SAPAG BUTTERFLY VALVES JMC

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Before installation these instructions must be fully read and understood

1.2.1 Storage conditions 1.3.2 Unpacked valves

The valves should be stored off the ground The lifting and the handling of these valves has
inaclean, dry indoor area. to be carried out by using appropriate means
Protect the valve from temperature and and by respecting the carrying limits. The
humidity extremes, and exposure to excessive handling must, preferably, be carried out on
dust, moisture, vibration, deformations, pallets, protecting the machined surfaces and
sunlight and ozone. seat to avoid damage.
When lifting the large dimension valves, the
Recommendations sling and the hooking of the load must be
1. Temperature: storage temperature below carried out by using the appropriate tools
25C, above 0C preferable below 15C. (brackets, hook, fasteners) and load balancing
2. Humidity: storage conditions should be such tools in order to prevent the valves from falling
that condensation does not occur, store in or moving during the lifting and handling.
a dry environment. Maximal 50% relative The valve may be lifted only by slings attached
humidity. to the flange holes or valve body; never to the
3. Light: valve rubbers should be protected actuator or the valve opening.
from light, in particular direct sunlight or
strong artificial light with high ultra violet.
4. Ozone: storage rooms should not
contain any equipment generating ozone.
Please read these instructions carefully E.g.lamps, electric motors.
Hazard potentials:
disregarding of instructions IMPORTANT
improper use of product Before valves are being installed or used
insufficiently qualified personnel thefollowing actions are recommended.
1. Valves/parts have to be inspected and
Valve application to be within the pressure/ thoroughly cleaned if required.
temperature limits indicated in the P/T diagram. 2. Rubber parts need to be greased with
siliconegrease if not present anymore.
Essential points and functions of the valve 3. All surfaces in contact with seats have to be
should be inspected on a regular basis. thoroughly cleaned and greased with silicone
grease if stored for more than 5 months.
1 STORAGE AND HANDLING
1.3 Handling
1.1 Protection 1.3.1 Packed valves
Sapag butterfly valves are delivered with Lifting and handling of the packed valves in
protection in accordance with the Sapag crates should be carried out by appropriate
Engineering Instructions, to protect the valve lifting equipment. If a fork lift truck is used,
seats and disc from damage. Wrapping and/or appropriate fork hitches are required.
covers should be left in place until immediately The lifting and handling of packed valves in
before fitting to the pipe. cases will be carried out in the lifting points.
The transportation of all packed material
1.2 Storage should be carried out safely and according
When valves are to be stored for some time thelocal safety regulations.
(2months or more) before being fitted,
storageshould be in the original delivery
cratesor cases.

www.valves.emerson.com 2017 Emerson. All rights reserved. VCIOM-03322-EN 15/04

SAPAG BUTTERFLY VALVES JMC
INSTALLATION AND MAINTENANCE INSTRUCTIONS

2 INSTALLATION 2.2 Flange and pipe compatibility

Check matching of flange drilling pattern of
WARNING valve and pipe flange before assembly.
For safety reasons, it is important to take the Flanges have to meet the following
following precautions before you start work on requirements:
the valve: - The face inside diameter should be:
1. Personnel making any adjustments to the valves D min. : The valve Q-dimension + adequate
should utilize suitable equipment. All required disc clearance.
personal protection means should be worn. D max.: The inside diameter (ID) of standard

D max./min.
2. The line must be depressurized before pipe for the nominal size ISO4200.
installing the valve. For larger inside pipe diameters

YY

Q
3. Personnel trained in all aspects of manual and contact factory.
mechanical handling techniques only must - If the flange (or pipe) is provided with a
carry out handling of the valves. raised face, the diameter of this shall be at
4. Misuse of the valve is not allowed. For least 10mm larger than the YY-dimension
example: the valve, handles, actuators or other of the valve.
parts may not be used as climbing tools. - The use of the flange gaskets is not allowed
5. Ensure that valve pressure/temperature since it might damage the valve.
limitations marked on the identification tag are - The Sapag seat face design eliminates the
within the service conditions. The trim number need for the gaskets.
on the valves tagplate identifies the valve - Use flange bolting in agreement with
materials. See Product Manual for valve specific appropriate standard.
P/T diagram and trim number definition.
6. Ensure that valve materials are compatible Do not use flange gaskets!
with the pipeline fluid.
2.3 Valve installation
2.1 Valve inspection The valves are bi-directional and may be fitted
1. Carefully remove the valve from the in either direction relative to the flow. The valve
shipping package (box or pallet) avoiding any will control flow equally in either direction. The
damage to the valve or, in case of automated recommended installation position is shaft
valves, to the electric or pneumatic/ horizontal and the lower disc edge opening
hydraulic actuator or instrumentation. down-stream. (Especially for slurry service
2. Confirm that the materials of construction and media with a tendency for sedimentation).
listed on the valve nameplate are For optimum valve control and smooth
appropriate for the service intended and are performance, it is recommended to have a
as specified. 10to 20 pipe diameters of straight run inlet
3. It is not allowed to use third party spare piping and 3 to 5 pipe diameters straight outlet
parts. In case of third party spare parts, piping. A valve is no crow-bar. Do not use the
safeoperation is not guaranteed. valve to spread the flanges. Seat damage might
be theresult.

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SAPAG BUTTERFLY VALVES JMC
INSTALLATION AND MAINTENANCE INSTRUCTIONS

NOTES 2.5 Sources of possible danger

The valve can be installed in the pipe-line either This section contains some examples of
with or without the actuator mounted on top of the possible foreseen danger sources.
valve. Make sure that you can turn the disc cautious
so you can detect a mismatch resulting from a disc 2.5.1 Mechanical
touching the adjacent piping. A. When manual operators are used, available
Do not use the valve as a support of the pipe line space should be checked in order to avoid
construction. hands being clamped.
Adjacent piping must be positioned so that minimal B. Mechanical sparks caused on impact of
piping stresses are transmitted to the valve flanges valve and e.g. tooling, are a potential source
during or after installation. of ignition of surrounding atmosphere.
Handling and lifting of the valves during installation
MUST be performed following the same instructions 2.5.2 Electrical
described in previous paragraph 1.3 Handling. If static charges or stray electrical currents
can initiate explosions, the valve should be
IMPORTANT grounded to earth.
Mating flange faces should be in good condition
and free of dirt and/or inclusions. Both pipe 2.5.3 Thermal
insides to be well cleaned. A. If the valve is used in applications with a
fluid temperature above 40C the outside
1. Check whether the flange distance meets of the body might be hot. Sufficient
the valve face-to-face dimensions. Spread measurements should be taken to avoid
with adequate tooling the flanges for easy burning. A manual operated valve should be
insertion of the valve. opened and closed with sufficient protection
2. Close the valve so far, that the disc edge is for the personnel operating the valve.
at least 10mm within the body. Forexample: protecting gloves.
3. Insert the valve between the flanges, center B. Hot surfaces can be a potential source of
the valve body and insert all flange bolts. ignition of environment.
4. Maintain the valve flange alignment while
gradually removing the flange-spreaders 2.5.4 Operational
and tighten the flange-bolts hand tight. Closing a valve too fast may result in
5. Slowly open and close the valve to check waterhammer in the upstream part of the
foradequate disc clearance. pipeline. Waterhammer results in excessive
6. Cross-tighten all bolting to the proper torque. stresses in the valves body and will cause
severe damage.
2.4 Valve verification Waterhammer should be avoided in all
Check the operation of the valve by operating circumstances.
it to full open and full close. To verify the Due to differential pressure across the valve
valve operation, the disc position indicator on disc, butterfly valves have the tendency to
the actuator or the manual operator should be closed by the flow. Thisis called dynamic
rotate between the full open and full close torque. Take care when unlatching or removing
indicators. Generally the valve disc travels the valve operating mechanism. The valve
clockwise to close. might be closed by the dynamic torque created
by the flow.

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SAPAG BUTTERFLY VALVES JMC
INSTALLATION AND MAINTENANCE INSTRUCTIONS

2.6 TROUBLESHOOTING GUIDE

Symptom Possible cause Resolution
Valve would not rotate Actuator has failed Replace or repair
Valve packed with debris Flush or clean valve to remove debris
Valve leaking Valve not fully closed Close valve
Debris trapped in valve Cycle and flush (with valve open) to remove debris
Seat is damaged Replace seat
Jerky operation Debris trapped in valve Cycle and flush (with valve open) to remove debris
Air supply actuator inadequate Increase air supply pressure and/or volume

3 MAINTENANCE 3.4 Valve assembly WARNING

1. Place the valve on a horizontal support. Depressurize and, if necessary in case of
The Sapag butterfly valve JMC is designed to Inspect correct position of bearings. For dangerous fluids, drain the line and flush with
require a minimum of maintenance. some sizes a circlip should be mounted on appropriate cleaning fluid before starting any
driving shaft and in disc bottom shaft hole. maintenance. Failure to do so may cause serious
3.1 Routine maintenance 2. Collapse the seat in the shape of a heart personal injury and/or equipment damage.
Routine maintenance or lubrication is not perpendicular to the shaft holes. Pull the Before disassembling the valve ensure the valve
required other than periodic inspection to seat lip over the edges and push the hubs has been decontaminated correctly from any
ensure satisfactory operation and sealing. If into the shaft holes. Divide the rubber harmful gasses or liquids and that it is within a
problems occur with valve pressure tightness equally over the complete circumference. safe temperature range for handling.
the seat can be replaced. 3. Put some silicon grease on the inside of Personnel making any adjustments to the valves
the seat. Especially on the circumferential should utilize suitable equipment.
3.2 Removing the valve contact area between shaft and seat, the All required personal protection means should
1. Turn the disc to the nearly closed position. shaft bearing and seat hole. be worn.
(The disc is in line with the keyway in Pay attention!! Area between seat outside Only personnel trained in all aspects of manual
thestem). and body inside should be free of grease. and mechanical handling techniques must carry
2. Secure the valve with proper lifting 4. Lift the disc in vertical position (shaft holes out handling of all valves.
equipment and loosen all flange bolts and horizontal) leaving the shaft holes free.
remove the bolts, which prevent removing of 5. Let the disc descend into the seat until the
the valve. shaft holes of body and disc are exactly
3. Spread the flanges width adequate tooling, inline.
and remove the valve. 6. Insert the bottom shaft in the initial position
as marked during disassembly. Take care of
3.3 Valve disassembly spline or key position if applicable.
1. Place the valve on a horizontal support. 7. Insert driving shaft with fixed thru bolt. Put
2. Turn the disc to the full open position. the shaft in the initial position as marked
3. Remove the actuation. during disassembly. Position of spline, key
4. Secure the disc with proper lifting or square should match exactly. Look at
equipment. the mark on shaft and disc placed during
5. Remove the bottom plug or cover. disassembly. When the shaft is ca 10 cm
6. Remove the nut of the thru-bolt at before its landing surface the shaft seal
bottomhub. should be placed on the shaft top. For some
7. Mark the position of the bottom shaft and of sizes a circlip should be mounted near
the driving shaft versus the disc. stemhead to lock up the seal.
8. Pull the driving shaft and belonging 8. Mount nut and ring on thru bolt at bottom
thru-bolt out off body and disc. If required shaft side and tighten.
use threaded hole in stemhead. Support 9. Place bottom plug or cover and tighten
shaft and disc during removal. It is possible screws.
that also the shaft seal is removed. 10. Remount the actuation and test valve
9. Remove bottom shaft. If necessary the
shaft can be pushed out with help of a bar
through the body driving shaft hole.
10. Lift the disc out off the body.
11. Pull the lip of the seat out off the groove and
deform the seat to the shape of a heart and
remove the seat.

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SAPAG BUTTERFLY VALVES JMC
INSTALLATION AND MAINTENANCE INSTRUCTIONS

PARTS LIST DN50 - 125

Part Name
1 Body
2 Disc
3 Driving (top) shaft
4 Bottom shaft
5 Seat
6 Bearing
7 Nut + spring washer
8 Plug
9 Seal
10 Thru bolt
11 Bushing

DN250 - 300
PARTS LIST DN150 - 300
Part Name
1 Body
2 Disc
3 Driving (top) shaft
4 Bottom shaft
5 Seat
6 Bearing
7 Nut + spring washer
8 Plug
DN150 - 200
9 Seal
10 Thru bolt
11 Key

PARTS LIST DN350 - 800

Part Name
1 Body
2 Disc
3 Driving (top) shaft
4 Bottom shaft
5 Seat
6 Bearing
7 Nut + spring washer
8 Plug
9 Seal
10 Thru bolt
11 Snap ring
12 Key

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SAPAG BUTTERFLY VALVES JMC
INSTALLATION AND MAINTENANCE INSTRUCTIONS

PARTS LIST DN900 - 1000

Part Name
1 Body
2 Disc
3 Driving (top) shaft
4 Bottom shaft
5 Seat
6 Bearing
7 Nut + spring washer
8 Cover
9 O-ring seal
10 Thru bolt
11 Snap ring
12 Screw + washer
13 Key
14 Bushing

PARTS LIST DN1050 - 1600 (PN10)

Part Name
1 Body
2 Disc
3 Driving (top) shaft
4 Bottom shaft
5 Seat
6 Bearing
7 Nut + spring washer
8 Cover
9 O-ring seal
10 Thru bolt
11 Snap ring
12 Screw + washer
13 Key
14 Bushing

PARTS LIST DN1600 (PN16) - 2400

Part Name
1 Body
2 Disc
3 Driving (top) shaft
4 Bottom shaft
5 Seat
6 Bearing
7 Nut + spring washer
8 Cover
9 O-ring seal
10 Thru bolt
11 Snap ring
12 Screw + washer
13 Key
14 Bushing

2017 Emerson. All rights reserved. 6