Installation services of industrial valves

Correct installation and commissioning of equipment is of paramount importance. Mirab, with the aim of preventing potential hazards and damages, reducing installation and maintenance time and costs, and increasing the lifespan of equipment, offers industrial valve installation and commissioning services with the highest quality standards. Our expert team, utilizing technical knowledge and extensive experience, carries out all stages of installation and commissioning with precision and high quality to ensure that your equipment operates optimally.

Mirab will not be held responsible for any damages resulting from non-compliance with relevant standards. Therefore, it is recommended that before installing, commissioning, and operating the product, the necessary instructions, specific to the conditions of each project, be carefully reviewed and studied. Our technical engineering team is always ready to answer questions and provide expert advice to our valued customers to ensure the optimal and safe performance of the equipment. Our services encompass initial inspection and evaluation, professional installation and commissioning, comprehensive user training, and tailored preventive maintenance solutions.

By choosing Mirab’s installation and commissioning services, you can ensure the optimal performance and longer lifespan of your equipment. We are here to support you by providing professional and expert services to meet your industrial needs and contribute to the success of your projects.

Pre-Purchase Technical Consultation

This consultation involves a detailed assessment of environmental conditions, selection of the most suitable valve type for a specific application, and evaluation of preventive maintenance and repair needs. By receiving technical consultation, you can prevent potential future problems, reduce maintenance costs, and increase the lifespan of your equipment.

Selecting the Right Valve

The choice of valve has a direct impact on system performance and efficiency. The type of valve should be selected based on the type of fluid (water, gas, oil, and acidic fluids), operating pressure and temperature, and the specific needs of the project.

Service and Maintenance

Assessing preventive maintenance and repair needs through technical consultation can prevent potential future problems, reduce maintenance costs, and increase the lifespan of equipment. Additionally, technical consultation helps optimize system performance and increase efficiency.

General Installation and Commissioning Recommendations

Mirab products are designed and manufactured to ensure safe and reliable operation when installed and operated in accordance with these instructions.

Sufficient Space: Ensure adequate space is provided for installation, maintenance, repair, and inspection of the product.
Secure Base: The product must be installed on a suitable and secure base.
Adequate Lighting: The installation area should be well-lit during installation and maintenance.
Pipe Supports: Pipes must have proper supports to prevent excessive force from being applied to the product body.
Vibration-Free Location: Avoid installing the product in areas exposed to external forces or vibrations.
Weather Protection: If installed outdoors, the product must be protected from direct weather elements.
Protective Covering: Protect the product during nearby construction or painting by covering it with appropriate materials.
Gearbox Protection: For gearboxes, if the valve is buried, the gearbox should be covered with a suitable cover. Telescopic couplings should be removed before installation and reattached afterward.
Welding Precautions: Welding operations should be completed before installing the product to the pipeline to prevent damage to seals and coatings. Remove all weld spatter and contaminants after welding.
Qualified Personnel: Installation and commissioning must be performed by qualified and experienced personnel.

Pre-Installation Preparations

Before commencing installation, the following steps must be taken:

Pipeline Preparation: The pipeline should be drained of any fluid and thoroughly inspected and cleaned.
Protective Covers: Do not remove any protective covers or flange caps until immediately before installation.
Visual Inspection: Conduct a visual inspection of the valve body, flanges, and actuator to ensure there is no damage from transportation.
Internal Cleaning: Inspect and clean all internal components, including sealing surfaces and discs. Ensure there is no paint, dirt, or other contaminants. If using a solvent for cleaning, verify that it will not harm the components.
Marking Verification: According to EN 19 standards, each product has markings (e.g., logo, size, pressure rating, material) on the body or a tag. Compare these markings with the product catalogue and the fluid’s operating conditions. Consult the manufacturer if the service conditions exceed the rated specifications.
Pressure Rating: Never exceed the valve’s rated pressure.
Alignment: Ensure that the pipes connected to the valve are perfectly aligned. Misalignment can cause stress and damage to the valve body and flanges.
Flange Compatibility: Verify that the flanges on the pipeline match the flanges on the valve.

Installation Procedures

General Guidelines:

Load Bearing: The product’s base should only support the product’s weight. Avoid applying additional loads.
Flange Spacing: Maintain a 20mm gap between pipe flanges for easier installation. This gap can be adjusted using suitable fittings.
Gaskets: Use braided rubber gaskets conforming to DIN 2690 and DIN EN 1514-1, especially for raised face flanges. Ensure gaskets are free from defects.
Flow Direction: For valves with flow direction indicators, ensure the flow is in the indicated direction.
Pre-Installation Test: Operate the valve before installation to verify proper function.
Gasket Adhesion: Secure the gasket to the valve flange using a small amount of gasket sealant.

Installation Steps:

Bolt Placement: Insert a few bolts through the bottom holes of the flange and tighten slightly.
Even Tightening: Tighten all bolts evenly, then tighten them diagonally in a crisscross pattern.
Bolt Length: Ensure all bolts protrude evenly.
Torque: Tighten bolts to the specified torque according to the material and bolt size. Refer to the torque table provided.

Avoid Overtightening: Overtightening can damage the bolts, flanges, and gaskets.
Flushing: After installation, flush the pipeline with the valve fully open.
Strainers: For control valves, install a strainer to prevent sediment buildup.
Actuators: For valves with actuators, operate the valve several times to ensure smooth operation.

Additional Considerations:

Valve Direction: Valves normally close in a clockwise direction.
Actuator Direction: Ensure the actuator operates the valve in the correct direction.
Force Application: Use the provided handwheel to operate the valve. Avoid using levers as they can damage the gearbox or valve shaft.
Operating Limits: Adhere to the specified operating temperature and pressure limits mentioned in the catalogue or the data sheet of the product.

By following these guidelines, you can ensure a correct and safe installation of your Mirab product.

DIN 267 Standard

The DIN 267 standard is a widely recognized international standard for bolted connections in industrial applications. It provides detailed torque tables for various types of bolts and nuts. Adherence to this standard is crucial as it significantly contributes to:

Safety: Proper torque ensures that connections remain tight, preventing loosening and potential hazards.
Longevity: Correctly torqued connections reduce wear and tear, extending the lifespan of equipment.
Cost-effectiveness: Preventing premature failure of components reduces maintenance costs.

General Maintenance and Repair Recommendations

Proper Selection and Installation: Choosing the right product and installing it correctly, along with following the provided maintenance and repair schedule, will extend the product’s lifespan.

Regular Inspections: It is essential to establish a regular inspection schedule and ensure it is followed by the operator.

Submerged Conditions: If installed in a tank or where submersion is possible, maintenance and repairs should account for the corrosive nature of the external surfaces.

Component Repair and Replacement: Worn or damaged internal components and sealing surfaces should be repaired or replaced as needed.

Qualified Personnel: Repairs and replacement of spare parts should be carried out by qualified and experienced personnel. If not qualified, attending Mirab training courses is recommended.

Safety Equipment: Use appropriate safety equipment when performing repairs and replacing parts.

Pressure Relief: Before any repairs, relieve the pressure in the pipeline. Do not open gearboxes, actuators, couplings, or any pressurized connections.

Actuator Disconnection: If the valve is controlled by an actuator (electric, pneumatic, or hydraulic), disconnect it from the external source first.

High Temperature and Hazardous Fluids: For high-temperature pipelines, allow sufficient time for the valve body to cool down after relieving pressure. For toxic or hazardous fluids, completely drain the fluid from the product.

Self-Locking: Some valves may not be self-locking. Carefully read the instructions for these products.

Post-Repair Inspection: After completing service and repairs, and before restarting the line, inspect all connections and ensure they are tight.

Coating Repair: If the valve body needs to be repainted on-site, use blue epoxy paint with a RAL 5005 code or equivalent.

Packaging and Transportation:

Products are typically packaged and secured according to their size and weight to protect them from weather conditions and potential damage. During transportation and storage, the valve disc should be slightly open. If the valve is equipped with an actuator, no force should be applied to the actuator or its mounting point on the valve. The tools required for lifting and transportation, such as slings, cables, or wire ropes, should be selected based on the valve's weight, as specified in the Mirab catalogue. For safe handling of heavy products, two lifting eyes are embedded in the body, and additional holes are provided in the flange for larger sizes. The valve should never be lifted or moved by the disc. During handling, maintaining a safe distance is essential to prevent personal injury.

Spare parts storage and handling:

Spare parts require careful protection and should typically be coated with anti-corrosion materials. It's advisable to code and label these parts for easy identification and use in the field. Products packaged in cartons should be handled with caution as the cartons may be damaged by moisture. Handle products carefully to avoid damage to the valve body, seals, and internal components. Transportation should be done using cranes or forklifts. Avoid using unauthorized heavy equipment such as excavators. During storage, open and close the valve completely at least once every three months to prevent sticking and the formation of potential deposits. If a product has been stored for more than two years, it's essential to perform a leak test before installation in the pipeline to ensure there are no leaks.

Valve Storage Conditions

Storage Environment: The product should be stored in a dry environment with adequate ventilation, away from heat sources and direct sunlight. Failure to do so may cause the elastomer-based sealing rubber to lose its flexibility over time, compromising its sealing performance. The storage temperature can range from -20°C to +40°C. If the storage temperature drops below 0°C, the product's body temperature should be brought up to +5°C before installation in the pipeline. Protective covers for the flange and body should not be removed until the product is ready for installation. Avoid placing any objects directly on top of the product. Storing the product directly on the ground (direct contact between the body and the ground surface) is not recommended. It is better to store it on a shelf or pallet. If the product is stored for a long period, it is recommended to place it on its base.