CE-Certificate/Installation Manual

AVK BUTTERFLY VALVES

PREFACE
This document serves as a valve manual directed to system engineers and other end users.
Regarding the actuation devices, please consult the enclosed users manual if an actuator has been previously
mounted on a valve.

A currently mounted valve in a European pipeline system may be subject to European directives regarding the valve/
actuator unit.

If applicable, end users and system engineers shall complete the certification procedure for the CE marking of the
system.

INTRODUCTION
The purpose of this manual is to instruct system engineers and end users on installation and usage procedures
regarding the butterfly valve in flanged pressurised piping systems.
This manual must be carefully studied prior to the handling and installation of the butterfly valve and should be kept
accessible after installation has been completed.
It is extremely prudent to incorporate these instructions throughout the entire installation process and all handling of
the butterfly valve.

This valve can be used as an isolating valve. However, it cannot be used as a regulating or control valve. The valves
material and coating are primarily intended for use with water, sewage and neutral liquids. If system conditions deviate,
either chemically or physically, from the intended norm of the valve, an acceptance for the application must be
obtained from AVK.

Warning: Not observing the recommendations and cautions explicitly presented in this manual will lead to limitations
of the valves warranty and possible unsatisfactory performance of the valve.

SAFETY PRECAUTIONS
Valves and actuators are essential control devices in a pressurised pipeline system. Incorrect handling, installation,
operation, and/or maintenance may cause serious injury to personnel as well as damage to the equipment. All
handling, installation, operation, and maintenance instructions presented in this manual must be followed carefully.

For valves with an end of line duty, it is strongly recommended to mount a blind flange or a grating at the open face
end of the valve, taking into account the displacement of the disc when the valve is open.

If system pressure or temperature exceeds proposed limits for the valve, discontinue operation immediately.

Always avoid contact with the disc during valve operation.

VALVE DESCRIPTION
General
Essentially, the valve body is a cylindrical apparatus designed specifically for pressure containment. The lining of the
valve body is comprised of either A) a full, yet loosely lined rubber, adequate for sealing and corrosion protection,
and containing integral flange gaskets or B) epoxy, requiring a loose flange gasket. The valve body is equipped with
end connectors enabling mounting between pipe flanges as either lugs or flanges. One shaft extends from the body
through an ISO flange and is used to operate the disc by means of the actuation device. The disc is a circular device
that is capable of a 90 rotation along the shafts axis. The outer edge of the disc is either in a closed position, sealed
against lining of the valve, or meets a seat in the body. The action of the valve is dependent on the position of the
disc. When the disc becomes perpendicular to the pipeline, the valve is closed. When the disc becomes parallel to
the pipeline, the valve is fully open. The orientation of the disc is indicated by a groove at the end of the shaft that is
in-line with the disc.

Valve characteristics
The valve has been designed for and tested at an established working pressure according to the PN value marked on
the body, unless a type plate indicates a lower pressure. The minimum and maximum service temperatures restricted
by the lining material are indicated on the valve label or the accompanied datasheet. The valve is mainly designed for
use with water, sewage, and neutral liquids, but may also be used in other duties after consulting AVK. Please note
that the life time of the valve may be reduced when used in slurries, corrosive and erosive liquids, or cavitations due
to high flow velocity.

AVK INTERNATIONAL A/S/June 2004-rev. A

51756XAB
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AVK BUTTERFLY VALVES

HANDLING AND STORAGE

Handling
To avoid mechanical damage, valves must be handled and lifted with care. In addition, they must not be exposed to dirt or chemicals that
might damage the material of their construction. The most critical exposure points to the valve are its ends (flanges) and inside liner/epoxy
coated seat. The handling procedure should affirm that appropriate equipment is to be used to move/lift the valve, and that valve stability is
a must before being lowered and its sling removed.

Storage
Valves should be stored under dry, dark, and cool conditions, preferably indoors with a temperature higher than the dew point. If outdoor
storage is unavoidable, valves should be placed off the ground or pavement, protected from direct sunlight, and its ends should be covered.
The valve should also be stored in slightly open position to avoid deformation of the rubber lining/seat gaskets.

INSTALLATION
Inspection prior to installation
Prior to installation, you should make a visual inspection of the valve for damages that may have occurred during transport, handling, or
storage that might affect the valve performance. Carefully unpack/inspect the valve and check labels and other markings on the valve.
Extensively inspect the valve interior and lining through the end parts/flanges. The valve must be clean, free from foreign bodies, and
undamaged. Check that all electrical components are marked with the correct IP rating and hazard class if the valve is to be used in a
hazardous location. If possible, actuate the valve through close - open - open - close cycles to check the function of the valve. Avoid contact
with the valve disc during operation. Immediately prior to installation, check the flanges to which the valve is to be fastened. The flanges
shall have a raised or a flat face. The sealing face shall be smooth, without burrs, grooves, weld spatters, sharp edges, as well as free from
dirt. The inside flange diameter shall be large enough to accommodate the protrusion of the valve disc when the valve is open. Interference
between disc and pipe shall be checked in order to avoid complications. If needed, check the inside diameter of the flange in relation to the
flange gasket.

Installation between flanges

Please note, that valves with an inside rubber liner do not require additional flange gaskets as the lining will seal against the mating flange
face. The valve is bi-directional; the direction of installation is therefore not decisive. When installed in a horizontal pipe system, valves larger
than DN 300 shall have the shaft positioned horizontally. Check that the face to face length between the pipe flanges enables installation of
the valve without damaging the rubber lining. Place the slightly open valve in the centre of the pipeline.

Check that the bolts have the right sizes and lengths. Tighten the bolts in a cross directional way (fig. 1). For valves with a rubber liner, until
the valve body (metal) touches the flange face. For valves with loose flange gaskets, please observe the gasket manufacturers recommenda-
tions. Flange adapters or dismantling joints are recommended to allow adjustment of the face to face dimensions. In order to avoid overheat-
ing of the lining, do not weld a connecting flange to the pipe after installation of the valve.

Testing
Open and close the valve, if possible by hand, to ensure that there is no disc interference (obstruction).
Clean the pipeline interior with a rinsing liquid. Connect the actuator (if mounted) to the power supply in accordance with the users manual.
Check the operability and tightness when the system is under pressure (max. pressure 1.1 x PN for closed valves, 1.5 x PN for open valves
according to EN 593 (EN 1074)) before covering/closing the installation.

OPERATING CONDITIONS
Check the following points when the valve is operating:
- The noise level when the fluid is flowing through the valve. The noise should be less than (70 dB(A)).
- Whistling sounds in the liquid pipe lines
- Noise from pebble and gravel moving with the flow
- Mechanical noise from moving valve/actuator parts.

Note: High noises (70-85 dB(A)) can be reduced by insulating the valve. High noise levels (>85 dB(A)) might be a warning of serious troubles.
System engineers should be contacted to determine the cause and evaluate possible need for action. Also check the noise level when the
valve is closing.

Warning: Rapid closure of a valve in a flowing liquid pipeline can cause substantial pressure surge which may result in a water hammer effect.
If such cases, the closing time of the valve shall be extended by adjusting or changing the actuator.
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AVK BUTTERFLY VALVES

MAINTENANCE
It is recommended to periodically schedule partial, as well as full cycle exercises of valves that remain in either closed or open positions for
long periods. Please note that ageing valves may suffer variable reduction in operability.

The changing of one actuator or later fitting to another type of actuator is possible, however torque levels and ISO flange sizes must be
observed. For further information, see separate datasheet from AVK.

Please note that for safety reasons, the removal of actuators while the valve is under pressure is not recommended.

TROUBLE SHOOTING
Leakage through flange gaskets can be caused by the following:
- Valve is not centred in the pipe centre line
- Gasket surface/rubber lining is damaged
- Bolt torques have not been correctly calibrated
- In regard to loose gaskets, refer to the recommendations of gasket supplier
- In regard to loose liner valves, refer to table 1

Internal leakage beyond the closed disc can be caused by the following:
- Permanent damage in the sealing areas caused by foreign objects
- Erosion of sealing surface due to frequent operation
- Actuator is not fitted correctly and is thus end loading on the shaft
- Actuator is incorrectly adjusted
- In regard to torque adjustments of gear box/actuator, refer to table 2

Shaft leakage can be caused by the following:

- Shaft sealing is aged or damaged. Please consult AVK for further instructions

TABLES Fig. 1

Table 1: Recommended torques on flange bolts

Observe gasket suppliers recommendations

Valve size Bolt torque

DN 40 - DN 125 50 Nm
DN 150 - DN 350 100 Nm
DN 400 - DN 500 160 Nm
DN 550 - DN 600 250 Nm

Table 2: Closing torque

Torque set at actuator Turns Handwheel Turns Rupture

Valve size (Actuator mountedto open max. closing to open Free running torque (Nm)
Series 756 on ISO-Gearbox) Actuator torque (Nm) Handwheel torque (Nm) (EN 1074)
DN 200 - DN 250 50 Nm 10 40 - 60 8.5 7 200
DN 300 - DN 350 - DN 400 100 Nm 17.5 80 - 100 - 120 9.5 7 380
DN 450 - DN 500 - DN 600 150 Nm 17.5 120 14*/21** - 14*/21** - 21 7 500 - 500 - 600
* Hand wheel operated / ** Buried version

Torque set at actuator Torque set at actuator

Valve size (Actuator mounted Valve size (Actuator mounted
Series 813 directly on valve shaft) Series 813 directly on valve shaft)
DN 40 10 Nm DN 250 330 Nm
DN 50 20 Nm DN 300 520 Nm
DN 65 30 Nm DN 350 721 Nm
DN 80 40 Nm DN 400 981 Nm
DN 100 60 Nm DN 450 1202 Nm
DN 125 80 Nm DN 500 1502 Nm
DN 150 130 Nm DN 600 2103 Nm
DN 200 170 Nm
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AVK BUTTERFLY VALVES

Declaration of Confirmity
In accordance with Annex II B to the Machinery Directive

Manufacturer: AVK International A/S

Bizonvej 1, Skovby
DK-8464 Galten
Denmark

Phone: +45 87 54 21 00
Fax: +45 87 54 21 20
Web: www.avkvalves.com

We hereby declare that the below products comply with the EN 292/1 and EN 292/2 standards in the EU
Machinery Directive.

Product: Shut off valves, type butterfly, centric and double eccentric, with flanges, Lug, Semi-lug,
or Wafer.

Serial no: AVK series 756 and 813.

Galten 21.04.2004

AVK International A/S

Morten Sderup Nielsen

Managing Director

AVK International A/S Bizonvej 1, Skovby 8464 Galten Tel.: +45 87 54 21 00 Fax: +45 87 54 21 20
www.avkvalves.com