUE CAN BE DETERMINED BY THE FOLLOWING: TORQUE Challenger Butterfly valve Torque chart are for Buna-N seats. Multiply this torque by the application factor 1. 1.0 x Operates once per week or more 2. 1.3 x Operates once per month 3. 1.5 x Operates once per 3 months The charted torques valves given are the total of all internal frictions. The effects of dynamic torsion is not considered in this chart. Torsional capability of valve shafts is not considered in this chart. All torques valve testing was done with standard seats. Size 50 19 65 23 80 34 100 45 125 73 (Nm) 150 118 5.3 Cv VALVES - VALVE SIZING Size 20 30 40 50 60 70 80 90 50 7 16 28 49 77 128 198 219 65 10 23 42 68 108 178 288 316 80 15 36 65 109 167 278 427 498 100 26 16 108 178 275 458 715 815 125 43 98 177 278 447 737 1095 1290 150 59 138 247 398 637 1097 1590 1895 FLOW CO-EFFICIENTS Cv is defined as the volume of water in US gallons per minute that will flow through a given restriction or valve opening with a pressure drop of one psi at room temperature. To convert Cv to Kv divide by 1.1553 11
5.4 TROUBLE SHOOTING: PROBLEM CAUSES REMEDIES Leakage between valve and handle. Stem seal leak. Clean or replace stem seal. Stem packing loose. Check stem seal, bush, washer and cir-clip are installed. Leakage past disc when closed. Disc has travelled past fully closed or not fully closed. Adjust notch plate and handle. Disc is worn or damaged. Clean or replace disc. Rubber seat is worn or damaged. Replace Seat (field replaceable) Leakage between valve and flange. Flange bolts are to loose. Tighten flange bolts as per recommended bolt tensions. Valve body seal damaged. Replace Seat (Field replaceable) Incompatible flange connection Check flange standard is the same as valve flange standard. Valve too hard to open or close. Foreign material jammed in valve Clean & remove obstructions Corroded valve parts Disassemble & clean valve parts. (Stem, Disc, Body) Flange bolts too tight creating Back off flange bolts and tighten bubble seat and disc groove. as per recommended bolt tensions. 5.5 WARRANTY This warranty covers faults in the products construction, material and assembly. Products which are within 12 months from the date of purchase and are found to be defective after inspection by a Challenger authorised representative in construction, material or assembly will be repaired or exchanged with an equivalent product free of charge (at the discretion of Challenger) Warranty Conditions: 1.The installation of the product is in accordance with the instructions provided. 2. Proof of purchase (including date of purchase) is provided. 3. The product has not been used in an unsuitable or improper manner. 4. The product has not been affected by inadequate or lack of maintenance. 5. The product has not been affected by unsuitable media, chemical or electrical influences. 6. Application does not exceed the max allowable temperature. 7. Pressure does not exceed 1050kpa 8. Installation is subject to the requirements of the applicable regulatory authority. 12