Mankenberg DA Series Installation instructions

Original operating manual

Sightglasses, flow indicators and flow

meters

Originalbetriebsanleitung

Schaugläser, Durchflussanzeiger und

Durchflussmesser

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

Table of contents EN

1 Introduction................................................................................................................................................. 4

2 Intended use ............................................................................................................................................... 4

3 Marking of the fitting .................................................................................................................................. 5

4 Safety instructions ..................................................................................................................................... 5

4.1 General precaution .............................................................................................................................. 5

4.2 Special safety instructions for the plant operator................................................................................. 5

4.3 Special hazards ................................................................................................................................... 6

5 Transport and storage ............................................................................................................................... 6

6 Installation................................................................................................................................................... 7

6.1 General notes ...................................................................................................................................... 7

6.2 Installation preparations....................................................................................................................... 8

6.3 Installation steps .................................................................................................................................. 8

7 Pressure testing the pipeline section....................................................................................................... 10

8 Initial start-up.............................................................................................................................................. 10

9 Normal operation........................................................................................................................................ 10

10 Maintenance................................................................................................................................................ 11

11 Troubleshooting help................................................................................................................................. 12

12 Information on REACH and RoHS ............................................................................................................ 14

12.1 Declaration on the REACH Regulation 1907/2006.............................................................................. 14

12.2 Declaration on the RoHS Directive 2011/65/EU .................................................................................. 14

13 Further information .................................................................................................................................... 14

14 Know How ................................................................................................................................................... 14

14.1 Tusk ..................................................................................................................................................... 14

14.2 Selection .............................................................................................................................................. 14

14.3 Glasses................................................................................................................................................ 14

14.4 Glass qualities ..................................................................................................................................... 14

14.5 Flow direction....................................................................................................................................... 14

14.6 Operating limit...................................................................................................................................... 14

14.7 Indicator flag for one direction ............................................................................................................. 14

14.8 Indicator flag for both directions........................................................................................................... 15

14.9 External indicator ................................................................................................................................. 15

14.10 Ball-type indicator ................................................................................................................................ 15

14.11 Indicator with impeller.......................................................................................................................... 15

14.12 Resistance to media ............................................................................................................................ 15

14.13 Installation............................................................................................................................................ 15

14.14 Operation............................................................................................................................................. 15

14.15 Maintenance ........................................................................................................................................ 15

Inhaltsverzeichnis DE

1 Einleitung .................................................................................................................................................... 16

2 Bestimmungsgemäße Verwendung.......................................................................................................... 16

3 Kennzeichnung der Armatur ..................................................................................................................... 17

4 Sicherheitshinweise ................................................................................................................................... 17

4.1 Allgemeiner Sicherheitshinweis ........................................................................................................... 17

4.2 Spezielle Sicherheitshinweise für den Betreiber.................................................................................. 17

4.3 Besondere Gefahren ........................................................................................................................... 18

5 Transport und Lagerung............................................................................................................................ 18

6 Einbau.......................................................................................................................................................... 19

6.1 Allgemeines ......................................................................................................................................... 19

6.2 Vorbereitung zum Einbau .................................................................................................................... 20

6.3 Schritte beim Einbau............................................................................................................................ 20

7 Druckprüfung des Rohrleitungsabschnitts ............................................................................................. 22

8 Erste Inbetriebnahme................................................................................................................................. 22

9 Normalbetrieb ............................................................................................................................................. 23

10 Wartung ....................................................................................................................................................... 23

11 Hilfe bei Störungen..................................................................................................................................... 24

12 REACH- und RoHS-Auskunft .................................................................................................................... 26

12.1 Erklärung zur REACH-Verordnung 1907/2006.................................................................................... 26

12.2 Erklärung zur RoHS-Richtlinie 2011/65/EU ......................................................................................... 26

13 Weitere Informationen................................................................................................................................ 26

14 Know-How ................................................................................................................................................... 26

14.1 Funktion ............................................................................................................................................... 26

14.2 Auswahl ............................................................................................................................................... 26

14.3 Gläser .................................................................................................................................................. 26

14.4 Glasqualitäten...................................................................................................................................... 26

14.5 Durchflussrichtung ............................................................................................................................... 26

14.6 Ansprechgrenze................................................................................................................................... 26

14.7 Anzeigefahne für eine Richtung........................................................................................................... 26

14.8 Anzeigefahne für wechselnde Richtung .............................................................................................. 27

14.9 Außenzeiger ........................................................................................................................................ 27

14.10 Kugel.................................................................................................................................................... 27

14.11 Flügelrad.............................................................................................................................................. 27

14.12 Medienbeständigkeit............................................................................................................................ 27

14.13 Einbau.................................................................................................................................................. 27

14.14 Betrieb ................................................................................................................................................. 27

14.15 Wartung ............................................................................................................................................... 27

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

Original operating manual

Sightglasses, flow indicators and flow meters DA

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

1 Introduction

This manual is intended to assist users of a MANKENBERG sightglass, flow indicator or flow meter during

installation, operation and maintenance. Read the manual thoroughly before installing or putting this valve into

service.

caution

Failure to follow the following instructions – particularly the cautionary and warning

notes – may lead to hazards and may invalidate the manufacturer's warranty.

MANKENBERG is at your servíce for any assistance and queries.

See Section Further information [}14] for the addresses.

Technical information is also available at www.mankenberg.de

2 Intended use

A MANKENBERG sightglass, flow indicator or flow meter is a device that is intended exclusively for on-site

inspection of the flow of a medium after it has been installed in a pipeline system. Therefore, one or two plates

of special glass are inserted.

Sightglasses, flow indicators and flow meters are also suitable for two-phase and multi-phase media and for

media tarnished by or intransparent from solids. The MANKENBERG catalogue gives detailed information for

selecting the appropriate type in the section <DA: Sightglasses, Flow indicators>.

The glass quality must fit the medium and the temperature. MANKENBERG designates the supplied glas quality

in the order confirmation.

To observe the flow with the naked eye, the following types are fitted with different installations:

DA [ .].10 Indicator flag;

DA [ .].30 Indicator with impeller;

DA [ .].40 Ball-type indicator (vertical installation only);

The type

DA [ .].00 has no moving installations and is intended for observing gas-liquid- and/or multiphase-mixtures.

With modified type number, some of these indicators are deliverable with two glasses, calibrated scale, two-

directional indicators or flow speeds above 1 m/s.

MANKENBERG planning documents are available to give users precise assistance in selecting and designing

the appropriate fitting, e.g.:

In the section

<DA, accessoires>

<Know-how and selection flow indicators>

with technical data and tables of the setting ranges and the dimensions.

MANKENBERG fittings are supplied as standard for screw-mounted or flange-mounted pipeline/tank

connections – also for special connections if required.

The upper limit of the permitted operating data for pressure and temperature is permanently marked on each

fitting supplied.

In the following sections the different construction types are combined under the heading of “sight glasses” apart

from a few sections that only apply to one of the construction types mentioned.

Original operating manual

Sightglasses, flow indicators and flow meters DA

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

3 Marking of the fitting

Each fitting bears the following markings as a minimum:

For Marking Remark

Manufacturer MANKENBERG See section Further information [}14] for the

address

Fitting design Sight glass + type

Flow indicator + type

Flow meter + type

Design name as per accompanying

MANKENBERG data sheet

Nominal diameter e.g. DN or G and numerical

value

Numerical value for DN in [mm], for G in [inches]

Nominal pressure PN or Class and numerical

value

Numerical value for PN in [bar], for Class in [lbs/

square inch]

pressure data are displayed as overpressure

above the atmospheric pressure

Max. permitted

temp.

Temperature and numerical

value

Temperatures above 50 °C entail a reduced

pressure resistance. This must be considered for

the corresponding material in accordance with the

DIN EN 1092 standard

Body material e.g. CrNiMo steel CrNiMo steel = high-alloy austenitic steel

Flow direction Indicated by an arrow

The markings (in the case of fittings made of deep-drawn stainless steel, they are etched into the body) should

neither be covered nor painted over, so that the fitting remains identifiable.

4 Safety instructions

4.1 General precaution

The same safety regulations apply to a fitting as to the system into which it is installed. These instructions only

give those safety recommendations that have to be additionally observed for the fitting.

4.2 Special safety instructions for the plant operator

The following requirements for the intended use of a fitting are not the responsibility of the manufacturer but

have to be guaranteed by the user:

The fitting may only be employed for the purpose described in section Intended use [}4].

Only competent specialist personnel may install, operate and service the fitting. Competent as defined in these

instructions refers to persons who, because of their training, specialist knowledge and professional experience,

are capable of correctly assessing and properly executing the work with which they are entrusted and of

recognizing and rectifying hazards.

The pipeline system must be properly designed and installed so that the fitting can be mounted and operated

without any tension.

The fitting must be properly installed in the correct mounting position.

Original operating manual

Sightglasses, flow indicators and flow meters DA

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

The usual flow rates should not be exceeded in the pipeline section during continuous operation, and abnormal

operating conditions such as vibrations, unusually high flow rates, etc. should be avoided or – if unavoidable –

clarified with the manufacturer in advance.

The prevailing operating conditions must comply with the limits of the design data stated in the MANKENBERG

order confirmation.

The corrosion protection for the fitting must be adapted to the local environmental conditions.

The fitting must not be coated with thermal insulation.

Detailed notes are provided on some of these prerequisites in the following sections.

4.3 Special hazards

danger of

fatalities

Before a fitting is removed from the system or before a fitting is dismantled but partially

remains in place, the pressure in the system on both the inlet and outlet side must be

completely reduced so that there is no uncontrolled flow of the medium out of the system.

If a glass plate is removed, it must be inserted again as described in section Troubleshooting

help [}12].

Otherwise there is a risk of fracture.

In the case of toxic or hazardous media, the system must be completely drained before the

fitting is removed.

Caution is required with residues that might continue flowing..

attention

If a fitting is removed from a system with a toxic medium and is taken out of the plant:

The valve must be properly decontaminated before repair.

5 Transport and storage

A fitting must be handled, transported and stored with care:

The fitting must be transported and stored in its protective packaging until it is installed.

attention

The fitting has moving internal parts.

Even packaged fittings should be transported smoothly without any shocks.

The glass plate is fragile.

Handle with care so that the glass does not shatter during transport/storage.

attention

In the case of a fitting that can no longer be transported by hand, the lifting gear must be

attached to a suitable position on the housing (branches).

Under no circumstances may the lifting gear be affixed to any attachments.

Original operating manual

Sightglasses, flow indicators and flow meters DA

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

» When the fitting is stored prior to installation, it should be kept in closed rooms and protected against

harmful influences such as dirt, moisture and frost.

» In special cases, the fitting is supplied free of oil, grease or silicone and is marked accordingly. A fitting such

as this must not come into contact with oil/grease/silicone during storage and handling (particularly when

subsequently unpacked).

» A MANKENBERG fitting generally has functional and/or sealing parts made of elastomer materials. These

cannot be stored for an unlimited period.

note

ISO 2230 describes the storage conditions for elastomers in detail and specifies the

permissible storage period.

Functional and sealing parts must be replaced well before the storage period expires.

They are available from MANKENBERG as a “service set”. See also section Troubleshooting

help [}12].

note

MANKENBERG fittings of small and medium nominal diameters are largely made of stainless

steel (high-alloy CrNiMo steel).

If, under exceptional circumstances, fittings are stored in a unpacked state, they must be

protected against ferritic dust to avoid corrosion.

note

The fitting is generally not capable of standing alone:

Handle with care so that the fitting does not tip over during transport/storage..

6 Installation

6.1 General notes

The same installation regulations apply to a fitting as to the system into which it is installed. The following

additional notes apply:

Section Transport and storage [}6] should also be observed during transport to the installation site.

The installation site to allow perfect functioning of a fitting should be a section of pipe without any flow

disruptions, without any angles and without any restrictors or shut-off devices close to the fitting, either

upstream or downstream (optimum distance = 10 x DN). If this does not apply, the installation situation should

be checked with the plant operator and/or MANKENBERG.

The statics of the pipeline must be designed so as to take account of the weight of the fitting – particularly those

with an eccentric mass. If required, the pipeline may have to be properly supported on both sides next to the

fitting (or at the fitting itself) – particularly in the case of fittings with a substantial mass and especially if

vibrations are to be expected in the system.

When the fitting is supported, it is important to check that all functioning parts remain capable of moving freely

and are not blocked.

The fitting must not be coated with thermal insulation.

caution

A fitting that is operated at a medium temperature above 130°C needs undisrupted removal of

heat if it is to function perfectly.

Failure to observe this instruction may cause damage to the fitting and hence in the

pipeline system as well.

To protect internal functional parts (e.g. indicator flag) against damage and/or blockages, it may be necessary to

install a strainer and/or filter upstream of the fitting.

Original operating manual

Sightglasses, flow indicators and flow meters DA

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

note

The mesh size of the sieve/filter for protecting against aggregates in the pipe section should be

selected by the plant operator according to the operating conditions.

Failure to observe this instruction may impair the function of the fitting and lead to

damage.

6.2 Installation preparations

It is necessary to ensure that a fitting is not installed unless its matches the operating conditions in terms of

function, pressure and temperature, range, body material as well as connection type and dimensions.

danger of

fatalities

No fitting may be operated that does not have a sufficient pressure and temperature range for

the operating conditions – see section Intended use [}4] and markings on the fitting.

The manufacturer MANKENBERG should be consulted in the case of any applications outside

of this range.

Failure to observe this regulation may mean danger to life and limb and may cause

damage to the pipeline system.

Newly installed tanks and pipeline sections must be thoroughly rinsed and cleaned before commissioning.

The corrosion protection for the fitting must be adapted to the local conditions:

important

note

If it is to function perfectly, the fitting must not be installed in a high lying pipe section: In a high

lying section, the observation of the flow may be (considerably) troubled.

If a sight glass may be installed in any desired, only vertical or only horizontal direction is

described in the project (catalogue) data of the sight glasses.

6.3 Installation steps

Fittings should only be finally unpacked at the installation site and inspected for damage prior to assembly.

Damaged fittings must not be installed - under no circumstances those with a damaged glass.

It is necessary to ensure that the covers have been removed from all the connection branches before

installation.

The fitting should be inspected to ensure that it is clean. Interior parts must be free of liquid (e.g. condensate): if

necessary, connecting branches should be cleaned before installation with clean compressed air.

The type and dimensions of the line or tank connections must match the fitting to be installed and be flush with

the connecting surfaces of the fitting as well as in a parallel plane to the fitting itself.

If the fitting is marked with an arrow on the housing, the flow in the pipe section must match the marked

direction of flow.

caution

If installed in the opposite direction to the arrow, the fitting will not perform its intended

function.

The fitting mist be installed without any tension. In the case of an already installed system, the geometry of the

pipeline must match the face-to-face length of the fitting.

Original operating manual

Sightglasses, flow indicators and flow meters DA

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

note

It is necessary to ensure that even under operating conditions no tension from the pipeline

is transferred to the fitting.

caution

A MANKENBERG fitting made of "high grade" or "high grade pure" stainless steel (austenite,

e.g. 1.4404 or 1.4435) does not need any surface protection for normal environmental

atmosphere and for normal weather conditions.

External parts of the fitting made of low-alloy or non-alloy materials that are supplied ex-works

with a primer have to be provided with a suitable coating by the customer.

Caution:

Never paint over the marking(s) of the fitting (either etched into the body or on nameplate).

In addition, the following applies to the pipeline connection:

With flanges:

note

The sealing surfaces on the body of the fitting are formed in accordance with the

MANKENBERG order confirmation. The accompanying flange seals are generally not

included in the MANKENBERG supply schedule.

During installation, centre the fitting by means of the flange screws on the mating flange before the screws are

tightened.

With screw-mountings:

note

The connecting surfaces on the body of the fitting are formed in accordance with the

MANKENBERG order confirmation. The required seals are generally not included in the

MANKENBERG supply schedule.

With welding ends:

Properly performed welding must ensure that no significant tension is transferred to either the section of pipeline

or the body of the fitting.

Under no circumstances may the body of the fitting exceed the temperature marked on it; otherwise the sealing

and functional parts will be damaged and the whole fitting will become unserviceable.

caution

When a fitting with a body made of "high grade" or "high grade pure" deep-drawn parts (visible

on the body connection with clamp rings) is welded, the welding joint must be carried out with

special care; it is recommended that the body should be kept cool with a damp cloth.

Failure to observe this regulation may cause damage to the glass plate and/or distortion of the

body. Even the finest crack of the glass plate or 0.1 mm of permanent distortion in the seat

region may render the fitting unserviceable.

Original operating manual

Sightglasses, flow indicators and flow meters DA

DA-4.X.22.3 Issue 01.09.2022 www.mankenberg.com

7 Pressure testing the pipeline section

The fitting has already been pressure-tested by the manufacturer. The following points should be observed

when conducting a pressure test on a pipeline section with a sight glass installed:

According to EN 12266-1, the test pressure may under no circumstances exceed 1.5 times the value

indicated on the body with “PN” or “Class”.

If any leakage occurs on the fitting, section Troubleshooting help [}12] should be observed.

note

If the pipe section is flushed and/or dried after assembly or pressure testing, it is necessary to

make sure that the fitting - especially the glass plate - has not been damaged by corrosion or

excessively high temperature.

8 Initial start-up

danger of

fatalities

No fitting may be operated that does not have a sufficient pressure and temperature range for

the operating conditions – see section Intended use [}4] and markings on the fitting. The

manufacturer MANKENBERG should be consulted in the case of any applications outside of

this range.

Failure to observe this regulation may mean danger to life and limb and may cause

damage to the pipeline system.

danger

At the beginning of or shortly after the initial start-up, the sieve or the filter insert of any

installed strainer/filter should be cleaned in order to avoid blocking the strainer/filter.

caution

After the initial start-up:

Check the seals on screw-mounted parts of the body - especially on the glass plate - and

reseal if necessary. Ask MANKENBERG for tightening torque, if necessary.

Observe the relevant notes in section Troubleshooting help [}12] .

9 Normal operation

A properly selected sight glass works automatically and does not need any form of auxiliary energy.

danger of

fatalities

It is necessary to ensure that the materials selected for the parts of the fitting in contact with

media are suitable for the media in use. The manufacturer accepts no liability for any damage

due to corrosion by aggressive media on parts made of unsuitable materials - especially of

unsuitable glass quality.

Failure to observe this regulation may mean danger to life and limb and may cause

damage to the pipeline system and to the fitting.

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