Operating Instructions

Transcription

1 Armaturen GmbH Armaturen, Rohre, Sonderteile aus Edelstahl fittings, pipes, special parts of stainless steel Operating Instructions Safety valve spring loaded TYPE FSV2000 M & S Armaturen GmbH Industriestraße Friedeburg Germany Phone: +49(0) Fax: +49(0) info@ms-armaturen.de Internet: Rev.2 / Page 1 of 21 BA92010GB.doc

2 Copyright M&S Armaturen GmbH Reproduction, copying or distribution of this document or any parts thereof in any form whatsoever without the written consent of M&S Armaturen GmbH is prohibited. 1 Table of contents 1 Table of contents Symbols used Use and operating principle Transport and storage Checking the delivery contents Transport Safety advice Assembly Installation Disassembly Repairs/Maintenance Cleaning Design of safety valves spring loaded Technical Data Diagrams of efficiency Special valves Marking of the safety valve spring loaded Dimensions FSV Material and surfaces Gaskets Material properties Additional equipment Lifting cylinder Heating equipment Valve position indicator Cleaning equipment Safety valve with manual adjustment Sectional drawings Replacing wear parts Safety valve spring loaded DN Disassembly / assembly of lifting cylinder Safety valve spring loaded DN Faults, possible causes, remedies System capacity tables Rev.2 / Page 2 of 21 BA92010GB.doc

3 2 Symbols used Danger warnings Danger warnings are denoted by the danger symbol which appears on the left and are framed. Information Descriptions to which particular attention must be paid are denoted by this symbol which appears on the left and are also framed. 3 Use and operating principle The component tested safety valve is designed as normal safety valve for gases and vapours. It is mainly used in food, drink, and pharmaceutical industry where parts of the production line must be secured against overpressure. The normal safety valve is a fitting that prevents exceeding the permissible operating pressure by more than 10%. The flow direction of the medium is marked with an arrow on the housing. The normal safety valve responds within a pressure rise of max. 10% and reaches the stroke required for the mass flow to be discharged. There are no other requirements to the opening characteristics. Normal safety valve open within an opening pressure difference of 10% of the start-to-leak pressure. For start-to-leak pressures < 1.0 bar, the opening pressure difference can be up to 0.1 bar. Normal safety valves close within a pressure drop of 10% with compressible media and 20% with incompressible media. Rev.2 / Page 3 of 21 BA92010GB.doc

4 4 Transport and storage 4.1 Checking the delivery contents When you receive the safety valve, check the delivery against the order to make sure they correspond. Check that the delivery is complete, and check its condition. If there are visible signs of transit damage and/or packing units are missing notify the forwarding agent immediately in the consignment note. You (the recipient) should take recourse against the forwarding agent immediately in writing, and M&S Armaturen GmbH must be informed of this action. Complaints regarding transit damage that is not immediately evident must be made to the forwarding agent within 6 days. The recipient must bear the costs for claims made after this period. 4.2 Transport The packing units/safety valves must only be transported using suitable lifting equipment and slinging gear. Pay attention to the graphic symbols on the packaging. Transport the safety valve carefully to prevent damage from sudden impacts; exercise due care when loading/unloading. Rev.2 / Page 4 of 21 BA92010GB.doc

5 5 Safety advice The operator must ensure that the safety valve is only used as intended, the safety valve is only used when in perfect, functional condition, only sufficiently qualified and authorised personnel installs and maintains the safety valve, the legal requirements of the regulations on occupational safety, system safety and operational safety are met. Prior to maintenance works, the container or the pipeline system containing the valve must be depressurised and fluid-free! Prior to dismounting the spring housing, the spring must be completely unloaded. Freezing, gluing and locking of the safety valve must be avoided. In operation without exhaust line, media can abruptly gush out of the valve outlet. - Danger of scalding, injury and explosion! During blow-out, loud flow noise can occur. For safe maintenance of the valve, observe the installation instructions. Rev.2 / Page 5 of 21 BA92010GB.doc

6 6 Assembly 6.1 Installation The parts are delivered in lifted state. Prior to commissioning, release the lift. Observe the relevant national guidelines and regulations. The component must be installed in vertical position under consideration of the flow direction. In exceptional cases horizontal installation is also possible (specify upon ordering). In co-ordination with manufacturer and operator, this installation can be permitted. The factory-set start-to-leak pressure may not be modified. It is secured by a locking sleeve..at the outlet side, free and pressureless flow must always be ensured. No static, dynamic or thermal load may be transmitted to the valve. The connections between safety valve and system must be dimensioned adequately. They must be designed according to the corresponding rules and regulations (e.g. AD2000). The safety valve must be lifted regularly to check its function and to remove any deposits. The parts are delivered in lifted state. Prior to commissioning, release the lift [see chapter 14, fig. 5,7]. - For DN25-50, lift by turning the handwheel clockwise. After lifting, loosen the handwheel (9) from the pressure pin (8) by a counterclockwise turn. - For DN65-100, lift by pressing the lifting lever (19). 6.2 Disassembly The valve may only be disassembled when depressurised. Secure the valve against falling down (e.g. with suitable sling gear). Prior to disassembly, lift the safety valve manually Loosen the exhaust line (if present) Remove any pneumatic connections Disconnect the supply line. The safety valve can then be removed Rev.2 / Page 6 of 21 BA92010GB.doc

7 7 Repairs/Maintenance The maintenance intervals differ from case to case, the operator should define them by himself basing on sporadic checks. To replace the gaskets refer to the installation instructions (chap. 15). Grease all gaskets slightly. Recommended: Paraliq GTE 703 by Klüber Lubrication M&S Armaturen GmbH cannot accept liability for claims made as a result of nonobservance of these Operating Instructions or constructional changes to the safety valve spring loaded. Any other use or use outside the defined scope is considered to be improper use. M&S Armaturen GmbH will not accept liability for losses incurred as a result of improper use. 8 Cleaning Manual or automatic lifting of the valve disc during the cleaning process allows for flushing the cleaning agent over the contact surface between disk gasket and seat as well as through the housing with the valve outlet side. An optional spray cleaning device below the valve disc can serve to clean the part of the valve that comes into contact with the product, i.e. up to the valve disc. 9 Design of safety valves spring loaded In order to meet the individual requirements of every customer, M&S safety valve spring loaded are dimensioned according to the given technical specifications. To project the safety valves, we need the following information: Material (in contact with product) Surface Service medium (gases, bases, acids, vapours, etc.) Concentration Temperature (min., max.) Operating pressure (set pressure of the safety valve) Filling power of the tank Rev.2 / Page 7 of 21 BA92010GB.doc

8 10 Technical Data The safety valves are approved for non-toxic gases, vapours and non-sticky liquids. They passed a TÜV component test and an acceptance test in a housing. In addition, they meet the requirements of the Pressure Equipment Directive (PED) and have a CE marking. The maximum operation or sterilisation temperature depends on the gasket material. The permissible pressure range is listed in the following table. Tab. 1: Pressure ranges DN Gases + vapours Saturated vapour Liquids [bar] 25 [b ] [b ] / Diagrams of efficiency Air see attachment Water see attachment Saturated vapour see attachment 10.2 Special valves If the required pressure is beyond the pressure range as listed in tab. 2, the TÜV component test becomes void; no performance data can be created! The valves may not be used as valves with safety function! Rev.2 / Page 8 of 21 BA92010GB.doc

9 10.3 Marking of the safety valve spring loaded [stamped on the housing] Component mark: TÜV SV 08 xxx xx D/G/F 0,xx x,xx (example) TÜV = TÜV marking SV = safety valve 08 = year of component test xxx = component test number xx = smallest flow diameter d 0 upstream of the valve seat D/G = designed for vapour and gases F = designed for fluids 0,xx = awarded outlet number α w x,xx = adjustment pressure in bar Valve number: yymmnnn yy = year of manufacture mm = month nnn = sequential number Rev.2 / Page 9 of 21 BA92010GB.doc

10 10.4 Dimensions FSV2000 Fig. 1 DN25-50 Fig. 2 DN Fig. 3 DN25-100, adjustable Fig. 4 DN with automatic lifting Tab. 2: Dimensions FSV2000 DN A [mm] B [mm] Ø C [mm] D [mm] G [mm] H [mm] I [mm] Rd52x1/ Rd65x1/ Rd78x1/ Rd95x1/ Rd110x1/ Rd130x1/ Rev.2 / Page 10 of 21 BA92010GB.doc

11 11 Material and surfaces in contact with product: /AISI /AISI 316L (optional) not in contact with product: /AISI 304 Gaskets: EPDM, FKM, and PTFE (depending on order and/or version) Inner surfaces: R a 0.8µm Outer surfaces: polished metal, lathed 12 Gaskets The following tables list the abbreviation, the temperature range and important properties of the standard gasket materials as well as their compatibility with different media. Tab. 3: Abbreviation and temperature range Abbreviation Temperature range EPDM -35 C to 140 C FKM -20 C to 200 C PTFE [Teflon] -200 C to 260 C 12.1 Material properties Evaluation: 1= very good, 2= good, 3= satisfactory, 4= sufficient, 5= deficient, 6= insufficient Tab. 4: Material properties EPDM FKM PTFE [Teflon] Ageing resistance Ozone resistance Gasoline resistance Ethanol resistance Oil and grease resistance Acid resistance Base resistance Hot water resistance Vapour resistance Gas impermeability Rev.2 / Page 11 of 21 BA92010GB.doc

12 13 Additional equipment [see fig. 1-4] 13.1 Lifting cylinder The safety valve can be equipped with a pneumatic lifting cylinder if required for cleaning purposes and/or function check. Control air: 6 bar 13.2 Heating equipment The heating equipment serves as anti-freeze safeguard. The valve casing can be equipped with heater cartridges. Overheating of the valve seat must be avoided at all costs 13.3 Valve position indicator A proximity switch to signal the open position of the valve disc can be installed at the lifting cylinder or the protective hood, if required Cleaning equipment [no figure] A tube adapter with an integrated cleaning nozzle can be installed below the valve Safety valve with manual adjustment The start-to-leak pressure of the valve is adjustable Rev.2 / Page 12 of 21 BA92010GB.doc

13 14 Sectional drawings Fig. 5 Safety valve, constant DN25-50 Fig. 6 Safety valve, adjustable DN Rev.2 / Page 13 of 21 BA92010GB.doc

14 Fig. 8 Lifting cylinder Fig. 7 Safety valve, constant DN Fig. 9 Installation of Stepseal K 15 Replacing wear parts The valve may only be disassembled when depressurised. Do not mismatch or modify any components of the safety valve. After valve assembly, perform a functional check. Rev.2 / Page 14 of 21 BA92010GB.doc

15 15.1 Safety valve spring loaded DN25-50 [see fig. 5-6, 9] a) Loosen and remove handwheel (9) b) Screw out the pressure pin (8), Attention: Pay attention to the pretension of the pressure spring c) Remove locking sleeve (7) d) Unscrew the grooved nut (4) from the housing (1) e) Remove upper part (3) f) Pull off the pressure spring (10) with the guide bushes (11) upwards from the spindle (6), remove split holding ring (12) g) Pull spindle (6) and valve disc (5) with guide (2) out of the housing (1) The valve is then sufficiently disassembled to replace the wear parts. Disassembly / assembly of the wear parts h) Remove the housing O-ring (16) and insert new O-ring into the groove i) Remove sealing ring Stepseal K (17) incl. O-ring from the guide (2) and insert new O-ring into groove, press new Stepseal K ring into a kidney-shape and place it on the O-ring (fig. 8) j) Remove cap nut (13) and washer (14) from the valve disc (5) and take off the flat gasket (15), insert new gasket, put washer into place, secure cap nut with suitable adhesive (e.g. Loctite) and screw it tight Before assembly, clean the parts and grease wear parts slightly Assembling the safety valve spring loaded k) Insert spindle (6) and valve disc (5) with guide (2) into the housing (1) l) Plug pressure spring (10) with guide bushes (11) and holding ring (12) onto spindle (6) m) Screw tight the upper part (3) and the housing (1) using the cap nut (4) n) Plug the locking sleeve (7) onto the pressure pin (8) o) Screw both parts into the upper part (3) and tighten. p) Assemble the handwheel (9) but do not pull it too tightly against the pressure pin (8) Rev.2 / Page 15 of 21 BA92010GB.doc

16 15.2 Disassembly / assembly of lifting cylinder [see fig. 8] a) Screw cover (31) out of the cylinder (30), Attention: Pay attention to the pretension of the pressure spring b) Remove pressure spring (34) c) Loosen and remove lifting disc (33) d) Pull out the piston (32) The O-rings ( ) are now accessible and can be replaced. e) Insert greased O-rings (35+36) into piston (32) f) Push piston into cylinder (30) g) Screw in the lifting disc (33). h) Insert pressure spring (34) i) Screw cover (31) into cylinder (30) 15.3 Safety valve spring loaded DN [see fig. 7, 9] a) Loosen hexagon screws (24), pull lifting lever (19) and remove hood (18) b) Unscrew hexagon nut (23) and driving plate (22) c) Loosen lock nut (21) d) Unscrew out the pressure screw (20), Attention: Pay attention to the pressure spring e) Remove grooved nut (4) or cap nuts (25) from the housing (1) f) Remove spring hood (17) g) Pull off the pressure spring (10) with the guide bushes (11) upwards from the spindle (6), remove split holding ring (12) h) Pull spindle (6) and valve disc (5) with guide (2) out of the housing (1) The valve is then sufficiently disassembled to replace the wear parts. The work must be done as described under DN25-50 chapter 15.1 h-j. Rev.2 / Page 16 of 21 BA92010GB.doc

17 Assembling the safety valve spring loaded a) Insert spindle (6) and valve disc (5) with guide (2) into the housing (1) b) Plug pressure spring (10) with guide bushes (11) and holding ring (12) onto spindle c) Screw the spring hood (17) and the housing (1) together using the grooved nut (4) or cap nuts (25) d) Screw in the pressure screw (20) with the lock nut (21) up to the scale mark, and lock it e) Screw driving plate (22) onto spindle and lock with hexagon nut (23) f) Pull lifting lever (19), plug it onto the spring hood (17) with the hood (18) and tighten with hexagon screws (24) 16 Faults, possible causes, remedies During troubleshooting, you must observe the safety instructions by all means. If a functional or operational fault occurs, you must check whether the installation has been performed and completed according to this operating instructions. If the faults cannot be remedied with the help of the table below, Troubleshooting, contact the supplier/manufacturer. Fault Possible causes Remedy Safety valve does not respond, no flow Adjustment pressure too high Replace safety valve; system must be depressurised Viscous or sticky media The medium is frozen or solidified Use heater cartridges, install upstream bursting disc, if required, system must be depressurised Heat up the system Rev.2 / Page 17 of 21 BA92010GB.doc

18 Not liftable Safety valve leaks at the seat The form-fit connection between valve disc and valve spindle is broken Lifting cylinder defective The operating pressure is higher than 90% of the startto-leak pressure Disc gasket defective Replace safety valve; system must be depressurised Replace safety valve; system must be depressurised The operating pressure must be less than 90% of the start-to-leak pressure Leakage between housing and upper part Housing O-ring (16) defective Replace O-ring (16), system must be depressurised Valve position indicator does not operate or is inaccurate Proximity switch defective Lifting cylinder does not operate Replace switch Check cylinder, system must be depressurised Blows off permanently Handwheel (9) not loose Loosen handwheel (9) from the pressure pin (8) by turning it counterclockwise Wobbling Capacity too low Design of safety valves too large Exhaust line too long or diameter too small Safety valve incorrectly designed for the system Select smaller safety valves; system must be depressurised Select a larger rated width; system must be depressurised Redimension safety valve and replace it, system must be depressurised Usage of safety valves does not meet the valid regulations DGR, DIN, AD, TRD etc. Change conditions, system must be depressurised Rev.2 / Page 18 of 21 BA92010GB.doc

19 17 System capacity tables Tab. 6: Medium air 20 C DN 25 DN 40 DN 50 DN 65 DN 80 DN 100 p (bar) m 3 n /h m 3 n /h m 3 n /h m 3 n /h m 3 n /h m 3 n /h Rev.2 / Page 19 of 21 BA92010GB.doc

20 Tab. 7: Medium water 20 C DN 25 DN 40 DN 50 DN 65 DN 80 DN 100 p (bar) m 3 /h m 3 /h m 3 /h m 3 /h m 3 /h m 3 /h Rev.2 / Page 20 of 21 BA92010GB.doc

21 Tab. 8: Medium saturated vapour DN 25 DN 40 DN 50 DN 65 DN 80 DN 100 p (bar) kg/h kg/h kg/h kg/h kg/h kg/h Rev.2 / Page 21 of 21 BA92010GB.doc