Ball Valve Type 21

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Transcript

- 0 -
ASAHI AV Valves
Serial No. H – V027 E – 2
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 face pressure
           between ball and seat
(8) Disassembling method
for parts replacement
(9) Mounting actuator, metal insert and base(panel)
(10) Inspection items
(11) Troubleshooting
(12) Handling of residual and waste materials
(13) Inquiries
ASAHI ORGANIC CHEMICALS INDUSTRY CO., LTD.
Ball Valve Type 21
User’s Manual
13
14
13
13
11
4
3
2
1
1
9
9
10
- 1 -
(1) General operating instruction
○ Operate the valve within the range of the published working temperature and pressure.
(The valve can be damaged by operation beyond the maximum allowable range of temperature vs pressure.)
○ To select a valve in appropriate materials, refer to “CHEMICAL RESISTANCE ON ASAHI AV VALVE”.
(Some chemicals give heavy damage to valve materials.)
○ 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.
○ Do not use the valve for fluid containing slurry. (The valve will not operate properly.)
○ Do not use the valve on condition that fluid has crystallized.
(The valve will not operate properly.)
○ Caution: Certain liquid such as H2O2, NaC1O, etc may be prone to vaporization which may cause irregular
pressure increases, which may destroy the valve.
(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.
- 2 -
(3) Name of parts
No. DESCRIPTION No. DESCRIPTION
◯1 Body ◯7 Seat
◯2 Ball ◯8 O-ring (A)
◯3 Carrier ◯9 O-ring (B)
◯4b End connector (Flanged end type) ◯10 Cushion
◯4c End connector (Socket end type) ◯11 O-ring (C)
◯4d End connector (Threaded end type) ◯12 O-ring (D)
◯4e End connector(Spigot type) ◯13 Stop ring
◯5 Union nut ◯14 Handle
◯6 Stem ◯15 Screw
No. DESCRIPTION No. DESCRIPTION
◯1 Body ◯7 Seat
◯2 Ball ◯8 O-ring (A)
◯3 Carrier ◯9 O-ring (B)
◯4b End connector (Flanged end type) ◯10 O-ring (C)
◯4c End connector (Socket end type) ◯11 O-ring (D)
◯4d End connector (Threaded end type) ◯12 O-ring (E)
◯4e End connector(Spigot type) ◯13 Stop ring
◯5 Union nut ◯14 Handle
◯6 Stem
Nominal size 15-50mm (1/2”-2”)
Nominal size 65-100mm (2 1/2”-4”)
- 3 -
(4) Comparison between working temperature and pressure
Nominal size: 15mm-50mm (1/2”-2”) Nominal size: 65mm (2 1/2”)
Nominal size: 80mm, 100mm (3”, 4”)
Do not operate the valve beyond the range of working temperature and pressure.
(The valve can be damaged.)
Caution
- 4 -
(5) Installation procedure
Flanged type (Material: PVC, C-PVC, PP, PVDF)
   
● Torque wrench ● Spanner wrench
● AV gasket ● Bolt, Nut, Washer (For many flanges specification)
(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 below the values in the following
(A failure to observe them can cause destruction due to stress application to the pipe)
Unit : mm (inch)
Nom. Size
Axial
Misalignment
Parallelism
(a-b)
15-25mm
(1/2”-1”) 1.0 (0.04) 0.5 (0.02)
40-80mm
(1 1/2”-3”) 1.0 (0.04) 0.8 (0.03)
100mm
(4”)
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 15mm(1/2”)
20mm
(3/4”)
25mm
(1”)
32mm
(1 1/4”)
40mm
(1 1/2”)
50mm
(2”)
65mm
(2 1/2”)
80mm
(3”)
100mm
(4”)
Torque
value
17.5
(179)
[155]
17.5
(178)
[155]
20.0
(204)
[177]
20.0
(204)
[177]
20.0
(204)
[177]
22.5
(230)
[200]
22.5
(230)
[200]
30.0
(306)
[266]
30.0
(306)
[266]
Remark
Necessary items
(Axial misalignment) (Parallelism)
  Avoid excessive tightening. (The valve can be damaged.)
Remark
Fig. 1
- 5 -
   Threaded type (Material : PVC,C-PVC,PP,PVDF)
   
 ● Sealing tape(A non-sealing tape can cause leakage.)
● Strap wrench(Do not use Pipe wrench.)
● Spanner wrench
Procedure
1) Wind a sealing tape around the external thread of joint, leaving the end (about 3mm) free.
2) Loosen the union nut ◯5 with a strap wrench..
3) Remove the union nut ◯5 and the end connector ◯4d .
4) Lead the union nut ◯5 through the pipe.
5) Tighten the external thread of the joint and the end connector ◯4d lightly by hand.
6) Using a spanner wrench, screw in the end connector ◯4d by turning 180°-360°carefully without damaging it.
7) Make sure that the O-ring (A) ◯8 is mounted.
8) Set the end connector ◯4d and union nut ◯5 directly on the body without allowing the O-ring (A) ◯8 to come off.
9) Tighten the union nut ◯5 lightly by hand.
10) Using a strap wrench, screw it in by turning 90°- 180°carefully without damaging it.
Necessary items
Make sure that the threaded connections are plastic x plastic.
(Metallic thread can cause damage.)
Remark
Avoid excessive tightening. (The valve can be damaged.)
Remark
Avoid excessive tightening. (The valve can be damaged.)
Remark
- 6 -
   Socket type  (Material : PVC,C-PVC)
   
 ● Adhesive for hard vinyl chloride pipes
● Strap wrench (Do not use the pipe wrench)
  Procedure
1) Loosen the union nut ◯5 with a strap wrench.
2) Remove the union nut ◯5 and end connector ◯4c .
3) Lead the union nut through the pipe.
4) Clean the hub part of the end connector ◯4c by wiping the waste cloth.
5) Apply adhesive evenly to the hub part of the end connector ◯4c and the pipe spigot.
       Adhesive quantity (guideline)
Nom. Size 15mm(1/2”)
20mm
(3/4”)
25mm
(1”)
32mm
(1 1/4”)
40
(1 1/2”)
50
(2”)
65
(2 1/2”)
80
(3”)
100
(4”)
Quantity(g) 1.0 1.3 2.0 2.4 3.5 4.8 6.9 9.0 13.0
6) After applying adhesive, insert the pipe quickly to the end connector ◯4c and leave it alone for at least 60
seconds.
7) Wipe away overflowing adhesive.
8) Make sure that O-ring(A) ◯8 is mounted
9) Set the end connector ◯4c and union nut ◯5 directly on the body without allowing the O-ring (A) ◯8 to come off.
10) Tighten the union nut ◯5 lightly by hand.
11) Using a strap wrench, screw it in by turning 90°-180°carefully without damaging it.
Necessary items
Do not install a socket type valve where the atmospheric temperature is 5℃ or lower.
(The valve can be damaged.)
Remark
 Do not apply more adhesives than necessary.
 (The valve can be damaged due to solvent cracking.)
Remark
Avoid excessive tightening. (The valve can be damaged.)
Remark
- 7 -
   Socket type  (Material : PP,PVDF )
   
● Strap wrench (Do not use the pipe wrench.)
● Sleeve welder or automatic welding machine
● User’s manual for sleeve welder or automatic welding machine
  Procedure
1) Loosen the union nut with a strap wrench.
2) Remove the union nut ◯5 and the end connector.
3) Lead the union nut ◯5 through the pipe.
4) For the next step, refer to the user’s manual for the sleeve welder or the automatic welding machine.
5) After welding, make sure that the O-ring (A) ◯8 is mounted.
6) Set the end connector ◯4c and the union nut ◯5 directly without allowing the O-ring (A) ◯8 to come off.
7) Tighten the union nut ◯5 lightly by hand.
8) Use a strap wrench, screw it in by turning 90°-180°carefully without damaging it.
   Spigot type  (Material : PVDF )
   
● Strap wrench (Do not use the pipe wrench.)
● Automatic welding machine
● User’s manual for automatic welding machine
  Procedure
1) Loosen the union nut with a strap wrench.
2) Remove the union nut ◯5 and the end connector.
3) Lead the union nut ◯5 through the pipe.
4) For the next step, refer to the user’s manual for the sleeve welder or the automatic welding machine.
5) After welding, make sure that the O-ring (A) ◯8 is mounted.
6) Set the end connector ◯4e and the union nut ◯5 directly without allowing the O-ring (A) ◯8 to come off.
7) Tighten the union nut ◯5 lightly by hand.
8) Use a strap wrench, screw it in by turning 90°-180°carefully without damaging it.
Necessary items
Remark
  Avoid excessive tightening. (The valve can be damaged.)
Necessary items
Remark
  Avoid excessive tightening. (The valve can be damaged.)
- 8 -
Nominal size 15mm - 50mm (1/2” – 2”)
{15mm-50mm(1/2”-2”)}
It is recommended to install the valve with the threaded carrier to the upstream side of the system.
This allows for an increase safety factor and eliminating a threaded connection when used as a blocking valve.
This also allows the down stream union nut and end connector to be removed safely under pressure.
It increases the safety where there is no chance of thread leakage or accidentally removing the carrier.
The designation of the up stream side (non threaded carrier is marked as shown) on the body.
Caution
- 9 -
(6) Operating Procedure
○ Turn the handle gently to open or close.
(Turn the handle clockwise to close and counter clockwise to open.)
Fully closed …… The position of the handle should be perpendicular to the pipe.
Fully opened …… The position of the handle should be parallel to the pipe.
(7) Method of Adjusting Face Pressure between Ball and Seat
   
● Strap wrench ●Safety goggles
● Protective gloves ●Screwdriver (+) (only with nominal size 65~100mm)
Procedure
1) Completely discharge fluid from pipes.
2) Turn the handle to full close.
3) Loosen the right union nut and the left one ◯5 with a strap wrench.
4) Remove the body part from piping system.
5) Pull the handle off the body part.
6) Engage the upper convex part of the handle with the concave part of
the union ◯3 .
7) Make an adjustment by turning the union clockwise (to tighten it)
or counter clockwise (to loosen it).
8) Make sure that the handle can be operated smoothly.
9) Assemble the valve by following the above procedure in the reverse
order, starting at 6)
Remark
Avoid excessive tightening. (The valve can be damaged.)
Fully opened Fully closed
Necessary items
Wear protective gloves and safety goggles as some fluid remains in
the valve. (You may be injured.)
Caution
As for nominal size 65-100mm (2 1/2”-4”), loosen the screw ◯15
properly with a screwdriver before pulling it off..
Caution
As for nominal size 15-50mm
Only the union ◯3 on the right side when viewed from the
trademark (AV mark) can be adjusted.
As for nominal size 65-100mm
adjust the unions on both sides.
Caution
- 10 -
(8) Disassembling Method for Replacing Parts
   
● Strap wrench ●Safety goggles
● Protective gloves

Procedure
1) Completely discharge fluid from pipes.
2) Turn the handle to full close.
3) Loosen the right union nut and the left one ◯5 with a strap wrench.
4) Remove the body part from piping system.
5) Pull the handle off the body part.
6) Engage the upper convex part of the handle with the concave part
of the union.
7) In the engaged state, turn the handle ◯14 counter clockwise to loosen it
and remove the union ◯3 .
8) Remove the seat ◯7 carefully by hand without damaging it.
9) Push out the ball ◯2 by hand.
10) Push out the stem ◯6 from the top flange side to the body side.

Procedure
Carry out the assembly work in the reverse procedure from item 10)
Necessary items
Wear protective gloves and safety goggles as some fluid remains in the valve.
(You may be injured.)
Caution
With regard to item 8), before installing seat ◯7 on the valve, check the seat for its face and back.
Caution
As for nominal size 65-100mm (2 1/2”-4”), loosen the screw ◯15
properly with a screwdriver before pulling it off..
As for nominal size 15-50mm
Only the union ◯3 on the right side when viewed
from the trademark (AV mark) can be adjusted.
As for nominal size 65-100mm, adjust the unions on both sides.
Remark
Remark
- 11 -
(9) Mounting actuator, Ensat and base (panel)
○ Attach actuator to the top flange
Procedure
1) Remove the handle ◯14 .
2) Fix the stand ◯24 to actuator ◯23 with bolt (A).
3) Fix the stem ◯6 to the joint ◯25 with screw (B) ◯28 .
4) Engage the joint ◯25 with actuator ◯23 .
5) Fix the stand ◯24 to the top flange
with bolt-nut (B) ◯27 .
6) Make sure that the valve works smoothly, by operating actuator ◯23 by hand.
○ Attach Inserted metal to the bottom stand.
Procedure
Refer to the user’s manual for the Inserted metal
(Commercially available.)

As for nominal 65mm-100mm, tighten the screw ◯15
properly before removing it.
Remark
Bottom stand dimension Unit; mm
Nom.Size S1 S2 S3
15mm (1/2”) 19 7.3 11
20mm (3/4”) 19 7.3 11
25mm (1”) 19 7.3 11
32mm (1 1/4”) 30 9 15
40mm (1 1/2”) 30 9 15
50mm (2”) 30 9 15
65mm (2 1/2”) 48 9 6
80mm (3”) 55 11 7
100mm (4”) 65 11 8
Nominal 15-50mm(1/2”-2”)
Bottom stand
Nominal 65-100mm (2 1/2”- 4”)
Bottom stand
- 12 -
○Fixation of bottom stand with panel
Nominal size: 15mm-50mm (1/2”-2”)
Nominal size: 65mm-100mm (2 1/2”-4”)
Before the fixation After the fixation
Before the fixation After the fixation
- 13 -
(10) Inspection items
○Inspect the following items;
(11) Troubleshooting and action
Problem Cause Action
The carrier is loosened.
Adjust the face pressure between the
ball and the seat.
(Refer to page 9)
The seat is scratched or worn. Replace the seat with a new one.
Foreign matter is in the valve. Clean up.
Fluid leaks from the valve
even when the valve is closed
fully.
The ball is scratched or worn.
Replace the scratched ball with a new
one.
The union nut is loosened. Tighten up the union nut.
The carrier is loosened.
Adjust the face pressure between the
ball and the seat.
(Refer to page 9)
Fluid leaks from the valve.
The O-ring is scratched or worn. Replace the O-ring with a new one.
Foreign matter is in the valve. Clean up.
The handle can not be turned
smoothly.
Deformation. (By heat etc.) Replace the parts.
The stem is broken. Replace the stem with a new one.
The handle fails to engage.
The engagement between the stem and the ball
is broken.
Replace the stem and ball with new
ones.
(12) Handling of residual and waste materials
In discarding remaining or waste materials, be sure to ask waste service company.
(Poisonous gas is generated.)
Remark
(1) Check for any flaw, crack, or deformation on the outside.
(2) Check whether fluid leaks to the outside.
(3) Check whether tightness of bolt nut.
(4) Check whether the operation of the handle is smooth.
- 14 -
(13) Inquiries
Head Office : No. 2-5955, Nakanose- Cho, Nobeoka – City, Miyazaki- Pref. , Japan.
Tel (81) 982-35-0880 Fax (81) 982-35-9350
Tokyo Office : (Furukawachiyoda Bldg.) No. 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:Am Wehrhahn 33, 40211, Duesseldorf, Germany.
Tel (49) 6172-9175-0 Fax (49) 6172-9175-25
ASAHI AMERICA Inc.: 35 Green Street Malden, Massachusetts U.S.A. 02148
Tel (1) 781-321-5409 Fax (1) 781-321-4421
- 15 -
Ball Valves Type 21
ASAHI ORGANIC CHEMICALS INDUSTRY CO., LTD.
Information in this manual is subject to change without notice. 2001. 2

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