2 MODEL NO. H/CC41224X3 74/CS64AA2

Transcription

1 API TUV Method of Model Numbering For Valve Type FL H C C X 7 C S AA FL MODEL NO. H/CCX 7/CSAA ORIFICE LETTER ACC. TO API 5 MATERIAL TYPE CONNECTION RATING FOR INLET & OUTLET SPECIAL FEATURES/EXTRA ACCEORIES 'X' FOLLOWED BY THE FOLLOWING NOS. D, E F G H J K, L M, N, P Q R T FLOW DIA 'do' ACC. TO TUV C - CS, ASTM A WCB ( 0 TRIM) C - CS, ASTM A WCB ( TRIM) S -, ASTM A 5 CF ( 0 TRIM) S5 -, ASTM A 5 CF ( TRIM) S -, ASTM A 5 CF M ( TRIM) L -, ASTM A 5 CF ( 0 L TRIM) L -, ASTM A 5 CF M ( L TRIM) 00 - OTHER, TO SPECIFY HS - ASTM A 7 GR. WC ( TRIM) LS - ASTM A 5 GR. LCB ( TRIM) AY - ALLOY - 0 (ALLOY - 0 TRIM) HY - HASTELLOY - 'C' (HASTELLOY - 'C' TRIM) SP - SPECIAL CI - CI TO IS 0 ( 0 TRIM) A - ANSI 50 # B - ANSI 00 # C - ANSI 00 # 0 - OTHER, TO SPECIFY - PN 0 - PN - PN 5 - PN PN 0 - OTHER, TO SPECIFY - OPEN BONNET - JACKETED TYPE - TEST GAG - 'O' RING DISC - STELLITED NOZZLE & DISC 7 - COOLING SPACER - DRAIN PLUG Please refer to our new model Numbering CONSTRUCTION TYPE B - BELLOWS C - CONVENTIONAL O - OTHER, TO SPECIFY SPRING MATERIAL 0 - OTHER, TO SPECIFY - CS CD. PLATED - HIGH TEMP. ALLOY - STAINLE STEEL STANDARD ACCEORIES 0 - OTHER, TO SPECIFY - CLOSED, SCREWED CAP - PACKED LEVER CAP NOTE Prefix B is used in the st block along with orifice letter/flow dia for IBR (Indian Boiler Regulations) approved valves. PROCEDURE FOR VALVE SIZING & SELECTION First refer to Type FL, Standard Pressure Series. If the range is insufficient, refer to Type FL, High Presure Series... Valves manufactured by FAINGER LESER based on DIN design are type tested & approved by the International Agency, TUV (the German Type Test approving Authority) and the local statutory bodies like the CCoE (Chief Controller of Explosives), the IBR (Indian Boiler Regulations Act, 950) etc. Sizing calculations are according to ASME Sec. VIII Div. / API RP 50 or DIN 0 / TRD, AD-Merkblatt A, ISO, IBR 950, where applicable. For IBR Valves of FAINGER LESER, the assigned value of constant is: C=. Relieving capacity of the selected Valve would meet the customer required capacity. Flange rating and center to face dimensions are according to API 5 / DIN 0. Valves with special connections and different center to face dimensions can also be provided on request. FAINGER LESER Valves are tested for seat leakage according to API 57. FAINGER LESER April 00 /0

2 FL Safety Valve with Closed Cap, H H~ Y C B /0 FAINGER LESER April 00

3 Assembly of Flanged Spring Loaded Safety Valve FL 9 H H Item Part Name Body Seat/Nozzle Disc Guide Bonnet Spindle Split Ring Spring Plate Adjusting Screw Lock Nut Spindle Cap Name Plate Spring Stud Hex. Nut Roll Pin Securing Ring Gasket Ball Pin Lead Seal Seal Wire Securing Ring Cap H, Gastight Cap H Lifting Device H, Gastight Lever Cover H Lever H Lifting Fork Shaft Spacer O-ring Support Ring/Gland Washer Hex. Nut Circlip 7 5 FAINGER LESER April 00 /0

4 FL Standard Materials for Valve Type FL (Standard Standard Materials Pressure Series) TYPE PART No. PART NAME STANDARD MATERIAL (Also Refer to Method of Model Numbering for Details) C / C S/S5/S SPECIAL- SPECIAL- SPECIAL- C L O S E D C A P, H PACKED LEVER, H BODY NOZZLE DISC AEMBLY SPINDLE GUIDE/ GUIDE INSERT BONNET SPINDLE SPLIT RING SPRING PLATE ADJUSTING SCREW LOCK NUT CAP () SPRING STUD HEX. NUT ROLL PIN SECURING RING GASKET BALL SPACER LEAD SEAL SEAL WIRE LEVER LIFTING FORK LEVER SHAFT SPINDLE CAP PIN GLAND HEX. NUT A Gr. WCB A Gr. WCB A Gr. WCB CS CD. PLATED A Gr. WCB CS CD. PLATED/ ALLOY STEEL A 9 Gr. B7 A 9 Gr. H LEAD MS CS CS CS A 5 CF /M A 5 CF /M A 5 CF /M A 5 CF /M / ALLOY STEEL A 9 B/BM A 9 Gr. /M LEAD MS CS A 7 Gr. WC A Gr. WCB A 7 Gr. WC CS CD. PLATED A Gr. WCB ALLOY STEEL A 9 Gr. B7 A 9 Gr. H LEAD MS CS C.S. C.S. A 5 Gr. LCB A 5 Gr. CF M A 5 Gr. LCB A 5 Gr. CF M A 9 Gr. B7 A 9 Gr. H LEAD MS CS A 5 Gr. CF /M Hastelloy-C Hastelloy-C A 5 Gr. CF /M A 5 Gr. CF /M A 5 Gr. CF /M A 9 Gr. B/BM A 9 Gr. /M Non Asb./PTFE Non Asb./PTFE LEAD MS CS NOTE Material of construction will vary according to the service conditions and customer requirement. Other special materials, for example, Monel, Alloy-0, CF, CF M and accessories such as Balanced Bellows, Cooling Spacer, Test Gag, Heating Jacket, Drain Plug, Soft Seat (O-Ring) Disc etc. can be provided on request. TEMPERATURE Vs. MATERIAL OF CONSTRUCTION SPRING 0 C F DIN.00 (CS) DIN.0 () DIN.59 (ALLOY STEEL) BODY 0 C /0 0 F ASTM A 5 LCB ASTM A WCB ASTM A 5 CF /M ASTM A 7 WC Note: The above material is for standard construction. Suitable material to be used for corrosion resistant/special application. FAINGER LESER April 00

5 Overall Dimensions FL. For API 5 (Orifice based) Valves Orifice Details Height H Approx. Center to face Sl. No. Inlet Size inches Outlet Size inches Max. Set Pr. bar g Letter Area sq. in. Area sq. Dia, "d" Weight Approx. kgs. Closed Cap, H Packed Lever, H Outlet "B" Inlet "C" "Y" ½ ½ ½ D E F G H H J J K L L M N P Q R T NOTE Flange ratings and center to face dimensions are according to API RP 5 as applicable for Full Nozzle Safety Valves of inlet size " (5) and above. For revised sizes due to higher pressure & Temp., refer to page # 7/0. For smaller sizes, refer to FL 59 & FL 59 series.. For do based Valves Height H Approx. Center to face Sl. No. Inlet Size Outlet Size Max. Set Pr. bar g do Weight Approx. kgs. Closed Cap, H Packed Lever Cap, H Outlet "B" Inlet "C" "Y" FAINGER LESER April 00 /05

6 FL Discharge Capacities Calculation of mass flow acc. to ASME Sec. VIII Div. / API 5 Saturated Steam capacity in lb/h Air capacity at 5 C in scfm Water capacity in U.S.gpm Orifice SET PREURE, psig Letter Medium D Steam Air Water E Steam Air Water F Steam Air Water G Steam Air Water H Steam Air Water J Steam Air Water K Steam Air Water L Steam Air Water M Steam Air Water N Steam Air Water P Steam NOTE Capacities shown here are indicative. For detailed calculations, please provide the complete process data. /0 FAINGER LESER April 00

7 Discharge Capacities Calculation of mass flow acc. to DIN 0 TRD, AD-Merkblatt 000-A, ISO Saturated Steam capacity in kg/h Air capacity at 5 C in Nm /h Water capacity in m /h Flow SET PREURE, bar g Medium dia Steam NOTE Air Water Steam Air Water Steam Air Water Steam Air Water Steam Air Water Steam Air Water Steam Air Water Steam Air Water Steam Air Water Steam Air Water Steam Air Water FL Capacities shown here are indicative. For detailed calculations, please provide the complete process data. FAINGER LESER April 00 /07

8 FL Discharge Capacities Calculation of mass flow acc. to IBR 950 (Saturated Steam capacity in kg/h) Flow SET PREURE, bar g dia NOTE Capacities shown here are indicative. For detailed calculations, please provide the complete process data. /0 FAINGER LESER April 00

9 Accessories FL. Safety Valves with Stainless Steel Bellows There are two reasons for the use of stainless steel bellows: a) Bellows reliably seal the bonnet to the outlet chamber, protecting the guides, moving parts and the spring against failure through action of the fluid, such as dirt, corrosion, impurities or temperature. of the b) Stainless-steel bellows compensate for the effects of back pressure. They are so designed that the effective area bellows is equivalent to that of the seating area. bellows Stainless-steel bellows must be used when built-up back pressure exceeds 5% of set pressure. Stainless steel can be used for back pressure up to a maximum of 5% of the set pressure. The stainless-steel balanced bellows inherent stiffness affects set and function performance. The min. set pressure is also dependent on the nominal dia. (DN) chosen. Depending on the set pressure, either single or doublewalled stainless steel bellows (standard) are used. A shield may also have to be installed if the unit is subjected to a particularly high level of stress, such as abrasive fluids, flow A ¼ BSP/NPT control thread is fitted into the bonnet to monitor the efficiency of the bellows. A discharge pipe can be attached to the ¼ threaded drain, in the event that provisions have to be made for a safe discharge of fluids in special cases e.g. aggressive or toxic fluids. The design height of the safety valve is altered if the stainless steel bellows are installed. Material & Limits of Application Bellow material : L Temperature limits : O Up to 50 C Set pressure :.0 bar min. Back pressure : Max. 5% of set NOTE Special materials and lower set pressures are also possible. Please check availability. FAINGER LESER April 00 /09

10 FL Accessories. Safety Valves with Heating Jacket Safety Valve can be fitted with a heating jacket for special applications. Areas of application are systems to be protected from media, which are viscous, sticky or have tendency to crystallize out of solution. In case of flanged Safety Valves without stainless steel bellows, only the bodies are fitted with a heating jacket. The heating Safety Valves with stainless steel bellows For Safety Valves with stainless steel bellows, the bonnet spacer required to house the bellows is fitted with an additional heating jacket. Both heating jackets are joined by a threaded pipe bend. o. Safety Valves with Cooling Spacer for higher temperature (above 00 C) To protect the sliding parts and the spring against inadmissible influence of temperature an additional equipment will be o o necessary for all flanged spring loaded valves if the fluid temperature is 00 C (75 F) and higher. o o If the temperature is higher than 50 C ( F) stainless steel bellows should be provided as far as they are not fitted already by reason of the back pressure ratio /0 FAINGER LESER April 00

11 Accessories FL. Safety Valves with Test Gag In order to allow the adjustment of each Safety Valve in a plant provided with several Safety Valves or to carry out a pressure test above the allowable operating pressure a test gag is required. The test gag is fitted in the lever cover and exerts force on top of the spindle. After testing the test gag shall be removed. 5. Safety Valves with Lift Stopper That Safety Valves are only available in standardized nominal diameters, the valve could in a given application be oversized. It is therefore recoended to reduce the lift by means of a lift stopper, thus reducing the coefficient of discharge in addition. Lift stoppers must allow a lift of at least. Lift limitation by bush Lift limitation by gag FAINGER LESER April 00 /

12 Instructions for the Treatment and Installation of Pressure Relief Valves. FL. General Notes Pressure Relief Valves are highly quality instruments which should be handled with great care. To ensure the correct performance of a pressure relief valve all parts are made with exact precision. Only this precision ensures the correct functioning of the pressure relief valves. Careless handling of the finished valve in workshops, stores, during transportation or installation could cause leakage or possibly permanent damage (also refer to API Report Guide for inspection of refinery equipment, Chapt. XVI Pressure Relieving Devices" Para 00 and 00). The sealing surfaces have been ground and lapped with high precision to ensure the required tightness. Even though the surfaces are extremely hard, the seal can still be damaged. By all means, one must take care to prevent impurities from entering the valve during transportation, installation and operation. When installing pressure relief valves with threaded connections, use only metal seal washers. Seal materials such as hemp or PTFE tape should not be used as this type of material can break off and enter the valve causing it to leak. If valves with open bonnets and/or levers are to be painted after despatch from the factory, care must be taken to protect the sliding parts. Otherwise the correct operation of the pressure relief valve may be affected.. Transport Protection The inlet and outlet of the pressure relief safety valves are protected during transportation with plastic caps. These caps should only be removed just before installing the valve. The lifting lever of spring loaded pressure relief valves is secured with a wire to the bonnet. This wire should be removed only after installation. For testing the set pressure or tightness of the pressure relief valve remove also this wire and take care that the lever is not engaged with the spindle cap.. Installation/Assembly. General Notes Spring loaded pressure relief valves should be installed with the bonnet VERTICALLY UPWARDS. Furthermore, pressure relief valves should be mounted in such a way that no inadmissible static, dynamic or thermal loads can be transmitted to the valve due to up and downstream pipe work. If necessary, expansion possibilities should be provided. Stresses by incorrect mounting should be avoided.. Draining of Condensate To prevent dirt and all kinds of impurities from the pressure relief valve the drainage of discharge pipe According to rules a drain hole of sufficient size must be incorporated at the lowest point of pipe work. In all cases the discharge pipe must first slope in a downwards direction and fitted with a suitable size drain hole before any bends are connected (refer to sketch). Exception: In special cases, for instance on board of ships an optional drain hole may be recoended in the valve body as it may be that pipe work drainage cannot be guaranteed at a lower point than the valve. The standard drain hole which will then be supplied by the factory is /" BSP. But, by all means, the discharge pipe must be drained too. In extreme cases this hole can be drilled outside of our factory provided that special care is taken to ensure that no damage is done to the sealing surfaces. All drainage pipes that have been connected must be free of restriction and the ends easily seen. Care must be taken when discharging any drainage to prevent injury to personnel. For example on steam connect a suitable steam trap. Note! When valves are supplied with a drain hole that is not going to be used the plastic plug fitted in the hole must be removed and replaced by a metal plug.. Mounting Brackets For pressure relief valves with mounting brackets a fastening possibility for the brackets should be provided to withstand the forces of reaction when valve blows off. The bracket holes can be drilled on request.. Insulation In case any insulation of the pressure relief valve is provided, the bonnet must be kept free to avoid unacceptable heating up of the spring..5 Inlet Pipe The inlet pipe for pressure relief valves should be as short as possible and should be so arranged, that when the valve is in its fully open position the pressure drop the be must not exceed % of set pressure, the edging at inlet pipe should be rounded off or at least be chamfered. If the calculation results in a higher than % pressure drop of set pressure then the inlet pipe size must be enlarged.. Discharge Pipes/Back Pressure The discharge piping on vapours and gases should installed in an ascending direction, on liquids in an inclined direction. FAINGER LESER April 00 /

13 FL Instructions for the Treatment and Installation of Pressure Relief Valves. The discharge pipework of all pressure relief valves should be so arranged that the back pressure, which is built up during blow off, does not exceed a max. 5% of set pressure. In case of higher back pressure, pressure relief valves with pressure compensating metal bellows (balanced type) shall be used. In case the back pressure is >0.5 times set pressure the capacity of the pressure relief valves must be recalculated..7 Pressure Relief Valves with bellows Pressure relief valves with elastomer bellows (TRD 7) as well as metal bellows have a vent hole in the bonnet. When fitting pressure relief valve with a vent hole care must be taken to prevent moisture from entering the bonnet. However, fluid escaping from the vent hole indicates that the bellows have failed. Repair is required. When pressure relief valves with bellows are used with toxic or inflaable fluids, care must be taken to fit a suitable vent pipe to provide safe venting. For this purpose, the vent can be threaded /" BSP female on request.. Mode of Operation/Maintenance The working pressure of the plant should be at least 5% below the blow down pressure of the valve to enable a correct reseat. When a slight leakage occurs, due to deposits between the sealing surfaces, surfaces can be cleaned by operating the lifting lever causing the valve to blow off. The valve should be closed by sudden release of the lever. If this procedure does not stop the leakage, the valve seals are probably damaged. Repairs should be carried out at our It is recoended and in Germany required by Rules to lift manually the valve lifting lever from time to time in order to prevent accumulation of deposits that will affect valve operation. For steam generators, the following requirements are established in the German Technical Rules for Steam Boilers TRD 0, edition., Section. "Testing of pressure relief valves is required for plants operating with demineralized water and for hot water generators at intervals of at least months, with the exception of power plants. For other steam generators, the test interval should not exceed weeks". It is important to ensure that the lifting lever does not engage the spindle cap after the lift operation. The lever must be deflected towards the center line of the bonnet until the lifting fork is disengaged. For pressure relief valves with open bonnet, a drain groove is provided in the guide flange. Whilst blowing, condensate escaping through the clearance between guide disc and spindle is drained through this groove. According to DIN specification 75, Oct. 7 Edition "Explanations", Para. pressure relief valves represent the last step in the line of protection for the vessel, and they should be able to prevent excess pressure when all other automatic or pilot operated checking instruments have failed. To guarantee this function pressure relief valves require, like all other technical equipment, regular service. How often a valve must be checked, depends on the actual operating conditions, so that no general indications can be given. Usually pressure relief valves operating in a corrosive atmosphere or on laden fluids require service more often than valves operating clean conditions. This also applies if the pressure relief valve operates frequently causing a higher wear out to the seat and disc. Special consideration is required if conditions such as vibration (to be avoided, if possible) pressure pulsation and/or Add, drain pipe in case of prepared drain hole / FAINGER LESER April 00

14 Dismantling and Assembly Instructions For Valve Type FL, FL 59 & FL 59 Series FL. Loosen the existing lead seal.. Press the lever () towards the middle until it reaches the stop so that the lifting fork() no longer holds the spindle cap ().. Loosen and remove the lever cover ().. Loosen the spindle cap () from the spindle (), remove the securing ring (9) and the pin (7). 5. Loosen the lock nut (9) of the adjusting screw ().. Turn the adjusting screw () anticlockwise to remove the all spring tension. 7. Remove the hex. nuts (5) from the flange of the bonnet (9).. Lift off the bonnet (9). 9. Remove the upper spring plate (). 0. Lift of the spring (5) and remove lower spring plate () and split rings ().. Remove spindle () with guide () and disc (7).. Carefully clean seat (5) and disc (7), and if required body internals.. Refit spindle () with guide () and disc (7).. Fit the split rings () into spindle groove and retain with the securing ring (59); slip on lower spring plate () to locate on split rings (). 5. Replace spring (5).. Slip on the upper spring plate () onto the spindle (). 7. Align adjusting screw (), and bonnet (9), over the spindle () and refit.. Fit and tighten the hex. nuts (5). 9. Load the spring (5) to obtain the required set pressure. Clockwise rotation of adjusting screw () increases pressure. Anticlockwise rotation of adjusting screw () reduces pressure. 0. Tighten the lock nut (9) onto the adjusting screw ().. Refit and secure spindle cap () by pin (7) and securing (9).. Screw-on the lever cover ().. Pull the lever () towards the middle so that the lifting fork () is pushed under the spindle cap ().. Test spindle will lift correctly by pulling lever. These instructions are applicable for Relief Valves, CAUTION During all work the spindle has to be secured against twisting in order to prevent damage to the sealing surfaces. 9 FAINGER LESER April 00 /5

15 FL Dismantling and Assembly Instructions For Valve Type FL 59 Series Remove lead seal. Remove pin (7). Pull lever () from lever cover. Unscrew and remove lever cover (). Slacken locknut (9). Turn adjusting screw () to the required set pressure. Draw attention to the admissible pressure range of the spring! Clockwise turning of adjusting screw increases the spring tension, obtaining a higher set pressure. Turning anticlockwise of adjusting screw reduces the spring tension, obtaining a lower set pressure. Reassemble in reverse order and lock at the set pressure. 7 9 Lifting Device H Spring Replacement. Remove lead seal.. Remove pin (7).. Pull lever () from lever cover ().. Unscrew and remove lever cover (). 5. Remove Pin (7).. Remove spindle cap () from spindle (). 7. Slacken lock nut (9) of adjusting screw ().. Turn adjusting screw () anticlockwise to remove all spring tension. 9. Unscrew bonnet (9), but first loosen discharge pipe. 0. Remove upper spring plate (7).. Lift off the spring (5).. Withdraw assembly of spindle (), lower spring plate () and disc (7).. Carefully clean seat () and disc (7), and if required body internals.. Refit spindle () with lower spring plate () and disc (7). 5. Replace spring (5).. Slip on upper spring plate (7) to the spindle (). 7. Align adjusting screw () and bonnet (9) over spindle () and refit.. Load the spring (5) to obtain the required set pressure. Draw attention to the admissible pressure range of the spring! Clockwise rotation of adjusting screw () increases pressure. Anticlockwise rotation of adjusting screw () reduces pressure. 9. Tighten locknut (9). 0. Refit spindle cap () on the spindle ().. Drive in pin (7).. Screw on lever cover ().. Refit lever ().. Drive in pin (7). 5. Seal the valve. ATTENTION Care should be taken to ensure valve spindle is not rotated. / FAINGER LESER April 00