Gate Valves - Brochure

1Ductile Cast Iron Gate Valvesfor water and gas supply FITTINGS AND VALVES2 3Ductile cast iron valvesIn Germany alone, thousands of kilometers of pipes ensure a reliable supply of water, anytime and anywhere. The piping used needs to meet the highest require-ments:• Resist intense soil movement• Reliability even after many service years• Ensure perfect hygiene• Safe transport of our drinking water without lossThe right coating is what mattersIn the end, however, it is the coating that reliably guarantees permanent hygiene in our drinking wa-ter supply system. This is why the surface protec-tion is as equally important as the base material.All Düker valves receive a seamless and pore-free Epoxy Powder coating or are completely enamelled. This procedure offers permanent corrosion and encrustation protection, and additionally makes the pipes extremely adhesion and shock resistant.The Epoxy Powder is applied onto the clean blasted cast part at 200° C with a layer thickness of at least 250 µm. As a member of the “Gütegemeinschaft Schwerer Korrosionsschutz” (GSK) society, Düker is entitled to carry the RAL quality seal.Enamel, on the other hand, is a sign for integral corrosion protection. The per-fectly smooth surface prevents potential bacteria build-up. Biofilm adhesion is actively prevented thus ensuring a hygienically and physiologically safe drink-ing water supply.Etec enamel is a composite material which en-ters a permanent chemical connection with the cast iron pipe section. Its main strengths are:• Inside and outside corrosion protection including class III soil• High degree of resistance to mechanical stress (friction, impact, pressure, push)• Ageing resistanceReliable, Dependable and EconomicalAnother important element for a safe and above all leak-proof pipeline is its connections.In addition to the tried and tested flange connec-tions, Düker also offers, depending on the applica-tion area, socket systems with the corresponding coupling adapters for an axial-restraint connection securing tensile strength:• Düker SMU and• Düker SPEZIAL for threaded couplings• Tyon SIT® and• TYTON SIT PLUS® for TYTON®-sockets • Novo SIT® and• Novo GRIP® III for Novo socketsDuctile cast ironDuctile cast iron is a special form of cast iron which is also known as spherulitic graphite iron.This material withstands both internal and ex-ternal pressure as well as virtually all impact caused by soil or traffic. It is therefore reliable and ideally suited to meet the requirements of our service pipes.Cast iron is a natural material and forms the foun-dation of the Düker valves. Due to its outstanding material properties, it complies 100% with the fol-lowing requirements:• Long service life• High density• Excellent corrosion resistance• Economic efficiency• And, finally, it is 100% recyclable• Prevention of blistering between the carrier material and coating caused by diffusion of water through the coating• No sub-surface migration even in the case of local damage• Climate and media resistance (UV-radiation, humidity, temperature, organic solvents)Etec enamel – the special surface protection for valvesA safe connection living up to its promise4 5 6Alternative for gasDN 40 – 300, PN 10 – 16Gate Valves 2004 and 4004Entirely shock-resistant enamelling for best possible corrosion protection and 100% hygieneArea of application: Drinking water• EPDM vulcanized wedge and gasketArea of application: Gas/waste water• NBR vulcanized wedge and gasketCorrosion protectionSeamlessly and fully enamelled shock-resistant housing inside and out-side according to the DEV guide-line (class III soils, DIN 3475) or with full EKB coverage for gas applications.Medium temperature range for gas and drinking water from -10 °C to +60 °C.Long service life of the valve • Coating optimized head piece and housing • Highly corrosion resistant to class III soils following the requirements of the DVGW publication GW 9Operator friendly • Low torques due to sophisticated design• Low coupling moment and high drive reserves• New wedge guidance with vulcanized plastic sliding shoes Maintenance-free operation• New spindle bearing designNo restrictions in ground installation• Concealed lock nut in the head piece with a protective plastic cap against solid objects and humidity• No additional measures required for the installation in highly aggressive soils• Easy handling in all installation situationsUniversal application options• Interface installation set – without adapter according to GW 336PN 10 16Test pressure in bar according to DIN EN 12266-1Housing 17,0 25,0Closure 11,0 17,6Highest admissible positive operating pressure in bar 10,0 16,0Area of application and inspection for use inGas pipes according to DIN 2470, part 1 > pressure tests according to DIN 3230, part 5, PG 2 • •Gas plants according to DIN 30 6902, part 1> pressure tests according to DIN 3230, part 5, PG 3 • •Gate valve construction length according to DIN EN 558 basic series R14 and R15DNmmPN barFTF mmR14 FTF mmR15h1mmDmmKmmno.of holesLmm?a mmU TNmWeight kgR14 Weight kgR1540 10 / 16 140 240 207 150 110 4 19 14 11 30 11,2 12,550 10 / 16 150 250 233 165 125 4 19 14 13 40 13,3 14,765 10 / 16 170 265 270 185 145 4 19 17 14 60 17,0 18,880 10 / 16 180 280 270 200 160 8 19 17 16 35 17,8 17,5100 10 / 16 190 300 295 220 180 8 19 19 25 45 22,5 24,6125 10 / 16 200 325 330 250 210 8 19 19 25 45 27,8 31,0150 10 / 16 210 350 373 285 240 8 23 19 30 45 36,0 40,6200 10 230 400 462 340 295 8 23 24 34 60 54,8 61,5200 16 230 400 462 340 295 12 23 24 34 60 54,4 61,0250 10 250 450 648 400 350 12 23 27 43 150 104,4 113,6250 16 250 450 648 400 355 12 28 27 43 150 104,0 113,0300 10 270 500 723 445 400 12 23 27 51 150 146,7 161,0300 16 270 500 723 445 410 12 28 27 51 150 146,0 160,0Dimensions and weightsDetails and materialsOptimal protection • Media-free spindle bearing • Full corrosion protection with etec enamelFull protection during transport and storage• Edge protection between head piece and housing, passage flanges with plastic cap protectionExtensive accessory program• GW 336 compliant installation set• Adjustable/rigid telescope with Clip Pins• Uni-Clip installation set• Height adjustable and rigid street caps• Operating keys• Hand wheelsVersions• With flange connection• With socket connectionItem Description Material DN 80 – 200Item Description Material DN 40 – 65 & DN 250 – 3001 Housing EN-JS 1050 1 Housing EN-JS 10501 Sealing wedge EPDM W270/NBR* 1 Sealing wedge EPDM W270/NBR*1 Spindle nut CuZn36Pb2As/bronze* 1 Head piece EN-JS 10501 Spindle 1.4021 (X20Cr13)/1.4571* 1 Spindle 1.4021 (X20Cr13)/1.4571*1 Gasket EPDM W270/NBR* 1 Lock nut CuZn35-NiMn2AIPb4 Cylinder head screw A2-70 1 Spindle nut CuZn35-NiMn2AIPb/bronze*1 Clamping piece CuZn35-NiMn2AIPb 1 Screen TPE1 Head piece EN-JS 1050 2 Slide ring red brass1 Lock nut CuZn35-NiMn2AIPb 6 Cylinder head screw A2-701 Adapter cap EPDM 2 O-ring EPDM W270/NBR*3 O-ring EPDM W270/NBR* 1 O-ring EPDM W270/NBR*1 Retainng ring 1.4541 (X6CrNiTi1810) 1 Head seal EPDM W270/NBR*2 O-ring EPDM W270/NBR* 1 Grooved cylindrical pin A2-701 Edge protection PVC* waste water version DN 80 – 200DN 40 – 65 &DN 250 – 3007 8 9PE 100 pipe welding pipe ends as injection molded part (black for water and gas) with stainless steel support sleeve.For welding in PE pipelines applying the heating element butt welding method. Pipe length laid out for two welding processes. Inspection according to DIN 3230-5 PG-2 or PG-3; including 3.1 B certificate according to EN 10204.Area of application gas• For all gases according to DVGW publication G 260/IInspection report Engler-Bunte-Institute regarding connection techno-logy on the basis of DVGW-VP 600, melting index group MFI 005 and MFI 010, according to the guidelines of the DVGW publication G 477 and bulletin DVS 2207. Gas PN 10 pipe connection pieces.As an option, the gate valve 4004 may be equipped with a hand wheel, an installation set for ground installation, electric or pneumatic drive and clear shaft end.Minimum wall thickness according to DIN 8074Gate Valve 4004 with PE 100 Pipe Ends for WeldingThe innovative valve series for the application with plastic pipesDN mmPN barL mmh1 mmETE mm?a mmØ Dmm80 10 650 268 114 17 90100 10 710 294 127 19 110100 10 760 294 127 19 125125 10 790 330 140 19 140150 10 840 372 140 19 160150 10 890 372 140 19 180200 10 970 460 152 24 200200 10 960 460 152 24 225As an option, the gate valve 4004 with PE 100 pipe ends for welding may be equipped with a hand wheel, an installation set for ground installation, electric or pneumatic drive and clear shaft end.As molded parts, the PE pipe ends for welding are extruded and mechanically processed. These PE pipe ends for welding are mounted tension-free and friction-locked as plug-in connection in the TYTON® socket. Locking and pull-out protection is ensured through a thrust resisting joint ring on the outside. During the welding process, the advantage of this design is that it enables the valve to be flex-ible without impairing pull-out protection and tightness. Area of application water• For drinking water DIN EN 1074-part 1 and part 2 • For temperatures up to +60 °CEPDM vulcanized wedge and gaskets are KTW and W 270 tested. Pipes according to DIN 8074, inspection report Engler-Bunte-Institute re-garding connection technology on the basis of DVGW-VP600, melting index group MFI 005 and 010, according to the guidelines of the DVGW publication G 477 and bulletin DVS 2207.Corrosion protectionThe standard version of the gate valve is equipped with a high quality epoxy powder coating according to the RAL-GZ 662 quality assurance of the “Güte-gemeinschaft schwerer Korrosionsschutz (GSK)”, the German quality association for Corrosion Protection of Powder Coated Valves and Fittings.Maintenance-free operation• New spindle bearing designNo restrictions in ground installation• Concealed lock nut in the head piece with a protective plastic cap against solid objects and humidity• No additional measures required for the installation in highly aggressive soils• Easy handling in all installation situationsUniversal application options• Interface installation set – without adapter according to GW 336Full protection during transport and storage• Edge protection against impacts between head piece and housing, PE endsVersions• Type 4004 – 430 PE 100 on one side, TYTON® or novo socket on the other side• Type 2004 – 420 PE 100 end on one side, flange on the other side• Also refer to service connection valve type 1004 DN 25 – 50 with PE 100 welding pipe endsLong service life of the valve • Coating optimized head piece and housing • Highly corrosion resistant to class III soils following the requirements of the DVGW publication GW 9Operator-friendly• Low torques due to sophisticated design• Low coupling moment and high actuator reserves• New wedge guidance with vulcanized plastic sliding shoes Optimal protection • Media-free spindle bearing • Full corrosion protectionDimensionsDN mmd mmSDR 11mmSDR 17 mm80 90 8 5100 110 10 7100 125 11 7125 140 13 8150 160 15 10150 180 16 11200 200 18 12200 225 21 1310 11Exchange and Repair Gate Valve 2004 and 4004 The perfect valve for the application in pipe trenchesThe loose flanges have a limited sliding tolerance (+/- 6mm). In addition, they are tightly connec-ted to the valve housing guaranteeing tensile strength. The design of a loose flange valve is defined as follows:The construction length is prepared direction minus tolerance. Additional allowance for clear-ance is caused through the elimination of the flange gaskets on the loose flange sides. The gas-ket is integrated in the loose flange.Dimensions and weights type 4004Area of application water• For drinking and untreated water up to PN 10/16• Ambient temperature up to +60 °C• For all plant and pipeline network operatorsCorrosion protectionShock resistant enamelling inside and outside. Loose flanges guaranteeing tensile strength in black with EKB coating.Cam lockThrust resisting jointFlange sealingLoose flangeDNmmPNbarFTFmmFTFvariableDmmKmmh1mm?ammLmmWeightkg80 10 / 16 280 ± 6 mm 200 160 270 17 19 20100 10 / 16 300 ± 6 mm 220 180 295 19 19 25125 10 / 16 325 ± 6 mm 250 210 330 19 19 33150 10 / 16 350 ± 6 mm 285 240 373 19 23 44200 10 400 ± 6 mm 340 295 462 24 23 65200 16 400 ± 6 mm 340 295 462 24 23 65The basis of this valve is the tried and tested Düker repair valve concept. This series has undergone continuous innovations and improvements and is now available with the nominal diameters DN 80–200.The proven concept allows operators cost efficient utilization of their resources – either for new building projects or as a replacement valve in the course of facilities and public power supply redevelopment measures. Depending on the material choice of the adjusting and disassembling devices, the savings potential for new investments is between 5 and 20%.Long service life of the valve • Coating optimized head piece and housing • Highly corrosion resistant to class III soils following the requirements of the DVGW publication GW 9 • Loose flanges guaranteeing tensile strength on both sidesOperator-friendly• Low torques due to sophisticated design• Low coupling moment and high drive reserves• New wedge guidance with vulcanized plastic sliding shoesMaintenance-free operation• Newly designed spindle bearing / or new spindle bearing design No restrictions in ground installation• Concealed lock nut in the head piece with a protective plastic cap against solid objects and humidity• No additional measures required for the installation in highly aggressive soils• Easy handling in all installation situationsQuick replacement as and when required• Valve exchange only even in adjusting and disassembling devices are connected with permanent spindles• Ability to even out misalignments on the existing pipeline• Installation of the gasket ring does not require spreading between pipeline and valveUniversal application options• No changes necessary. Ready for use in facilities and ground installation• Universal interface to the installation set – without adapter according to GW 336• Use of complete flanges with DIN EN 1092-2 complying connections Optimal protection • Media-free spindle bearing • Full corrosion protection with etec enamelSaving time and materials• No need for adjusting and disassembling devices• Minimizing labor time as a result of integrated loose flanges with sealing elements guaran-teeing tensile strengthFull protection during transport and storage• Edge protection between head piece and housing12 13Gate Valve 4004 with Exhaust UnitThe perfect valve for modern gas distribution systems – with simple and fast gas ventilationArea of application gas• For all gases according to DVGW publication G 260/I Inspection report: Engler-Bunte-Institute regard-ing connection technology on the basis of DVGW-VP 600, melting index group MFI 005 and 010, according to the guidelines of the DVGW publica-tion G 477 and bulletin DVS 2207. Gas PN 5• It is used for retrofits or new construction of PE gas pipes in the pressure range = PN 4The gate valve with exhaust unit is equipped with PE 100 pipe ends for welding. Type • Identical with the 4004 series • As molded parts, the PE pipe ends for welding are extruded and mechani-cally processed. They are mounted tension-free and friction-locked as plug-in connection in the TYTON® socket. Locking and pull-out protection is ensured through a thrust resisting joint locking ring on the outside• The length of the PE pipes section enables double socket welding. The PE pipes are available pursuant to DIN 8074 in SDR 11 and, alternatively in SDR 17• The exhaust pipes are welded on the casing with steel pipes until the first ball valve is reached (DN 80 – 200 = 1“)• The height depends on the pipe coverage or the customer’s request. One ball valve each is welded to the upper end of the blow out valves down to the shut-off position. Both blow-out pipes are locked with the Düker gate valve by means of a tripe clamp via the installation setThe most important elements1 = Welded transition2 = Ball valve3 = PE welding pipe end4 = Exhaust pipe in DN 32 PE5 = Ball valve with temperature resistant pipe end6 = Plug with relief drilling7 = For all sizes with the same blow-off ball valve8 = Two weldings possible13457862ABCDDimensions in mmA 190B min. 400C min. 110D approx. 350 at DN 80approx. 370 at DN 100approx. 450 at DN 150 / 200DN mmPN barL mmh1 mmETE mm?a mmØ Dmm80 16 650 268 114 17 90100 16 710 294 127 19 110100 16 760 294 127 19 125125 16 790 330 140 19 140150 16 840 372 140 19 160150 16 890 372 140 19 180200 16 970 460 152 24 200200 16 960 460 152 24 225Functions of the ventilation pipesThe filling up of gas pipes also leads to the formation of air pockets. So far, the removal of these air pockets has been associated with an enormous effort, often accompanied by the installation of additional valves or other ventilating devices. Using the Düker gate valve 4004 will significantly sim-plify the ventilation process. After the filling procedure of the gas pipes, only the ball valves mounted on the exhaust pipes are opened for the air pocket to escape. Once the air has been entirely removed, the ball valve shuts. The system is then ready to operate. During gas pipe repair work too, where parts of the gas distribu-tion system needs to be shut down, the gate valve 4004 renders work much easier. First, the gas is discharged through the attached ventilating pipes. Then, the system is flushed with nitrogen. This ensures the removal of all remaining gas and enables risk-free gas pipe work. After repairing or retrofitting the part of the system in question, the pipe is immediately ready for operation again, because the gate valve 4004 also facilitates ventilating during the refill process.Dimensions14 15Gate Valve 3004 with Steel Pipe Ends for WeldingEntirely shock-resistant enamel on the inside and “PUR” polyurethane coating on the outside – the perfect solution for gas supplyArea of application gas• For all gases according to DVGW publication G 260/I with inspection PG 3Corrosion protectionEnamel on the inside pursuant to the DEV guideline (except for the welding area). Outside coating “PUR” polyurethane.The inspection is carried out in line with DIN 30677, part 2 and according to 15 kV.Gate valve type 3004Resilient seated with a smooth passage accord-ing to DIN EN 13774. Housing and head piece in GJS-400-18 with shoed ends from St. 35.8 edge form 22. Wedge with new guidance, vulcanized plastic sliding shoes. Stainless austenitic Cr steel 1,4021 spindle and wound up thread. Media-free spindle bearing. Spindle sealing with two O-rings and back seal.The 3004 gate valve is also available as “blow-out unit” in two versions, either steel ends or PE ends. CERTIFICATE The Certification Body of TÜV SÜD Management Service GmbH certifies that Düker GmbH & Co. KGaA Würzburger Straße 10 D-97753 Karlstadt Hauptstraße 39-41 D-63846 Laufach has established and applies a Quality Management System for Development, manufacture, supply and service of valves used in water- and gas industries, high pressure ductile iron fittings, drain pipes and fittings, highly acid resistant glass lined components, castings made to specification, centrifugal casting plants for production of castings as well as cokeless cupola furnaces An audit was performed, Report No. 70008454 Proof has been furnished that the requirements according to ISO 9001: 2008 are fulfilled. The certificate is valid until 2012-03-23 Certificate Registration No. 12 100 21864 TMS Munich, 2009-04-08 QMS-TGA-ZM-07-92 Quality on the highest possible levelWe are the first to set the highest requirements for the quality of our products. And, as a result, we have introduced a modern quality management system according to DIN EN ISO 9001 already in 1993 which has also been TÜV CERT certified.In addition, Düker products have undergone other tests and approval proce-dures in line with product or market specific standards and regulations.It is not unusual that quality criteria are met within the context of quality assurance associations that are way beyond the standard requirements.16 17Our know-how for your benefitThe Düker name has been synonymous for premium quality iron casting for more than 500 years. We are today among the leading manufacturers of valves and pressure pipe fittings for drinking water and gas supply as well as for pipes and fittings for drainage technology.To be “very good” is setting a high standard. Every day, we try to achieve just a little bit more. This is why many developments made by Düker are recog-nized as quality standard among experts today. And we keep on learning and growing.Our long-standing tradition is what you can benefit from. All of our qualified teams in engineering, sales, production and service are happy to assist you with all questions regarding “drinking water and gas supply”. From planning to logistics and finally to in-stallation. On top of that, we are able to consult you on more complex pipe line projects also for as long as our valves and pipes are in use.Düker fittings are used all over the world and are subject to very high requirements, especially when it comes to drinking water. This is why all valves are developed and manufactured applying the greatest possible care and attention to detail. Needless to say, before any product leaves Düker, it is thorough-ly put to the test.More than 500 Years of Experience in Iron CastingIt also goes without saying that our valves are in line with the most current: • KTW recommendations• Guidelines of the Federal Environment Agency for the hygienic evaluation of organic materials that come in contact with drinking water• Requirements of the DVGW publication W 270 “Microbial enhancement on materials to come into contact with drinking water - Testing and assessment”18FITTINGS AND VALVES DRAINAGE TECHNOLOGYENGINEERINGGLASS LINING TECHNOLOGIESJOBBING FOUNDRYDüker GmbH & Co. KGaAHauptstraße 39-41D-63846 LaufachGermanyPhone +49 6093 87-250Fax +49 6093 87-246Internet: www.dueker.deE-Mail: info@dueker.de770524 05/11 Specifications subject to change without notice.