Sei sulla pagina 1di 19

PER

RMAL
LOK 5

B
BULK
K MA
ATER
RIAL HAN
NDLIN2
2012
NG V
VALV
VE
INSTALLA
ATION, OP
PERAT
TION &
MA
AINTE
ENANCCE MA
ANUAAL

C
ClydeBergem
mannPowerG
Group
333SproulRoad
M
Malvern,PA19
9355
U
USA
TTollFreeTel:80
002382974
TT:610695970
00
FF:6106959724
W
Web:http://ww
ww.cbpg.com//
eemail:sales@deltaducon.com
m
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE


SAFETY WARNING:

Toavoidpersonalinjuryordamagetoproperty:

ThePermalok5valvedesignincorporatesaspringloaded,shearingdiscwhichrotates
asitcutsthroughthematerial.Inaddition,thecylinderandpivotarmontheoutsideof
thevalvemoveasthevalvecycles.Failuretooperatethevalvewithallguardsinplace
mayresultinseriousinjury.

Checkthattheliftinggearisratedtocarrytheweightofthevalve.
Makesuretheeyeboltshavethesamethreadastheboltholesandthattheyarewell
secured.

Duringinstallationitisrecommendedtoliftthevalveviasoftstraps.Thesecanbeto
theupperpartofthevalvebody.

Thoseinchargeofhandlingandmaintenanceofthevalvemustbequalifiedand
trainedinvalveoperations.

Useappropriatepersonalprotectionequipment(gloves,safetyshoes,etc).

Shutoffalloperatinglinestothevalveandplaceawarningsign.

Isolatethevalvecompletelyfromtheprocess.

Releaseprocesspressure.

Draintheprocessfluidfromthevalve.

Beforeinstallation,inspectthevalvebodyandcomponentsforanydamagethatmay
haveoccurredduringshippingorstorage.Makesuretheinternalcavitieswithinthe
valvebodyareclean.Inspectthepipelineandmatingflanges,makingsurethepipeis
freeofforeignmaterialandthattheflangesareclean.

Page 2 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

INTRODUCTION:

ThePermalok5Valveisdesignedforaggressivematerialhandlingapplications.The
valveisintendedforuseonsystemshandlingdry,powderedmaterialonly.Thevalves
maybesubjectedtovacuumorpressure,andmateriallowfromeitherdirection.Valves
maybeusedasanairlockvalve,divertervalve,orshutoffvalve.Permalok5valvesare
designedtocutthroughastaticormovingcolumnofmaterial.

BodyConstruction: CastIronorCarbonSteel
DiscandSeat: 440CStainlessSteel
OperatingLimits: 100psig,550F
RecommendedAirSupply: 80100psig

ThePermalokvalveisshippedcompletewithpneumaticcylinderoperator,open/closed
limitswitches,andsolenoidvalve.Limitswitchesandsolenoidsareselectedtomeet
contractspecifications.Whererequired,thelimitswitchesandsolenoidmaybewiredto
alocalterminalboxmountedtothevalvebody.

INSTALLATIONNOTES:

Permalok5valvesmaybeinstalledineitherverticalorhorizontalpipelines.When
installedinverticalpipelines,theactuatormaybeorientedsuchthatitisonthetopor
theundersideofthevalve.Wheninstalledinhorizontalpipelines,theactuatorshould
beinstalledpointinguporwithin45degreesofstraightup.

Permalok5valvesincludeflatfacebodyflanges.Fullfaceflangegasketsandflatfaced
matingflangesarerecommended.Whenboltingtomatingflanges,tightenbolts
graduallyfollowingasequencealternatingboltsonoppositesidesoftheflange.
Recommendedfinalbolttorquevaluesarelistedinthetablebelow.

NoteuseASTMA193B7boltswhenoperatingtemperatureexceeds450F.

ValveSize BoltSize ASTMA307B ASTMA193B7


24 5/811 17ftlbs 60ftlbs
58 3/410 30ftlbs 105ftlbs
1012 7/89 47ftlbs 170ftlbs

Page 3 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

VALVEOPERATION:

CAUTION:ThePermalok5valvedesignincorporatesaspringloaded,shearingdisc
whichrotatesasitcutsthroughthematerial.Inaddition,thecylinderandpivotarmon
theoutsideofthevalvemoveasthevalvecycles.Failuretooperatethevalvewithall
guardsinplacemayresultinseriousinjury.

Permalokvalvesaretypicallyassembledsuchthatthesolenoidvalvemustbeenergized
toopenthevalve.Thestandardpneumaticcylinderisdoubleacting,thereforethevalve
willfaillastpositionuponlossofair.Anoptionalfailsafeairreservoirsystemis
availabletoclosethevalveuponlossofprimaryairpressure.

Athreaded,pluggedportispresentonthevalvebody.Thismaybeusedforinspection,
orinjectionofpurgeair.Intermittentuseofpurgeairwhilecyclingthevalvemayaidin
removingmaterialdepositsandfreeavalvethatdoesnotfullyopenorclose.Ifpurge
airisintroduced,itshouldnotbeusedcontinuouslyduringnormalsystemoperation,as
thismayacceleratewearofinternalcomponents.

Page 4 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

VALVEMAINTENANCE:

Maintenancechecksshouldbeperformedasdescribedbelow.Theintervalslistedare
themaximumrecommendedvalues.Morefrequentchecksmaybenecessarybasedon
theoperatinghistoryofthesystem.

RecommendedInspectionSchedule
Item Interval
ValveAssembly 6months
ValveCycling 6months
Disc/SeatSealSurfaces,ValveInternals 12months
AirCylinderSeals 12months

ValveAssembly:Checkbodybolting,actuator&pivotarmmounting,mounting&
electricalconnectionsofsolenoid,limitswitches.Confirmmechanicallimitswitches(if
present)arenotbentorbroken.

ValveCycling:Observevalveopeningandclosingthroughseveralcyclestoconfirm
smoothoperationwithouthesitation,chatteringorexcessivenoise.Confirmvalve
reachesthefullyopenandfullyclosedlimitsandseatsproperly.

Disc/SeatSealSurfaces,ValveInternals:Disassemblematingequipmenttovisualize
interiorofvalve.Seatmaybeviewedwithvalvefullyopen.Discmaybeviewedwith
valvepartiallyclosed.Checkforlargeordeepscratchesornicksindiscorseat.Check
valveinternalsforexcessiveabrasivewearormaterialbuildup.Cleanandreplaceany
internalcomponentsasneeded.

AirCylinderSeals:Checksealsforleakagebyalternatelypressurizingbothsidesofthe
cylinder.PressurizePortA.Afterstrokeiscomplete,blockoffPortB,waitbrieflyand
checkforapressurebuildup.Next,pressurizePortB.Afterstrokeiscomplete,blockoff
PortA,waitbrieflyandcheckforapressurebuildup.

Page 5 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

TROUBLESHOOTING:

PROBLEM POSSIBLECAUSE SOLUTION


Valvechatter. Insufficientairvolume. Enlargeairlinetosolenoid.
Installairaccumulatorat
cylinder.
Valvedoesnotfully Insufficientairpressure. Confirmsupplyairiswithin
open/closeormoves Differentialairpressuretoo operatingrequirements.
slowly. high.Airlinetosolenoid Insufficientairvolume.
toosmall. Insufficientstroketime.
Lossofpowertosolenoid. Trydirectconnectiontoair
cylinder.
Solenoidobstructed. Cleanairlines,replace
solenoid.
Blowncylinderseal. Checkcylinderpiston&rod
seals.
Mediacompacted. Addpurgeairjustbefore
openingvalve,stopasvalve
closes.
Valvepositioned Checkcylinderorientation
incorrectly. ifvalveisinstalledin
horizontalpipeline.
Foreignobjectjammedin Checkbodyinspectionport.
bodyorexcessivematerial Disassemblevalve,remove
buildup. objectorcleanvalve.
Valveleaksinternally. Discsnotcoveringports.
Scoredorerodedseator Reconditionorreplace
disc. sealingsurfaces.
Discspringcompressedby Checkdiscspringforce.
weightofmedia. Replacewithheavyduty
springsifneeded.

Discspringbroken. Replacespring.
Valvecloses,butdoesnot Pressurelockbetween Lowervesselorline
reopen. discs. pressure.Installhigh
compressiondiscsprings.
Ventdisconhighpressure
port.

Page 6 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

REPAIR:

Permalok5valvesmaybereturnedtothefactoryforreconditioningifamajoroverhaul
isrequired.Repairssuchasreplacingpacking,discsorseats,limitswitches,solenoidetc.
maybeperformedonsite.PleasecontactClydeBergemannfordetailedrepair
procedures.

SPAREPARTS:

RecommendedsparepartsforthePermalok5Valveareincludedinthespareparts
listingprovidedforthecompletesystem.ClydeBergemannrecommendsthatyoukeep
afullsetofsparepartsininventory.Inaddition,itmayalsobevaluabletokeepa
complete,fullyassembledvalveininventorytoreducedowntimewhenrepairsare
necessary.

Foracompletelistingofpartsforallvalvesizes,refertotherelevantdrawingsinthe
followingpages.

Page 7 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 8 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 9 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 10 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 11 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 12 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 13 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 14 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 15 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 16 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 17 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 18 of 19
PERMALOK 5 VALVE

INSTALLATION, OPERATION AND MAINTENANCE

Page 19 of 19