MODEL 835-F SIGHT FLOW INDICATOR

Transcription

1 Page : Page 1 of 18 MODEL 835-F SIGHT FLOW INDICATOR

2 Page : Page 2 of 18 TABLE OF CONTENTS Detail Page No Product Warranty 3 Disclaimer of Warranties 4 Limitation of C-TRU s liability 4 Terms of Use About this manual Introduction System Description Indicator Options Available Models Standard Materials of Construction Standard Indicator Size & Specifications Indicator Pressure & Temperature Specifications Receiving Inspection Installation Effects of Related Piping Positioning of Specific Models Bolt Torque Sequence Bolt Torque Check Operation Pre Operational Check Hydrostatic Pressure Test Operating Maintenance Preventive Maintenance Maintenance Procedures Troubleshooting Removal / Disassembly / Reassembly Disassembly Reassembly Telephone Assistance Spares Storage European Community Declaration of Conformity Exploded View 18 TABLES Table DETAIL PAGE 1 Available Models 6 2 Standard Materials of Construction 7 3 Standard Indicator Size and Specification 7 4 Indicator Pressure and Temperature Specification 78 5 Troubleshooting 13

3 Page : Page 3 of 18 PRODUCT WARRANTY C-TRU PROCESS EQUIPMENTS warrants its products as designed and manufactured to be free of defects in material and workmanship for a period of 18 months from the date of dispatch or 12 months from the date of commissioning whichever is earlier subject to the use in the manner as stated by C-TRU. C-TRU will at its option, replace or repair any product or the defective part of any product, which fails during the warranty period due to defective material or workmanship on FOR Works basis within 60 days of receipt of product by C-TRU. Prior to submitting any claim for warranty service, the owner must submit proof of purchase to C-TRU and obtain written authorization from C-TRU to return the product. Thereafter, the product shall be returned at the cost and liability of the customer to C-TRU in Kansari, Khambhat, Gujarat with freight prepaid. This warranty shall not apply if the product has been disassembled, tampered with, repaired or altered outside of C-TRU factory, or if it has been subjected to misuse, neglect or accident or used in a manner other than as stipulated by C-TRU. Other than to repair, replace or refund described above the purchaser agrees that C-TRU PROCESS EQUIPMENTS shall not be liable directly or indirectly for any losses, costs, expenses, charges or damages of any kind arising out of the product, its use, installation or replacement, labeling instructions, information or technical data of any kind, description of product use, sample or model warnings or lack of foregoing. No other warranties written or oral, expressed or implied, including the warranties of fitness for a particular purpose and merchantability, are made or authorized. No affirmation of fact, promise, description of product use or sample or model shall create any warranty from C -TRU PROCESS EQUIPMENTS unless signed by its Chief Executive Officer or its General Manager. None of our products are manufactured, sold or intended for personal, family or household purposes or for any purpose other than as specifically stipulated by us in writing.

4 Page : Page 4 of 18 Disclaimer of Warranties The Terms & Conditions of Sale on the website of C-TRU and the offer sent by C-TRU states the entire obligation of C-TRU. The contents of this document shall not become part of or modify any prior or existing agreement, commitment or relationship between C-TRU and the buyer, save and extent to the extent that it limits the liability of C-TRU. There are no express or implied warranties set out in this document. The only warranties that apply between C-TRU and the Buyer are those stated in the above cited documents. C-TRU products have not been tested by C-TRU under all possible operational conditions and C- TRU may not have all the data relative to your application. The information in this document is not all inclusive and does not and cannot take into account all unique situations. Consequently the user should review this document in view of his/her application. Limitation of C-TRU s Liability In the event that a court holds that this document created some new warranties, C-TRU s liability shall be limited to replacement or repair under the standard warranty clause. Terms of Use The information provided in this document is provided as is without warranty of any kind. C-TRU disclaims all warranties, either express or implied, including the warranties of merchantability and fitness for a particular purpose. In no event shall C-TRU or its suppliers be liable for any damages whatsoever including direct, indirect, incidental, consequential, loss of business profits, punitive or special damages even if C-TRU or its suppliers have been advised of the possibility of such damages. Use of parts/spares/components that are not manufactured or supplied by C-TRU voids any C-TRU warranty and relieves C-TRU of any obligation to service the product under warranty. C-TRU recommends the use of only C-TRU manufactured or supplied parts to maintain or service C-TRU products

5 Page : Page 5 of ABOUT THIS MANUAL This manual has been prepared as an aid and guide for personnel involved in installation / operation and maintenance. All instructions must be read and understood thoroughly before attempting any installation / operation / maintenance. Failure to follow instructions could result in a malfunction or breakage of the sight flow indicator, resulting in personal injury or property damage Always wear safety glasses when installing, servicing or operating a sight flow indicator 2.0 INTRODUCTION Sight flow Indicators are used to observe flow or level. They are relatively simple devices that can be expected to be extremely reliable if the following criteria are met: 1) The proper unit must be selected for the service intended. 2) Large and rapid thermal changes must not be imposed on the unit. 3) Normal standards of good workmanship must be employed in the installation and maintenance of the unit. ARSEN Sight Flow Indicator product line includes Full View Sight Flow Indicators. These indicators have been designed to enhance the visibility of process media as they pass through the glass cylinder. Full viewing area expands the number of positions and locations in which the unit can be visibly mounted. At a glance Model 835-F Full View Sight Flow Indicator allows for monitoring of: Fluid movement change in direction on volume Colour Change in tint or hue Clarity Change in opacity, brightness or purity Liquid Interfaces Change in level or evidence of liquid in the viewing area Foam Interfaces Change in level or evidence of foam in the viewing area

6 Page : Page 6 of 18 Model 835-F Full View Sight Flow Indicators provide a clearly visible chamber for convenient fluid monitoring. The glass chamber assists the operations manager by creating an observation window to monitor fluid process volumes, directions and reactions without interrupting the process flow. Model 835-F Sight Flow Indicators are recommended for low-pressure applications where maximum visibility is necessary to effectively monitor fluid dynamics. 2.1 SYSTEM DESCRIPTION ARSEN Model 835-F Sight Flow Indicators consists of four basic components: Flanges: provides an in-line attachment capability for the Sight Flow Indicator. In addition, the body is machined to provide a recess for glass fitment and also provides an effective method of compressing and sealing gaskets on the glass ends to prevent leakage. Sealing Gaskets: the sealing gasket is placed in the recess provided in the body and is compressed by the studs and nuts to effectively seal the gap and prevent leakage between the flange and the glass tube. A variety of materials ensures that the gaskets are compatible to the fluid passing through the Sight Flow Indicator. Glass Tube: is the most vital component of the Sight Flow Indicator and is installed in series with the pipe line that is under observation and provides uninhibited view of the media passing through the glass tube. Stud Nuts: compress the glass tube between the flanges and provide rigidity to the sight flow indicator. 2.2 INDICATOR OPTIONS Plain: There are no internal indicating options available Drip: A drip pipe extended into the viewing area facilitates the creation of turbulence and enhances visibility. The drip tube is also widely used in applications where the flow is intermittent like in distillation systems. Ball : PTFE Ball is provided for vertically up ward flow. Lined: Available in all the options mentioned above but with End Flanges lined. Dual Glass: For Just that extra margin of safety 3.0 AVAILABLE MODELS Model Flanged Ends drilled to ASA 150 # and Table F 835-F Plain 835-FD With drip tube 835-FB With floating ball for vertically upward flow 835-FDW With dual window for that extra margin of safety Table 1

7 Page : Page 7 of STANDARD MATERIALS OF CONSTRUCTION 835-F 835-FD 835-FB 835-FDW 835-F Lined IC to A 216 Gr. WCB IC to A 351 Gr. CF8 IC to A 351 Gr. CF8M Lining Polymeric Lining Elastomeric Table STANDARD INDICATOR SIZE & SPECIFICATION Model No Type Size Flange Drilling 835-F Plain 835-FD With Drip tube 835-FB With Ball 15mm -150 mm 150 # & Table F 835-FDW With dual windows 835-F Lined With Polymeric / Elastomeric lining Table INDICATOR PRESSURE AND TEMPERATURE SPECIFICATION Never exceed the design ratings or application data limits. Exceeding design ratings or application data may cause severe personal or property damage.

8 Page : Page 8 of 18 Maximum Design Ratings for 150 # and Table F Units regardless of Material of Construction Size (mm) Maximum Pressure (Kg/cm 2 ) Gasket Material Maximum Temperature( 0 C) Asbestos PTFE Graphoil Aramid Viton Neoprene 148 Buna N 121 Table 4 Polymer Sight Flow Indicators ( Polypropylene C and PVC C ) are more heat sensitive than the gasket material 4.0 RECEIVING INSPECTION Upon receipt of the sight flow indicator check all components for damage incurred in transit. If damage is evident or suspected do not attempt installation. Notify carrier immediately and request damage inspection.

9 Page : Page 9 of INSTALLATION Qualified experienced personnel who are familiar with this equipment and have read and understood all the instructions in this manual should undertake installation. The user should refer to C-TRU PROCESS EQUIPMENTS product proposal to obtain overall dimensional information. Do not proceed with installation of the sight flow indicator unless: a) The glass is examined and is free of all imperfections. Glass that is chipped is weakened and should not be used under any circumstances. b) The connections and inside of the sight flow indicator have been cleaned and are free of any foreign material. 5.1 EFFECTS OF RELATED PIPING 1) Do not impose system-piping loads on the sight flow indicators. Unit is not designed to be a load-bearing component. Piping must be supported and aligned with sight flow indicator end connections to reduce the possibility of stresses imposed on the unit. Large heavy units must be independently supported to avoid stressing the piping. 2) Locate the sight flow indicator where it can be easily seen. 3) Locate the sight flow indicator away from areas where objects may be dropped, thrown or generally allowed to effect contact with the viewing glass. 4) Locate the sight flow indicator so it is protected from dust, grit, tools, and any other object that may scratch, chip or break the glass. 5) Considerations should be given to locations where the glass will not be subjected to large temperature variations. For instance, an indicator must not be placed in a hot process line where the opening of a door could inflict sudden blasts of cold air. Cold Wash down water is also a frequent enemy of glass in hot pipelines. A poor choice of installation locations could impose conditions of thermal shock where stress values approach twice those caused by temperature alone and are additive to mechanical stresses caused by pressure and bolting loads. 6) When bolting units to adjacent piping, care must be taken to ensure that bolts or studs do not project sufficiently past the flange to strike any part of the sight flow indicator thus avoiding potentially stripped flange connections or movement of the preset retainers.

10 Page : Page 10 of POSITIONING OF SPECIFIC MODELS Model 835-F Vertically / Horizontal Flow Model 835-FD Vertically Downward Model 835-FB Vertically upward Vital Information In Failure to mount, protect and locate the sight flow indicator as described above may cause property damage or physical injury to personnel. Information 5.3 BOLT TORQUE SEQUENCE CHECK FOR MODEL 835-F 5.4 BOLT TORQUE Vital Information

11 Page : Page 11 of 18 Bolt Torque is vital to the proper operation of a Full View Sight Flow Indicator. Every ARSEN Full View Sight Flow Indicator is torqued and hydrostatically tested prior to dispatch. Bolt torque values are provided on the label attached to the sight flow indicator Bolt Torque should be checked after initial installation and periodically thereafter, to ensure that the unit is in compliance with the torque values given on the label attached to the sight flow indicator 6.0 OPERATION Sight flow indicators provide a relatively inexpensive means of visually checking conditions of flow consistently and color of liquids and gases. They neither measure nor control flow but do offer an important human evaluation for checking or double checking systems. 6.1 PRE OPERATIONAL CHECK 1) Ensure that all installation procedures have been completed. 2) Ensure that glass is clean and free of any damage. 3) Check to determine that all connections are pressure tight. 6.2 HYDROSTATIC PRESSURE TEST 1) Take all precautions necessary to handle the possibility of leakage. 2) Pressure test all installations hydraulically to at least 2 Kg/cm 2, and correct any leakage before proceeding. 6.3 OPERATING Sight flow indicator installations should be brought into service slowly to avoid excessive shock or stress on glass. Rapid pressurization of sight flow indicators may cause glass breakage with resulting sudden release of pressure causing property damage, or physical injury to personnel. 7.0 MAINTENANCE Qualified experienced personnel who are familiar with this equipment and have read and understood all the instructions in this bulletin should undertake maintenance.

12 Page : Page 12 of 18 Do not proceed with any maintenance unless the sight flow indicator has been relieved of all pressure or vacuum, has been allowed to reach ambient temperature and has been drained or purged of all fluids. 7.1 PREVENTIVE MAINTENANCE The user must create maintenance schedules, safety manuals and inspection details for each specific installation. On all installations the user should regularly evaluate the following items for purpose of maintenance: 1) Glass for cleanliness and signs of damage or wear. 2) Sight flow indicator, for signs of leakage at gaskets or at connections. 3) Sight flow indicator, for signs of internal or external corrosion. The user must determine upon evaluation of his or her own operating experience an appropriate maintenance schedule necessary for his or her specific application. Realistic maintenance schedules can only be determined with full knowledge of the services and application situation involved. 7.2 MAINTENANCE PROCEDURES 1) Glass: Regular and careful attention must be given to the cleaning and inspection of glass. Glass that is etched or chipped is weakened and may break under pressure. a) Cleaning of Glass: Keep glass clean using a commercial glass cleaner and a soft cloth. Do not use wire brushes, metal scraper, or any device that could damage the glass. b) Inspect the surface of the glass for any signs of clouding, etching or deep physical damage such as bruises, checks or corrosions that extend through the outer surface of the glass into the interior, Detection of any such problem areas is sufficient evidence of damage. The sight flow indicator should be immediately taken out of service and the glass should be replaced. 2) Gaskets: A sight flow indicator that leaks at the gasket must be immediately taken out of service. Do not proceed with the operation of a sight flow indicator until glass and gaskets have been replaced. 3) Connection Leaks: A sight flow indicator that leaks at the connection should be corrected by tightening the bolts at the connection 4) Corrosion: may occur if the user has selected a material that is not compatible for the Model 835-F Sight Flow Indicator application. It is the responsibility of the user to select materials that are compatible with both the contained fluid and the surrounding environment. If internal or external corrosion is evident, an investigation must be immediately performed by the user. 7.3 TROUBLESHOOTING

13 Page : Page 13 of 18 Problem Possible Reason Remedy Glass becomes etched or clouded in Fluid being handled is not Replace the glass service compatible with the glass Mechanical Strains in the Align the pipeline to reduce pipeline the mechanical strain Glass continually breaks in service Warped Sight Flow Indicator Replace the Sight Flow flanges as a result of cyclic Indicator mechanical or thermal stresses Table REMOVAL / DISASSEMBLY / REASSEMBLY Do not proceed with the removal or disassembly of a Sight Flow Indicator from connecting pipelines unless it has been relieved of all pressure or vacuum, has been allowed to reach ambient temperature, and has been drained or purged of all fluids 8.1 DISASSEMBLY Model 835-F Full View Sight Flow Indicators should be disassembled by standing the Sight Flow Indicator on the flange on a clean, level table surface. Ensure that the unit is stable and secure, hold the Sight Flow Indicator firmly and loosen the nuts sequentially. Remove the glass and gaskets from the indicator using appropriate safety precautions. Once a Sight Flow Indicator has been disassembled, all glass must be disposed of since they are permanently deformed by compression during service DO NOT under any circumstances reuse glass or gaskets previously in service, since they can cause leaks or high stress points resulting in glass breakage and severe personal and property damage. Glass that is broken is dangerous and should be disposed of in a safe manner determined by the user.

14 Page : Page 14 of REASSEMBLY To prepare for installation of a new glass, clean the gasket seating surfaces on the flanges. This should be done using a soft metal scrapper to remove burrs, rust and remnants of the previous gaskets. Exercise extreme care to avoid gouging or scarring gasket seating surfaces. Refer to the exploded view for component identification, assistance and position 1) Carefully remove the glass tube from the shipping package and place in a safe area. 2) Clean any material from gasket seating cavity. 3) Place new sealing gaskets in the gasket-seating cavity of the flange. 4) Apply oil or anti seize to threads and screw the nuts to the length of the threads. 5) Place the studs through one flange end and fasten with nuts. 6) Set the connecting flange on the flat surface with the studs pointing vertically upward. 7) Carefully place the glass tube within the studs until it rests on the gasket place in the flange. 8) Now place the other flange through the stud holes such that it rests on the glass tube. 9) Screw the nuts onto the studs. 10) Use a torque wrench to tighten the nuts. Tighten bolts sequentially in increments of 3 fl/lbs or 50 % of torque values whichever is less. 11) After 24 hours in service relieve pressure or vacuum, drain the indicator and allow it to return to ambient temperature. Re-torque the nuts to the specified torque values. DO NOT re-torque a Sight Flow Indicator while under pressure. A Sight Flow Indicator in service must be freed of all pressure or vacuum, allowed to reach ambient temperature and be drained or purged of all fluids before re-torquing. Failure to follow this procedure may result in severe personal injury or property damage 9.0 TELEPHONE ASSISTANCE

15 Page : Page 15 of 18 Telephone Assistance and Equipment Return If you are having difficulty with your Sight Flow Indicator, notify your local C - TRU distributor or call us direct on / To help us to assist you more effectively, please have as much of the following information when you call: Model # Name of the company from whom you have purchased the Sight Flow Indicator Invoice # and Date Materials of Construction Serial Number of the Sight Flow Indicator Process Media Operating Temperature Operating Pressure Brief description of the problem Troubleshooting procedures that failed If attempts to solve your problem fail, you may be requested to return your instrument to our factory for intensive testing. You must obtain a Return Authorization ( R A) number from C TRU prior to returning anything. Failure to do so will result in the unit being returned to you, without being tested, freight collect. To obtain a R A # the following information in addition to that above is needed: Reason for Return Person to contact at your company Ship To address We recommend that you return the entire unit for testing. There is a minimum charge of Rs. 1000/- for evaluation of non-warranty units. You will be contacted before we repair the unit if there will be any additional charges. If you return a unit that is covered by warranty, but is not defective, the minimum charge will apply SPARES We recommend that a limited number of viewing glass and gaskets be held in your maintenance stocks. Our Sales department will provide a spare part recommendation upon request. It is critical that replacement component parts are identical in specification to the original component STORAGE Sight flow indicator and Spare Component part should be stored carefully in a clean dry area at a temperature preferably above freezing point.

16 Page : Page 16 of 18 REMEMBER an undetected defect in your sight glass, whether inherent or caused during handling, installation and operation, may mean a potential bomb in your plant. C -TRU PROCESS EQUIPMENTS Head Office: 53 Satyam Industrial Estate Subhash Road, Jogeshwari (East), Mumbai , Maharashtra - India Telephone No: (0) / Fax : (0) sales@arsen-india.com Website: Works: Jasma Industries Compound, Kansari, Khambhat , Gujarat - India 12.0 European Community Declaration of Conformity (Pressure Equipment Directive 97/23/EC) Manufacturer Office Address C TRU Process Equipments 53 Satyam Industrial Estate; Subhash Road; Jogeshwari East; Mumbai ; India

17 Page : Page 17 of 18 Factory Address Products Conformity Assessment Procedures followed Name of the notified body monitoring the Quality System Address of the notified body monitoring the Quality System Name and Address of the notified body that carried out the final inspection: Particulars of Authorized Signatory Jasma Industries Compound; Kansari; Khambhat Gujarat India Sight Flow Indicators Strainers Liquid Level Gauges Flush Bottom Valves Category III ; Module H Eurocert Greece EURO CERT 73 TATOIOY & CHAR, TRIKOUPI STR KIFSA; GREECE ICL CERTIFICATIONS LIMITED # 372 INDUSTRIAL AREA, PHASE 1 PANCHKULA HARYANA EURO CERT 73 TATOIOY & CHAR, TRIKOUPI STR KIFSA; GREECE Mr. Upen Vakil Chief Executive Officer C TRU Process Equipments Yours faithfully For C TRU Process Equipments Upen Vakil Chief Executive Officer 13.0 EXPLODED VIEW

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