Thermoplastic Swing Check Valves – Manual

ASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 0Serial No. H – V013 E – 2 Swing Check ValveUser’s Manual Contents(1) General operating instructions(2) General instructions for transportation, unpacking and storage(3) Name of parts(4) Comparison between workingtemperature and pressure(5) Installation procedure(6) Disassembling Method for Replacing Parts(7) Inspection items(8) Troubleshooting(9) Handling of residual and waste materials(10) Inquires11109121162118ASAHI AV VALVESASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 1 (1) General operating instruction? 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 AVVALVE”.(Some chemicals may damage incompatible valve materials.)? Do not use the valve to 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.)? Do not step on the valve or apply excessive weight on valve. (It can be damaged.)? Make sure to consult a waste treatment dealer to dispose of the valves.(Poisonous gas is generated when the valve is burned improperly.)? Allow sufficient space for maintenance and inspection.? Keep the valve away from excessive heat or fire. (It can be deformed, or destroyed.)? The valve is not designed to bear any kind of external load. Never stand on or place anything heavy on the valve atanytime.? Certain liquid such as H2O2, NaClO, 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 packed in the carton or box as delivered until installation.? Keep the valve away from any coal tar, creosote (antiseptic for wood), termite insecticide, vermicides, and paint. (This could cause swelling damage the valve.)? Do not impact or drop the valve. (It can be damaged.)? Avoid scratching the valve with any sharp object.ASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 2 (3) Name of parts Gasket type 15, 20mm(1/2”, 3/4”)No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION?1 Body ?5a Disc ?5j Seat?2 Bonnet ?5b Seat holder ?5?5k O-ring (A)?3 Shaft ?5h Bolt (B) ?6 Gasket (A)?4 Plug?5?5i Nut (B) ?7 Gasket (B)ASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 3 Gasket type 25-200mm(1”-8”)No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION?1 Body ?5b Seat holder ?5j Seat?2 Bonnet ?5c Bolt (A) ?5?5k O-ring (A)?3 Shaft ?5d Arm ?6 Gasket (A)?4 Plug ?5e Washer ?7 Gasket (B)?5 ?5a Disc?5?5f Nut (A) ?9 Bolt · NutASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 4 O-ring type 15, 20mm(1/2”, 3/4”)No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION?1 Body ?5a Disc ?5j Seat?2 Bonnet ?5b Seat holder ?5?5k O-ring (A)?3 Shaft ?5h Bolt (B) ?7 Gasket (B)?4 Plug?5?5i Nut (B) ?8 O-ring (B)ASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 5 Gasket type 25-200mm(1”-8”)No. DESCRIPTION No. DESCRIPTION No. DESCRIPTION?1 Body ?5b Seat holder ?5g Pin?2 Bonnet ?5c Bolt (A) ?5?5j Seat?3 Shaft ?5d Arm ?7 Gasket (B)?4 Plug ?5e Washer ?8 O-ring (B)?5 ?5a Disc?5?5f Nut (A) ?9 Bolt · NutASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 6Gasket type (4) Comparison between operating temperature and pressureDo not operate valve beyond the range of working temperature and pressure.(The valve can be damaged.)CautionASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 7O-ring typeDo not operate valve beyond the range of working temperature and pressure.(The valve can be damaged.)CautionASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 8 (5) Installation procedure ? 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.) Procedure1) Set the AV gasket between the flanges.2) Insert washers and bolts from the pipe side, insert washers and nuts from the valve side, and temporarilytighten them by hand. Unit : mm (inch)Nom. Size AxialmisalignmentParallelism(a-b)20-25mm(3/4”-1”)1.0(0.04)0.5(0.02)40-50mm(1 1/2”-2”)1.0(0.04)0.8(0.03)65-150mm(2 1/2”-6”)1.0(0.04)0.8(0.03)200mm(8”)1.5(0.06)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.)Recommended torque value Unit: N-m{kgf-cm}[lb-inch]Nom. Size 20mm(3/4”)25, 40mm(1”, 1 1/2”)50mm(2”)80, 100mm(3”, 4”)125, 150mm(5”, 6”)200mm(8”)Torquevalue17.5{179}[155]20.0{204}[177]22.5{204}[199]30.0{306}[265]40.0{408}[355]55.0{561}[488]Necessary itemsAvoid excessive tightening. (The valve can be damaged.)(Axial misalignment) (Parallelism)CautionCautionThe parallelism and axial misalignment of the flange surface should be under the values shown in thefollowing table to prevent damage the valve.(A failure to observe them can cause destruction due to stress application to the pipe) Avoid excessive tightening. (The valve can be damaged.)CautionFig. 1ASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 9 (6) Disassembling method for replacing parts ? Torque wrench ? Spanner wrench ? Protective gloves ? Safety goggles ? Bolt, Nut, Washer (For many flanges specification) ? AV gasket (When a non-AV gasket is used, a different tightening torque specification should be followed.) 1) Drain fluid completely from the pipe line.2) Loosen the connecting bolts and nuts, and remove the valve from pipeline.3) Loosen the bonnet ?2 and remove it from the body ?1 .Loosen the bolts and nuts ?9 and remove the bonnet ?2 .4) Loosen the plug ?4 and remove it. Thrust the bolt (A) to the threaded hole of shaft ?3 and pull outthe shaft from the body.Bolt sizeNom. Size 20-40mm(3/4”-1 1/2”)50mm(2”)65, 80mm(2 1/2”, 3”)100-200mm(4”-8”)Torque valve M4 M5 M6 M85) Check the worn of all parts. If the part is worn, replace it. 1) The produce of assembly is the almost reverse of its disassembly.2) Only seat can’t be replaced. When the seat has necessity to be replaced, replace the assembly part of seat.3) After completed the assembly, make sure that there is no leakage under the water pressure test.Necessary itemsWear protective gloves and safety goggles as some fluid remains in the valve.(You may be injured.)CautionASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 101) The produce of assembly is the almost reverse of its disassembly.2) Only seat can’t be replaced. When the seat has necessity to be replaced, replace the assembly part of seat.3) When the bonnet ?2 is replaced, make sure that the arm stopper direction of the bonnet.4) Tighten the bolt·nut ?9 diagonally and equally torque to fix the body ?1 and bonnet ?2 . Unit : N-m {kgf-cm} [lb-inch]Torque TorqueNom. Size PTFE Rubber Nom. Size PTFE Rubber25mm(1”)10.0{102}[89]6.0{61}[53]80mm(3”)20.0{204}[177]15.0{153}[133]30mm(1 1/4”)13.0{132}[115]8.0{82}[71]100mm(4”)25.0{225}[221]20.0{204}[177]40mm(1 1/2”)13.0{132}[115]8.0{82}[71]125mm(5”)25.0{225}[221]20.0{204}[177]50mm(2”)15.0{153}[133]10.0{102}[89]150mm(6”)30.0{306}[266]25.0{225}[221]65mm(2 1/2”)15.0{153}[133]10.0{102}[89]200mm(8”)30.0{306}[266]25.0{225}[221]5) After completed the assembly, make sure that there is no leakage under the water pressure test. (7) Inspection items? Inspect the follow items ;(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.ASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 11 (8) TroubleshootingProblem Cause TreatmentThe back pressure is low. Check for the back pressure.Seat is worn. Replacement.The Fluid is leaking past the fullyclosed position.Solid particles have lodged in thevalve.Clear the solid particles from thevalve.O-ring is worn. Replacement.Packing is worn. Replacement.Fluid leaks from the valveLooseness of bolts·nut. Retighten. (9) Handling of residual and waste materialsIn discarding remaining or waste materials, be sure to ask a waste service company.CautionASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 12 (10) InquiresASAHI ORGANIC CHEMICALS INDUSTRY CO., LTD.Nobeoka Head Office : 2-5955, Nakanose- Cho, Nobeoka –City, Miyazaki- Pref. , Japan. Tel : (81) 982-35-0880 Fax : (81) 982-35-9350Tokyo Head Office : (Furukawachiyoda Bldg.) 15-9, Uchikanda 2- Chome, Chiyoda-Ku, Tokyo, Japan. Tel : (81) 3-3254-8177 Fax : (81) 3-3254-3474Singapore Branch Office : 16 Raffles Quay, #40-03 Hong Leong Building, Singapore 048581. Tel : (65) 220-4022 Fax : (65) 324-6151Europe Representative Office : Kaiser-Friedrich-Promenade 61 D-61348 Bad Homburg v. d. H. Germany. Tel : (49) 6172-9175-0 Fax : (49) 6172-9175-25Shanghai Branch Office : Room 1301-P Shanghai Kerry Center, 1515 Nanjing Xi Road, Shanghai China Tel : (21) 5298-6900 Fax : (21) 5298-6556ASAHI /AMERICA Inc. :35 Green Street P.O.Box 653 , Malden, Massachusetts 02148 U.S.A. Tel : (1) 781-321-5409 Fax : (1) 781-321-4421DistributorASAHI AV VALVES Installation,Operation and Maintenance ManualSwing Check Valve 13Swing check valve.Information in this manual is subject to change without notice. 2003. 5ASAHI AV VALVES