Diaphragm Valves Type 15

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Keywords

valve, Diaphragm, ASAHI, Type, VALVES, Valves, Manual, Maintenance, 15-CE, Installation,Operation, torque, stopper, with, from, diaphragm, wrench, procedure, (The, bonnet, working, {459}, DN150, Caution, DN125, [400], items, waste, Rubber, Size, Check

Transcript

ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE
Serial No. H-V031 E-3-CE
Diaphragm Valves Type 15
User’s Manual
Contents
(1) General operating instructions
(2) General instructions for transportation,
unpacking and storage
(3) Name of parts
(4) Comparison between working
temperature and pressure
(5) Installation procedure
(6) Operating procedure
(7) Adjustment procedure for stopper
(8) Diaphragm replacement procedure
(9) Inspection items
(10) Troubleshooting
(11) Handling of residual and
waste materials
(12) Marking
(13) Inquiries
7
7
6
5
5
4
3
2
1
1
6
8
ASAHI AV VALVES
9
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 1
(1) General operating instructions
○Operate the valve within the pressure Vs temperature range.
(The valve can be damaged by operating beyond the allowable range.)
○Select a valve material that is compatible with the media, refer to “CHEMICAL RESISTANCE ON ASAHI
AV VALVE”.
(Some chemicals may damage incompatible valve materials.)
○Diaphragm part may become loose after long term storage or unused period, or by the change of temperature
during operation. Check it, and re-tighten the bolt diagonally, refer to the torque value on page 6.
○Adjust the stopper when the seat leaks during operation.
○Do not exert excessive force in closing or opening the valve.
○The valve is not designed to bear any kind of external load. Never stand on or place anything heavy on the valve
at anytime.
○When the valve is disposed of, contact waste disposal specialist.
(The valve generates toxic gas.)
○The valve should be installed at place where space for periodic
inspection & maintenance is sufficient.
○Do not store or install the valve near any heat source or hot
surface.
(The valve may cause deformation, destruction, and fire.)
(2) General instructions for transportation, unpacking and storage
○Keep the valve in its original packaging until needed for installation.
○Avoid contact with any coal tar creosote, insecticides, vermicides or paint.
(The force of swelling may damage the valve.)
○The valve is not designed to handle any kind of impact. Avoid throwing or dropping the valve.
○Avoid scratching the valve with any sharp object.
Bonnet tightening
torque value
N-m {kgf-cm} [lb-inch]
Nom. Size
mm (inch)
Rubber PTEF
125 (5)
45.0
{459}
[400]
45.0
{459}
[400]
150 (6)
45.0
{459}
[400]
45.0
{459}
[400]
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 2
(3) Name of parts
No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION
◯1 Body ◯10 Thrust bearing(A) ◯21 Gauge cover
◯2 Bonnet ◯11 O-ring (A) ◯22 Bonnet liner
◯3 Diaphragm ◯13 Handwheel ◯23 Stud bolt・nut
◯3a Inserted metal of DIA ◯14 Name Plate ◯24 Bolt・Nut
◯4 Cushion ◯15 Cap ◯26 Body liner
◯4a Cushion cover ◯17 Sheet ring ◯27 Rib liner
◯5 Compressor ◯18 Stopper ◯28 U-bolt・nut
◯8 Stem ◯19 Spring washer ◯29 Conical spring washer
◯9 Sleeve(A) ◯20 Nut
◯22 ,◯26 ,◯27 ,◯28 ,◯29 are used with special specification.
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 3
(4) Comparison between operating temperature and pressure
Do not operate valve beyond the range of working temperature and pressure.
(The valve can be damaged.)
Caution
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 4
(5) Installation procedure
   
● Torque wrench ● Spanner wrench ● Bolt, Nut, Washer (For many flanges specification)
● AV gasket (When a non-AV gasket is used, a different tightening torque specification should be followed.)
    Procedure
1) Set the AV gasket between the flanges.
2) Insert washers and bolts from the pipe side, insert washers and nuts from the valve side, then temporarily
tighten them by hand.
The parallelism and axial misalignment of the flange surface should be under the values shown in the
following table.
(A failure to observe them can cause destruction due to stress application to the pipe)
Unit : mm (inch)
Nom. Size AxialMisalignment
Parallelism
(a-b)
125,150mm
(5”, 6“) 1.0 (0.04) 1.0 (0.04)
3) Using a torque wrench, tighten the bolts and nuts gradually to the specified torque in a diagonal manner
(Refer to fig.1.)
 Specified torque value  Unit : N-m{kgf-cm}[lb-inch]
Nom. Size 125mm (5”) 150mm (6”)
Torque value 40.0{408} [355] 40.0{408} [355]
Necessary items
Avoid excessive tightening. (The valve can be damaged.)
(Axial misalignment) (Parallelism)
Fig. 1
Caution
Caution
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 5
(6) Operating Procedure
○ Open and close the valve by rotating handwheel.
○ The top of the travel stop will be flush with the top of the handwheel when the valve is fully closed.
(7) Adjustment procedure for stopper
● Spanner wrench ● Allen wrench
● Driver(-) ● Protective Gloves ● Goggles
    Travel stop adjustment
1) Loosen the gauge cover ◯21 with hand.
2) Loosen the nut ◯18 from the stopper ◯20 with spanner
wrench.
3) Loosen the stopper ◯20 .
4) ④Operate the handwheel to tighten gradually until the
leakage of fluid stops.
5) ⑤Tighten the stopper ◯20 until it stop, and then turn it
back (counter-clockwise) 180°.
6) ⑥Tighten the nut ◯18 to the stopper ◯20 with spanner
wrench.
7) ⑦Tighten the gauge cover ◯21 .
Necessary items
The valve is designed for manual operation only.
(The use of assist device may damage the valve.)
Full shut Half open Full open
Tightening torque of the screw
Unit : N-m {kgf-cm} [lb-inch]
Nom. Size 125mm (5”), 150mm(6”)
Torque valve 10.0 {102} [89]
Caution
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 6
(8) Diaphragm replacement procedure
   
1) Drain fluid completely from the pipeline.
2) Remove valve bonnet from the body.
3) Turn handle of valve clockwise until it stops.(Do not force it).
The compressor should be fully extended out of the bonnet.
4) Turn the diaphragm clockwise to remove the diaphragm and mount the new diaphragm by reversing step.
5) Mount the bonnet to the valve by reversing step 2. Tighten bonnet bolts by hand only.
6) Rotate the handle 360°counter-clockwise.
7) Using a torque wrench, tighten the bonnet bolts in a diagonal, criss-cross pattern.
Bonnet torque wrench Unit : N-m {kgf-cm} [lb-inch]
Nom. Size
125mm (5”),150mm (6”)
Rubber 45 {459} [400]
PTFE 45 {459} [400]
8) Re-adjust the stopper if necessary.
(9) Inspection items
○Inspect the following items.
(1) Check for any flaw, crack, or deformation on the outside.
(2) Check whether fluid leaks to the outside.
(3) Check the tightness of coupled bolt nut between the body and the bonnet and that of thegauge cover (loose or not).
(4) Check whether the operation of the handle is smooth.
Diaphragm
Necessary items
Wear protective gloves and safety goggles as some fluid remains in the valve.
(You may be injured.)
● Torque wrench ● Spanner wrench
● Protective gloves ● Safety goggles
Caution
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 7
(10) Troubleshooting and action
Problem Cause Treatment
The travel stop is not set correctly. Adjust the travel stop.
Solid particles have lodged in the
valve.
Clear the solid particles from the
valve.
Fluid is leaking past the fully closed
position.
Media has worn diaphragm and / or
weir. Replace.
The diaphragm has pulled off the
stem.
Replace diaphragm. If the valve is in
vacuum service, special vacuum
valves may be required.
Consult factory.Valve can not be fully open.
The metal joint failed. Remove diaphragm&compressor andreplace joint.
The stem is broken. Disassemble bonnet and replace thestem.
The handle spins freely.
The metal joint failed. Remove diaphragm&compressor andreplace joint.
Bonnet bolts have loosened. Re-tighten.
Media has crystallized on the
diaphragm.
Disassemble and clean on a regular
basis. Replace failed diaphragm, if
necessary.
Valve leaks between body and bonnet.
The diaphragm has failed due to
fatigue. Replace.
Valve leaks from stem. The diaphragm has failed. Replace.
(11) Handling of residual and waste materials
In discarding remaining or waste materials, be sure to ask a waste service company.
Caution
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 8
(12) Marking
Body
Material
Diaphragm
Material Nominal size
Nominal
press.
Max. allowable
working temp.
Max. allowable
working press.
DN125 PN 8 60℃ 7 BAR
Rubber
DN150 PN 8 60℃ 5 BAR
DN125 PN 7 60℃ 6 BAR
PVC
PTFE
DN150 PN 5 60℃ 4 BAR
DN125 PN 8 90℃ 5 BAR
Rubber
DN150 PN 8 90℃ 4 BAR
DN125 PN 7 90℃ 4 BAR
PP
PTFE
DN150 PN 5 90℃ 3 BAR
DN125 PN 8 120℃ 5 BAR
Rubber
DN150 PN 8 120℃ 4 BAR
DN125 PN 7 120℃ 4 BAR
PVDF
PTFE
DN150 PN 5 120℃ 3 BAR
If the nameplate is damaged or become dirty, let our Sales Division know
the “Manufacturing number”. We will send a new nameplate.
EN marking
DN : Nominal size
PN : Nominal press.
TB : Max. allowable
working temp.
PB : Max. allowable
working press.
Bottom view
CE0035 label
Valve label
02 B 00001 F
① ② ③ ④
① Year (ex. 02→2002)
② Month (ex. A→Jan. B→Feb. …… L→Dec.)
③ Ser. No.
④ Revision symbol
AOC symbol
※ Molded date
Date marking Valve type
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 9
(13) Inquiries
ASAHI ORGANIC CHEMICALS INDUSTRY CO., LTD.
Nobeoka Head Office : 2-5955, Nakanose- Cho, Nobeoka –City, Miyazaki- Pref. , Japan.
Tel : (81) 982-35-0880 Fax : (81) 982-35-9350
Tokyo Head Office : (Furukawachiyoda Bldg.) 15-9, Uchikanda 2- Chome, Chiyoda-Ku, Tokyo, Japan.
Tel : (81) 3-3254-8177 Fax : (81) 3-3254-3474
Singapore Branch Office : 16 Raffles Quay, #40-03 Hong Leong Building, Singapore 048581.
Tel : (65) 220-4022 Fax : (65) 324-6151
Europe Representative Office : Kaiser-Friedrich-Promenade 61 D-61348 Bad Homburg v. d. H. Germany.
Tel : (49) 6172-9175-0 Fax : (49) 6172-9175-25
Shanghai Branch Office : Room 1301-P Shanghai Kerry Center, 1515 Nanjing Xi Road, Shanghai China
Tel : (21) 5298-6900 Fax : (21) 5298-6556
ASAHI /AMERICA Inc. :35 Green Street P.O.Box 653 , Malden, Massachusetts 02148 U.S.A.
Tel : (1) 781-321-5409 Fax : (1) 781-321-4421
Distributor
ASAHI AV VALVES Installation,Operation and Maintenance Manual
Diaphragm Valves Type 15-CE 10
Diaphragm Valve Type 15
Information in this manual is subject to change without notice. 2003. 6
ASAHI AV VALVES

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