INSTRUCTIONS ON INSTALLATION, OPERATION …

1 INSTRUCTIONS ONINSTALLATION, OPERATION ANDMAINTENANCE FORKIRLOSKAR MULTI DOOR NONRETURN VALVESKIRLOSKAR BROTHERS LIMITEDMANUFACTURING UNIT, KONDHAPURI (PUNE)KIRLOSKAR BROTHERS LIMITED,VALVE BUSINESS UNIT, KONDHAPURI (PUNE)DOC. VBU/IOM/MDNRV-01, Page 2 of 13 Issue No. 00, Rev. 0, Date Introduction2 Inspections on Receipt, Handling, Storage & Inspection on Receipt & Storage & prevention3 INSTRUCTIONS for Checks on Valve Assembly before Checks for the Pipeline before Installation4 Pre- commissioning Commissioning5 Operation6 maintenance Instructions7 Troubleshooting of Kirloskar Multi Door Non Return Valves8 Recommended Spares for Butterfly Valves9 Safety INSTRUCTIONS 10 Ordering InformationKIRLOSKAR BROTHERS LIMITED,VALVE BUSINESS UNIT, KONDHAPURI (PUNE)DOC. VBU/IOM/MDNRV-01, Page 3 of 13 Issue No.

2 00, Rev. 0, Date MULTI DOOR NON RETURN VALVES1. INTRODUCTIONF igure 1 Kirloskar Multi Door Non Return Valves generally conform to IS 5312,Part-2 standard for dimensions, materials of construction and constructionalfeatures, as per the need of the application. These Multi Door Non ReturnValves are Metal Seated type with a choice of by-pass arrangement as anoptional accessory and have proven doors of the Multi Door Non Return Valve are hinged on Diaphragm. DoorRings and Diaphragm Rings are precisely machined, scraped and lapped to getmirror finish for achieving Kirloskar Multi Door Non Return Valves, No. of doors are two for sizes 600to 800mm, three for sizes 900 & 1000mm and four for sizes 1100 & Door Non Return valveTypical ViewKIRLOSKAR BROTHERS LIMITED,VALVE BUSINESS UNIT, KONDHAPURI (PUNE)DOC.

3 VBU/IOM/MDNRV-01, Page 4 of 13 Issue No. 00, Rev. 0, Date arrangement is provided at specific requirement from customer, andthe size of by-pass arrangement is referred from standard IS: 5312, INSPECTION ON RECEIPT, HANDLING, STORAGE & INSPECTION ON RECEIPT AND HANDLINGa. At receipt of the product, ensure that there are no transit damages tothe product received, especially on valve flanges, door / diaphragm ringfaces Also ensure that Parts and Accessories are received as per orderedscope of Ensure that adequate numbers of fasteners for mounting accessories While unloading the product, please use the provision of lifting made onthe valve ( Lifting Lugs, Lifting eye bolts).e. Use the safe lifting devices ( slings, hoists, hooks etc.) of Do not pass the slings through the weak parts of the product / accessory( By-pass bends when it is assembled with the valve).

4 G. The valve should be transported so that the Inlet Side flange rests on thehorizontal Support the valve properly during transportation to avoid Handle the product carefully do not push, drag, drop from damages, short supply or wrong supply are observed, report the same immediately to the contact person mentioned in this STORAGE & PRESERVATIONIf the valve has to be stored at site before INSTALLATION, a. Store it on horizontal level surface in dry and clean Store the products in well-covered sheds, protected from sun, rain In the instance if the valve is required to be stored for long duration,ensure that rust preventive should be applied on the machined It is advisable to give a coat of grease on seat rings during the storageperiod. Keep the seat rings away dusty BROTHERS LIMITED,VALVE BUSINESS UNIT, KONDHAPURI (PUNE)DOC.

5 VBU/IOM/MDNRV-01, Page 5 of 13 Issue No. 00, Rev. 0, Date INSTRUCTIONS FOR installation CHECKS ON THE VALVE ASSEMBLY BEFORE INSTALLATIONa. Before taking the Multi Door Non Return Valve for pipe installation , makesure that it is cleaned from inside and outside and there are no foreign ormetallic objects sticking on to its sealing elements. Also clean the valveinterior passages to remove any foreign matter & rust preventive onmachined Ensure that the entire rust preventive on the machined surface in the flowarea is removed, before the valve is put in Note the name plate details on valve body and check valve pressure ratingadequacy with respect to operating pressure. Also check direction of flow inthe pipe-line and place the Multi Door Non Return Valve Valves should be installed in the pipeline, only after verifying the sealingability of valve.

6 This can be done by examination of the seat surfaces forfreedom from surface damages, scratch marks / dent marks as well asuniform mating of body diaphragm rings and door rings. If any abnormalitiesare observed, contact Multi Door Non Return Valves are designed to generally operate horizontalpipe lines, unless otherwise prior specified by the customer at the time ofplacement of Operate the doors of Multi Door Non Return Valve manually from Full Closeto Full Open and Full Open to Full Close. Ensure that there is no undueresistance / friction in the Before connecting valve & pipeline flanges, ensure that they do not haveparallel, angular and radial gaps. While fitting the valve in pipeline, ensurethat diagonally opposite bolts are simultaneously & uniformly Orientation of Hinge Pins of the valve, while fitting in the pipe-line must behorizontal.

7 This can be ensured by checking level of the support for thevalve foot, using spirit CHECKS FOR THE PIPE-LINE BEFORE INSTALLATIONa. Clean the pipeline thoroughly so that it does not contain any solidmatters which may damage the valve Avoid parallel, radial and angular mismatch between connecting flangesof valve and the Upstream and downstream piping should be adequately supported andanchored (if required) in such a way that the piping system does notimpose any forces & moments on the valve body and the hydraulicKIRLOSKAR BROTHERS LIMITED,VALVE BUSINESS UNIT, KONDHAPURI (PUNE)DOC. VBU/IOM/MDNRV-01, Page 6 of 13 Issue No. 00, Rev. 0, Date arising due to valve closure is carried & sustained by valvesupports. Valve flanges are not designed to carry any external loads andmoments arising due to pipe expansions / contractions.

8 It is advisable touse Flange Adapter Assembly, after the valve to facilitate valvedismantling and to prevent any undue loads being transmitted to Provide suitable concrete block with foundation bolts for supporting thevalves. It is advisable to install a support for the valve at bottom toprevent any sagging to be caused by weight of the Ensure that pipeline flanges are parallel and are mating the valve flangewithout leaving any parallel or angular gap between the flanges. Do notover-tighten the flange bolts / nuts to make the flanges parallelforcefully. That may develop undue stresses in the valve flanges & bodyleading their deformation & If the Multi Door Non Return Valves are supplied with By-passarrangement (against specific order requirement), ensure the by-passarrangement on the valve is Maximum flow velocity in the pipe-line should not exceed 4 The valves are mainly designed for handling clear water with maximumimpurities of 5000 PRE-COMMISSIONING CHECKSa.

9 Ensure manually that the valve doors open and close Flow Direction of the valve matches with that in the The entire pipe flange bolting is properly Surge protection devices (if any) are COMMISSIONINGa. Open the By-pass Valve across the valve (if provided).b. Charge the pipe-line with Ensure that there is no leakage through flange the valve is commissioned for its OPERATIONa. By-pass valve (if provided) keep it open while every Start / Stopoperation cycle of the BROTHERS LIMITED,VALVE BUSINESS UNIT, KONDHAPURI (PUNE)DOC. VBU/IOM/MDNRV-01, Page 7 of 13 Issue No. 00, Rev. 0, Date Once the Multi Door Non Return Valve is closed, the By-pass valve maybe kept closed till next OPERATION of the maintenance INSTRUCTIONSM aintenance Check to CheckMethod ofCheckingWeeklyDuringOverhaul01 Leakage through valve seatVisual / Feel 02 Noise / Vibrations while Opening orClosing the ValveFeel 03 Condition of Door Ring / DiaphragmRing faces scratches, dent marks,intactness & continuity of contactVisual & feelergauge 04 Condition of Hinge PinsVisual Kirloskar Multi Door Non Return Valves require very little maintenance ifmaintenance check point are attended to during periodic inspection & duringoverhaul.

10 However valves could malfunction in unusual conditions of usage,water contamination and may require maintenance as below:7. TROUBLE SHOOTING OF KIRLOSKAR MULTI DOOR NON RETURN ReasonAction Required01 Leakage throughthe valve seata. By-pass connection open (if by-pass arrangement is provided)b. External object caught betweendoor ring & diaphragm Worn out / Deformed ordamaged seat ringsa. Close By-pass valveb. Try to flush away the externalobject by creating flow toflush it away. If it does notwork, open flanged joint toreach the object and removeit manually (**).c. Replace the Door Rings /Diaphragm rings (%%)02 Leakage throughside flangesa. Inadequate tightening of flangedjointb. Damaged gasketc. Parallel / angular gap betweenvalve and pipe flangesa.