AVK POWERSAVERTM GATE VALVES 55/35

1. Introduction

The AVK PowerSaverTM gate valve is a patented valve generation with

an approx. 60% reduction of the maximum closing torques compa-
red to the torques for traditional gate valves. However, the number of
turns from fully open to fully closed position is only approx. 12% hig-
her than for traditional valves. AVK PowerSaverTM valves therefore
need less energy for operation (T-key, handwheel, actuator), which is
both a handling and an economic advantage.

The valve has a full and straight bore corresponding to the nominal
diameter and can be installed independently of the flow direction.
Although vertical installation is preferred, polyacetal shoes on the
wedgeguides allow the valves to be installed in the horozontal or
verticalposition. Flow/pressure limitations outlined below should be
observed.

The valves are 100% factory tested hydrostatically to DIN 3230

part 4, PN 10 and PN 16.
The valves are suitable for installation under the following conditions:
Flow velocity up to 5 m/sec. with max. 6 bar differential pressure
across the closed valve.
Flow velocity up to 0.5 m/sec. with max. 16 bar differential pressure
across the closed valve.

The valves comply with the general standard and market needs
regarding installation, dimensions, materials, capacity and strength
for large diameter valves, combined with the easy, cost saving
operation of smaller valves.

The valves have a standard gland flange to ISO 5210 (F14 flange
and spindle diameter of 30 mm). Various optional extras like
bypass, can be supplied factory fitted or supplied in kit form for
retrofitting. See data sheet series 55/powersaver and chapter 2.3 in
this manual. The By-Pass system is not necessary for normal valve
function, but can be used with advantage, if slow filling, or emptying
of the pipe line is required.

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To minimize water hammer the recommended opening speed is min.
3 min. from fully open to fully closed position.

The AVK PowerSaverTM gate valves have many applications.

IT IS THEREFORE IMPORTANT TO STATE OPERATING TEMPERA-
TURE, PRESSURE, MEDIUM AND OPERATING CONDITIONS WITH
ENQUIRIES/ORDERS, SO THE MOST SUITABLE VALVE WILL BE
SUPPLIED FOR YOUR SPECIFIC PURPOSE.

2. Installation
AVK PowerSaverTM gate valves are for above ground or chambered
installation. Underground installation can be allowed but the bonnet
must as a minimum be in chamber. The valves must be protected
against freezing by insulation. Ice in the valve or valve bonnet may
lead to damage or malfunction.

2.1 Gasket
To ensure tightness it is important to select the correct type of gasket
for the medium. 2 gaskets with the correct flange size must be used.
Torque/compression information must be obtained from the
gasket supplier.

2.2. Bolts

Table 1 Bolts
DN Work pressure (bar)
mm PN 10 PN 16 Quantity

450 M 24 M 27 20
500 M 24 M 30 20
600 M 27 M 33 20

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2.2.1. Installation and tightening
The flanges should be cleaned before installation. The valve is placed
between the pipe flanges and the bolts inserted. Tighten bolts loose-
ly. Tighten bolts in a diagonal sequence (see below) to ensure flanges
are pulled parallel.

Finally,
tighten bolts to maximum torque levels given in table below, note
that the gasket supplier must inform of the correct torque:

Table 2 Max. bolt torque

Dimension Torque (Nm)

M 24 200
M 27 250
M 30 300
M 33 450

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2.3. Mounting of a By-Pass system
IMPORTANT! Before mounting of a By-Pass system the main valve
must not be under pressure, and the medium must be under the level
of the By-Pass flanges on the side of the valve.

Preparation of the main valve

The 2 blind flanges on the By-Pass bosses are removed and the
gaskets and flanges of the valve are thoroughly cleaned for dirt and
impurities.

Preparation of a By-Pass system

The 16 studbolts are screwed into the two cast iron bends,
8 pcs. in each, and the bends are fitted to the By-Pass valve,
together with the mating gaskets (see drawing).
The nuts are loosely fastened to ensure that the bends can move
freely in relation to the valve.

Mounting:
The By-Pass system is mounted on the main valve together with
the cleaned gaskets (new gaskets are reccomended), and the
previously removed nuts and washers are re-used for fastening.
All nuts are in principle tightened as shown on the drawing under
chapter 2.2.1. The nuts are to be tightened with approx 100 Nm.
The By-Pass system is now ready for use.

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3. Operation
The valve is equipped with an AVK PowerSaverTM which means that
the valve can only be used as an ON/OFF valve. Therefore the valve
must be FULLY opened to the torque indicated on the valve label
before the AVK PowerSaverTM goes into function. Otherwise the valve
will have an closing torque corresponding to a standard valve.

3.1. Right hand closing valves, CTC valves.

3.1.1. Closing
IMPORTANT! From factory the valve is delivered with the wedge in
almost closed position. Before the valve is put into service it must
be fully opened to activate the AVK PowerSaverTM (see 3.1.2.).

By manual operation the valve is closed by turning the handwheel

clockwise until the valve is completely closed. For closing torque by
manual operation see table 3.

Valves with actuators are closed by adjusting the actuator, so that

the output shaft moves clockwise in the actuator closing direction.
The on/off torque switch should be adjusted, so that the valve is not
closed/opened with a higher torque than indicated in table 3.
Going to closed position the actuator shall be switched off by means
of the on/off torque switch, not the limit switch. The limit switch can
be used as alarm indication in close direction by setting it 10 mm
above fully closed. See later description of typical operation with
electric actuator.

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3.1.2. Opening
By manual operation the valve is opened by turning the handwheel
anti-clockwise until the wedge is fully open, applying a torque of 150
Nm in the opening direction in fully open position.

Valves with actuators are opened by adjusting the actuator, so that

the output shaft moves anti-clockwise in the actuator opening direc-
tion. The on/off torque switch shall be adjusted, applying an opening
torque of 200 Nm in the fully open position. Going to open position
the actuator shall be switched off by means of the on/off torque
switch, not the limit switch. The limit switch shall in open position be
set to 50 % open valve. See later description of typical operation
with electric actuator.

3.2. Left-hand closing valves, CTO valves.

IMPORTANT! From factory the valve is delivered with the wedge in

almost closed position. Before the valve is put into service it must be
fully opened to activate the AVK PowerSaverTM (see 3.1.2.).

By manual operation the valve is closed by turning the handwheel

anti-clockwise until the valve is completely closed, for
closing torque by manual operation see table 3.

Valves with actuators are closed by adjusting the actuator, so that

the output shaft moves anti-clockwise in the actuator closing
direction. The on/off torque switch should be adjusted, so that the
valve is not closed/opened with a higher torque than indicated in
table 3.
Going to closed position the actuator shall be switched off by means
of the on/off torque switch, not the limit switch. The limit switch can
be used as alarm indication in close direction by setting it 10 mm
above fully closed. See later description of typical operation with
electric actuator.

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Table 3
Torques (Nm) Free running
Close Open Close Open* Turns to torque Rupture torque
DN Electric Electric Manual Manual Open open torque Nm
Actuator Actuator Operated Operated
450 320 200 240 150 41 25 1000
500 320 200 240 150 45 25 1000
600 320 200 320 150 54 25 1000

For electric actuators the recommended opening speed

is min. 3 min. corresponding to max. 19 turns/min.

*) Torque value to be applied in the opening direction in

order to activate the AVK PowerSaverTM

Table 4
Setting of end-stop switches on electrical operated valves.
Setting of switch approx. 10 mm before fully closed position,
from fully open valve.

DN 450 End-stop set 38 number of turns

DN 500 End-stop set 42 number of turns
DN 600 End-stop set 51 number of turns

3.2.2. Opening
By manual operation the valve is opened by turning the handwheel
clockwise until the wedge is fully open, applying a torque of 150 Nm
in the opening direction in the fully open position.

Valves with actuators are opened by adjusting the actuator, so that

the output shaft moves clockwise in the actuator opening direction.
The on/off torque switch shall be adjusted, applying an opening tor-
que of 200 Nm in the fully open position. Going to open position the
actuator shall be switched off by means of the on/off torque switch,
not the limit switch. The limit switch shall in open position be set to
50 % open valve. See later description of typical operation with elec-
tric actuator.

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3.3 Typical open/close cycle for electrical operated valves.

3.3.1.
Valve is fully open and PowerSaverTM is compressed by 200 Nm.

3.3.2.
Closing cycle starts and actuator is set to close-torque of 320 Nm
with limit switch set to approx. 10 mm over the bottom of the bore,
see table 4. Error read out will come if torque is drawn before limit is
drawn.

3.3.3
Opening requires larger torque than closing, since pressure on one
side of the valve will work against opening of the valve. Therefore
the opening torque is set to stall torque. At approximate 50% open
valve the limit switch draws and the torque switch set to 200 Nm
is now active. 200 Nm torque switch is turning off the actuator in
open position.

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PLEASE NOTE THE PHASE FOLLOW IS IMPORTANT SINCE
WRONG PHASE WILL CAUSE STALL TORQUE TO OPEN,
THUS CAUSING PERMANENT DAMAGE TO THE VALVE!!!

Wiring diagram recommended by AVK is to be found on the last

page in this installation manual. If any doubt please contact nearest
AVK sales outlet.

3.4. Marking
The valves are marked with a label on the valve bonnet, stating
torques for opening and closing. See page 12-13. The number of
turns and operating torques can also be seen in table 3 and 4 in this
manual.

4. Maintenance

4.1. General

If the valve is installed according to AVK's instructions, it is

maintenance-free.

However every 4-5 years it is recommended:

1) To make a routine check of the valve for leaks around the

stem and the flange gaskets. All seals will in the course of time
be influenced by air and sunlight, and careful checks can reveal
such leaks.

2) To adjust the bolts in the flange connections as the compression

of the flange gaskets may relax in the course of time and thus leaks
may arise. Please observe the bolt torques and sequence table
under chapter 2.2.

4.2. Replacement of stem sealing

AVK valves are factory lubricated and maintenance-free. If it should

be necessary to exchange the stem seal the following procedure
must be observed.

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4.2.1. Before replacement

Before replacement, the valve size should be advised to supplier.

A gasket set will be delivered consisting of:
- 1 wiper ring
- 2 internal stem seal O-rings
- 1 gland flange O-ring
- 1 nylon bearing

4.2.2. Disassembling

Important! Before
replacement of the
stem sealing the valve
must be fully opened
and not be under
pressure. This is
done by turning the
handwheel in opening
direction until impact.
It is very important to
ensure that the wedge
is fully open.

1) The 4 gland flange

bolts (pos. 4) are
unscrewed and the gland flange (pos. 6) is lifted out and pulled off
the stem.

2) Wiper ring (pos. 1), O-rings (pos. 2, 5) and bearing (pos. 3) are
carefully removed without damaging the gland flange.

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4.2.3. Assembling

1) The internal surfaces of the gland flange are cleaned and checked
for damages.

2) The new O-rings, wiper ring and plastic bearing are lubricated all
over with a thin layer of silicone grease (e.g. ROCOL : Mx 22)

3) Wiper ring, plastic bearing and O-rings are carefully fitted in the
cleaned gland flange (see figure)

4) Stem are cleaned and checked for damages.

5) The stem is applied a thin layer of silicone grease

(e.g. ROCOL : Mx 22)

6) The gland flange is fitted on the valve and fixed with the 4 gland
flange bolts (pos. 4).
Please ensure that the O-ring (pos. 5) is correctly mounted in the
recess. The bolts are tightened with a torque of 100 Nm.

7) The valve can be closed again by turning the handwheel in

closing direction.

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 Important installation instructions.
AVK PowerSaver gate valves - Not for complete buried service Valve bonnet shall be protected against freezing.
tm

NOTE: This valve must only be mounted with an eletric actuator after consulting with AVK International
in Denmark, or nearest AVK representative office.
Low torque valves AVK PowerSavertm valves.
Operating instructions for handwheel and electric actuated valves.
On-Off valve.
Each operation is to fully open or fully closed position, thus reaching end-stop torque given below, to maintain correct
function of the PowerSaver unit.
Operation torques for manual operated valves
Opening torque: Upon reaching 150 Nm.
Closing torque: Upon reaching 240 Nm for DN 450-500 and 320 Nm for DN 600.
Maximum torque open/closed 1000 Nm, exceeding this will damage the valve.
OW
OLL
H ASE F PHASE
Operation torques for electric operated valves. E P RONG N,
E TH OPE
Opening torque: Upon reaching 200 Nm.
SE NOT SINCE W QUE TO MAGE
Closing torque: Upon reaching 320 Nm. PLEA ORTANT ALL TOR ENT DA
P T AN
Maximum torque open/closed 1000 Nm, exceeding this will damage the valve. IS IM CAUSE S PERM VE!!!
ILL SIN G VAL
W U E
H U S CA TO TH
Endstop settings for electric operated valves. T
Opening direction: Upon reaching 50% open valve
Closing direction: Upon reaching aprox 10 mm before closed position.
For further information on endstop settings, please see installation manual.
Flow/pressure limitations.
Water flow and pressure must be within limits of:
Velocity up to 5 m/sec and max. 6 bar differential pressure, or velocity up to 0.5 m/sec and
max. 16 bar differential pressure.

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AVK product number 5540049

AVK International A/S/2002-03-10

515535BB