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Safety, Installation, Operations &


Assembly Instruction Procedure
For Diaphragm Valves

Prepared &
Reviewed By
Approved By
Sr. No. Date Revision Pages
QCM CI

1 01.01.2019 0 0
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SAVE THIS INSTRUCTION MANUAL

IMPORTANT SAFETY INSTRUCTIONS


When installing and using this equipment, basic safety precautions should always
be followed, including the following: Failure to follow instructions may result in
injury.
READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ON EQUIPMENT.
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Index
Section Contents
1 Scope
2 Manufacturer's Declaration
2.1 Safety Information
2.2 Explanation of the Symbols
2.3 General Safety Tips
2.4 Operator responsibilities
2.5 Special hazards
2.6 Transport and storage
3 Intended Use
4 Installation procedure
4.1 Installation in the pipeline
4.2 Tips on mounting and dismounting of valves
4.3 Self-draining
4.4 Fastening
4.5 Safety measures for installation
4.6 Pressure Test and Commissioning
5 Maintenance
5.1 Replacing the diaphragm
5.2 Dismounting the diaphragm
5.3 Mounting the diaphragm
6 Technical Data
7 Spare Parts
7.1 Diaphragms
8 Factory Contact Information
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1. Scope

Leistung valve series is specifically designed to meet today’s demanding


pharmaceutical and bio-pharma industry requirements. The advanced design
reduces maintenance requirement while providing superior performance.

To prevent potential injury and to avoid unnecessary servicing, we recommend


that this manual should be read by the installer carefully and completely before
installation.

For valves without ‘’BPE’’ Mark, the technical data are not binding and not
expressly warranted characteristics of the goods. They are subject to change.
Our general conditions of sale apply.

2. Manufacturer's Declaration

The manufacturer, Leistung Engineering Pvt. Ltd., Lambha (Ahmedabad, India)


declares, in accordance with the ASME ‘’BPE’’ that the diaphragm valves series
10, 20 & 30 are pressure-bearing components in the sense of the EC Directive
97/23/EC concerning pressure equipment and that they meet the requirements
pertaining to valves as states in this directive,

The ‘CE’ mark on the valve refers to this accordance [as per the directive on
pressure equipment, only valves larger than DN 25 (Connection Size 1”) can be
labeled with ‘CE’].

Operation of these diaphragm valves is prohibited until conformity of the entire


system into which the diaphragm valves have been installed is established
according to the above-mentioned EC-Directive.

3. Safety Information

3.1 Explanation of the symbols

Hazard notices are used in this manual to warn you of possible injuries or
damages to property. Please read and abide by these warnings at all times.

WARNING - Imminent danger! Failure to comply could result in


death or serious injury
CAUTION - Possible acute danger! Failure to comply could result in
serious injury
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NOTE – Important Information, failure to comply could lead to


injury or damage to property

3.2 General safety tips

The same safety instructions apply to the diaphragm valves as to the piping
system in which they are built:

The pressure, temperature & other technical data noted on valve


are limiting and should not be crossed at any time during
operation.
Use of higher pressures, temperature or other aids can cause
damage to the diaphragm valve, other accessories or machineries,
surroundings & personnel in vicinity.
CAUTION - We highly recommend that a qualified professional
should install and service this product.
NOTE – This manual contains important safety information that
must be furnished to the end user of this product. FAILURE TO
READ AND FOLLOW ALL INSTRUCTIONS COULD RESULT IN SERIOUS
INJURY.

KEEP SAFETY LABELS IN GOOD CONDITION AND

REPLACE IF MISSING OR DAMAGED

WARNING – Hazardous Pressure

 This equipment / component operate under pressure. Incorrectly, installed


and/or improperly tested equipment and/or component may fail resulting
in injury and/or property damage.
 This product is tested with all quality related tests at our premise. Even
though if you prefer to perform any test at your premise, then only a
qualified professional MUST conduct all pressure tests.
 This product is intended for above-ground/on-ground facilities only.
 DO NOT connect to a pressure system higher than recommended
pressure.
 Confirm that ALL system components, namely clamps, bolts and covers
have been tightened to the manufacturer’s recommendations.
 Do not open when valve is in pressurized condition.

3.3 Operator responsibilities


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The planner / installer of the piping system and the operator of such systems
into which the diaphragm valve has been installed are responsible for
ensuring that:
The diaphragm valve is used only as intended,
The piping system has been installed professionally and its operability is
checked regularly,
The valve is installed, serviced, maintained and repaired only by authorized
and specialized personnel,
Personnel is instructed regularly as to safety on the job and environmental
protection - particularly regarding pressure bearing piping systems,
Personnel is familiar with the manual and adheres to the instructions

3.4 Hazards

If the diaphragm valve is opened, the media can exit un-monitored.


Therefore, the valve may only be opened if the media can be safely collected
and / or diverted and spattering is prevented with relative safety measures.

When uninstalling the diaphragm valve, the following hazards can occur:
 Un-monitored exiting of the media from the pipe or valve, whether under
pressure or not,
 The media may continue to flow out of the pipe,
 Un-monitored exiting of the CIP / SIP media from the pipe and the valve,
 Residue of hazardous media may be present in the valve.

Therefore, prior to opening the pipe line and uninstalling the valve
 The pipeline must be completely relieved of pressure,
 The control line must be completely relieved of pressure,
 The pipeline must be completely emptied,
 In case of aggressive, hazardous, flammable or explosive media, the line
must be flushed,
 After dismounting, the diaphragm valve must be emptied completely. Allow
the valve to drain completely in the vertical position.

3.5 Transport and storage

The diaphragm valves must be handled, transported and stored with care:
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 The diaphragm valve should be transported and stored in its original


packaging
 Should the diaphragm valve be stored prior to final installation, it must be
protected from harmful influences such as dust, dirt, humidity and
especially from heat and UV radiation
 The connector ends of the diaphragm valve in particular should not be
damaged mechanically or otherwise
 The diaphragm valve should be stored in the same state as it was supplied

4. Intended Use

Diaphragm valves are designed exclusively for controlling the flow of media
within the permissible pressure and temperature range when installed in a
piping system.
 Cavitation must be avoided in control operations
 Due to the flexible diaphragm, the characteristic curve shows slight
hysteresis during opening or closing of valve

5. Installation Procedure

5.1 Installation in the pipe line


The same guidelines used for joining pipes, fittings and other piping
components applies to the installation of diaphragm valves.

5.2 Tips on mounting and dismounting of valves


The connecting elements are clamped or fused onto the pipe end depending
on the jointing method selected

5.2.1 Tips for Butt-welded joints


Only identical materials may be joined by fusion. Only qualified welder
shall perform fusion welding.
5.2.2 Tips for V-band (hygienic) clamp connection versions
The tightening torques of clamp screws and other useful information
can be found in Leistung Valve & Allied Product catalogue also
available on our website.

To open (Disassembly)
For clamp connection,
Loosen clamp nuts by hand. Loosen the clamp and slide them off from
respective ends. The diaphragm valve is then removed from the connecting
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adapters. The ‘O’-rings inserted between two mating adapters shall be


carefully removed and stored for future use.
To close (Assembly)
For clamp connection,
Carefully insert the ‘O’-rings on PCD of mating adapters. The diaphragm
valve is then inserted between the connecting adapters. The clamp shall be
put on respective ends when valve and ‘O’-rings are held at their respective
positions and the clamp nuts are tightened by hand.

5.3 Self-draining

To drain the diaphragm valve and the pipeline, the installation must have the
necessary incline. For optimal self-draining of the diaphragm valve, the
mounting angle can be found in Leistung Valve & Allied Product catalogue
also available on our website. The installation incline of approx. 1° to 2° has
not been taken into consideration in the given values.

5.4 Fastening

In piping systems which are subject to temperature changes, expansion and


bending forces occur if thermal expansion is hindered. These forces must be
absorbed by fixed points before or after the valve in order to guarantee
optimal operability of the valve.

Diaphragm valve and pipeline must be perfectly aligned so that no excessive


loads can act on the valve. Valve operation causes internal stress in the
pipeline. It is therefore important that the pipeline is secured with the
appropriate supports upstream and downstream from the diaphragm valve.

5.5 Safety measures for installation

 Inspect the diaphragm valve for transport damages (do not install a
damaged valve)
 Make sure that only diaphragm valves are built in with the correct
pressure rating, connection type, measurements and materials for the
respective application conditions
 Do a test run by opening and closing the diaphragm valve
 Do not install valves with a malfunction
 Do another test run after installation
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5.6 Pressure Test and Commissioning

Prior to commissioning the valve, the torque needs to be checked according


to 5.3 and, if necessary, retightened because the diaphragms can settle over
the course of time. Diaphragm valve pressure testing is subject to the same
regulations as the piping system; however, the test pressure may not exceed
the PN of the diaphragm valve. Detailed information is available in the
Leistung Valve & Allied Product catalogue also available on our website.

6. Maintenance

7.1 Replacing the diaphragm

The component with the most wear and tear in every diaphragm valve is the
diaphragm itself. Besides mechanical stress, the diaphragm is subject to wear
resulting from the flow media.

We therefore recommend inspecting the diaphragm at the latest


after 10,000 cycles at room temperature, with nominal pressure
and water.

If the flow medium has higher temperatures, other chemicals or


abrasive particles, we recommend more frequent inspections. The
diaphragm can be checked by dismantling the valve body.

7.2 Dismounting the diaphragm

Drain and de-pressurize the pipeline


Bring the valve into complete "OPEN" position

Dismantle the valve body by removing the screws which connect the valve
body to bonnet

Elastomer diaphragms
Elastomer diaphragms DN15 & DN20 have a pressed knob on top. To
remove the diaphragm , just pull strongly
Elastomer diaphragms DN25 to DN50 are retained by a threaded bolt
and are removed by rotating counterclockwise
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PTFE diaphragms
PTFE diaphragms are equipped with a bayonet catch. Rotate the
diaphragm 90° in any direction and pull out

7.3 Mounting the diaphragm

 Work in the reverse order to that indicated in 5.2


 However, only tighten the screws until the valve body is butt against the
diaphragm.
 Bring the valve into the "CLOSED" position
 Put the valve in the " OPEN" position again

Sr. No. DN Size Torque [N-m]
1 15 1/2" 8
2 20 3/4" 10
3 25 1" 13
4 40 1 1/2" 17
5 50 2" 17
6 65 2 1/2" 20
7 80 3" 22
Tighten/retighten the screws with the torque in the table below

7. Technical Data

It is important to observe the technical data during installation, operation and


maintenance.
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Recommended Operating Temperature
Diaphragm (°C) Inform
Material the
Process Cycle Sterilization Cycle
Elastomer 10 – 75 130 Max
Design Max. Allowable
Sr. PTFE Recommended
10 – 90 135 Max
Pressure Temperature
No Size DN Operating
(MAWP)
. Pressure (bar(g)) Min. (°C) Max. (°C)
(bar(g))
1 ½" 15 10 10 -10 135
2 ¾" 20 10 10 -10 135
3 1" 25 10 10 -10 135
4 1 ½" 40 10 25.5 -10 135
5 2" 50 10 20.5 -10 135
6 2 ½" 65 10 15.5 -10 135
7 3" 80 10 13.5 -10 135
personnel about the technical data.

7.1 Important technical information regarding valve:

7.2 Important technical information regarding diaphragm:

Leistung elastomer OR PTFE diaphragms are capable of withstanding


design conditions stated in 6.1. However, we strongly recommend that
the operating temperature for valves containing any of these diaphragms
shall be limited to following conditions to fully utilize and in some cases
enhance the lifecycle of diaphragm.

8. Spare parts

Spare Part Codes


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Sr. No. 1 2 3 4 5 6 7
DN 15 20 25 40 50 65 75

Size 1/2" 3/4" 1" 1 1/2" 2" 2 1/2" 3"


EPDM
LEDDVB LEDDVB LEDDVC LEDDVD LEDDVD LEDDVE LEDDVE
Diaphrag
E E E E E E E
m
PTFE
LEDDVB LEDDVB LEDDVC LEDDVD LEDDVD LEDDVE LEDDVE
Diaphrag
P P P P P P P
m
EPDM
Back LEPTDB LEPTDB LEPTDC LEPTDD LEPTDD LEPTDE LEPTDE
Support

9. Factory Contact Information

LEISTUNG ENGINEERING PVT. LTD.


Plot No. 3/103, NIDC, Nr. Bhammariya kava,
N.H. No. 8, Lambha, Ahmedabad-382405.
Tel. +91 79 2573 3411, 12
E-mail:ino@leistung.in
Web site: www.leistung.in