Installation and Maintenance Manual Forbes Marshall Disc Check Valve FMDCV (ANSI)

Transcription

1 Installation and Maintenance Manual Forbes Marshall Disc Check Valve FMDCV (ANSI) Energy Conservation Environment Process Efficiency

2 Table of Contents 1. Preface Important Safety Notes Brief Product Information Product Working Principle Installation Guidelines Startup and Commissioning Maintenance Guidelines Troubleshooting Available Spare Parts Warranty Period...13 PLEASE NOTE - Throughout this manual this cautionary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked. This symbol denotes CAUTION, WARNING or DANGER. Forbes Marshall Disc Check Valve

3 1. 2. Preface: This manual is intended for anyone using, commissioning, servicing, or disposing the below mentioned products safely and efficiently. Forbes Marshall Disc Check Valve [FMDCV (ANSI)] Sizes: 15 NB (½ ) / 20 NB (¾ ) / 25NB (1 ) / 40 NB (1 ½ ) / 50 NB (2 ) /65 NB (2½ ) / 80 NB (3 ) / 100 NB (4 ) PLEASE NOTE: Throughout this manual the following cautionary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked. Important Safety Notes: Read this section carefully before installing/operating/maintaining the product. The precautions listed in this manual are provided for personnel and equipment safety. Furthermore, Forbes Marshall accepts no responsibility for accidents or damage occurring as a result of failure to observe these precautions. Note that the product is designed to perform for non-contaminated fluids only. A contamination in the form of chemical, foreign particle etc. can lead to problem with product performance and life of the product. If these products in compliance with the operating instructions are, properly installed, commissioned, maintained and installed by qualified personnel (refer Section 2.7) the safety operations of these products can be guaranteed. General instructions for proper use of tools and safety of equipments, pipeline and plant construction must also be complied with. 2.1 Intended use: Check if the product is suitable for intended use/ application by referring to the installation and maintenance instructions, name plates and technical information sheets. i) The product is suitable for use as defined in the technical information sheet. In case the need arises to use the product on any other fluid please contact Forbes Marshall for assistance. ii) iii) iv) Check for the suitability in conformance to the limiting conditions specified in technical information sheet of the product. The correct installation and direction of fluid flow has to be determined. Forbes Marshall products are not intended to resist external stresses, hence necessary precautions to be taken to minimize the same. 2.2 Accessibility and Lighting: Safe accessibility and working conditions are to be ensured prior to working on the product. 2.3 Hazardous environment and media: The product has to be protected from hazardous environment and check to ensure that no hazardous liquids or gases pass through the product. FMDCV (ANSI) 1

4 2.4 Depressurizing of systems and normalizing of temperature: Ensure isolation and safety venting of any pressure to the atmospheric pressure. Even if the pressure gauge indicates zero, do not make an assumption that the system has been depressurized. To avoid danger of burns allow temperature to normalize after isolation. 2.5 Tools and consumables: Ensure you have appropriate tools and / or consumables available before starting the work. Use of original Forbes Marshall replacement parts is recommended. 2.6 Protective clothing Consider for the requirement of any protective clothing for you/ or others in the vicinity for protection against hazards of temperature (high or low), chemicals, radiation, dangers to eyes and face, noise and falling objects. 2.7 Permits to work: All work to be carried out under supervision of a competent person. Training should be imparted to operating personnel on correct usage of product as per Installation and Maintenance instruction. Permit to work to be complied with (wherever applicable), in case of absence of this system a responsible person should have complete information and knowledge on what work is going on and where required, arrange to have an assistant with his primary goal and responsibility being safety. Warning Notices should be posted wherever necessary. 2.8 Handling: There is a risk of injury if heavy products are handled manually. Analyze the risk and use appropriate handling method by taking into consideration the task, individual, the working environment and the load. 2.9 Freezing: Provision should be made to protect systems which are not self-draining, against frost damage (in environment where they may be exposed to temperatures below freezing point) to be made Returning products: Customers and Stockist are reminded that, when returning products to Forbes Marshall they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk. This information must be provided in writing including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous Disposals : o o If the Viton seat has been subjected to a temperature approaching 315 C (599 F) or higher it may have decomposed and formed hydrofluoric acid. Avoid skin contact and inhalation of any fumes as the acid will cause deep skin burns and damage the respiratory system. 2 Forbes Marshall Disc Check Valve

5 3. Brief Product Information: 3.1 Description: The FMDCV(ANSI) check valves are of the wafer pattern designed to be sandwiched between flanges. They are suitable for use on a wide range of fluids for applications in process lines, Hot water systems, steam and condensate system etc. face-to face dimensions conform to EN558 part 1 series Sizes and Pipe Connections : 15,20,25,32,40,50,65,80,100 NB suitable for installation between ANSI class 150 & Optional extras : Viton soft seats for oil, gas and steam application. EPDM soft seats for water applications. Materials No. Part Material 1. Body Austentic Stainless steel ASTM A351 CF8M 2. Disc Austentic Stainless steel ASTM A351 CF3M 3. Spring retainer Austentic Stainless steel ASTM A240 SS316L Standard spring Figure 1 : Forbes Marshall Disc Check Valve Standard Austentic Stainless steel IS4454:IV:GR. 3 SS Heavy duty spring Austentic Stainless steel IS4454:IV:GR. 3 SS316 FMDCV (ANSI) 3

6 3.4 Limiting Conditions: Body design conditions ANSI 300 PMO - Maxium operating pressure TMO- 3.5 Operating Range: Maximum Operating Temperature Standard Spring Heavy duty spring Without spring 0 Minimum operating Temperature (Standard disc)-10 C Temperature Vition Seat Limits EPDM Seat Designed for a maximum cold hydraulic test Pressure of : 49 bar g C C C C to C C to C 98 bar g A-B-D FMDCV (ANSI) E-C-D FMDCV (ANSI) Stranded Spring. 3.6 Certification: Available with IBR All certification / inspection requirement must be stated at the time or order placement. Standard Designed and manufactured in accordance with BS Standard Shut-off: Standard valves conform to DIN 3230 part 3, BN2 Valves conforming to DIN 3230 part 3 BO3 available on request. Soft seated versions meet DIN3230 part 3 BN 1 and BO1 provided a differential pressure exists. 4 Forbes Marshall Disc Check Valve

7 3.8 Product Dimension and Drawing: Figure 2 : Dimensional Drawing of Forbes Marshall Disc Check Valve (ANSI) Dimensions / Weights (approximate) in mm and kg SIZE A B C D E F G Weight 15NB 20NB 25NB 32NB 40NB 50NB 65NB 80NB 100NB 3.9 Kv Valves For Conversion : Cv (UK) = Kv x Cv (US) = Kv x DN Kv FMDCV (ANSI) 5

8 3.10 Opening Pressure in mbar : Differential Pressures with zero flow for standard and high temperature springs. Flow direction NB Where lowest opening pressure are required, valves without springs can be installed in vertical pipes with bottom-to-top flow. without spring Heavy duty springs approximately 700 mbar Pressure Loss Diagram 0 Pressure loss diagram with ope valve at 20 C. The valves indicated are applicable to spring loaded valves with horizontal flow. With vertical flow. Insignificant deviations occur only within the range of partial opening. 0 The Curves given in the chart are valid for water at 20 C To determine the pressure for other fluids the equivalent water volume flowrate must be calculated and used in the graph. Vw = r 1000 x v Where : Vw r V = Equivalent water volume flow in I/s or m/h = Density of fluid kh/cm = Volume of fluid I/s or m/h Pressure loss information for steam, compressed air and gases is available from Forbes Marshall. 6 Forbes Marshall Disc Check Valve

9 3.11 Seating Options: Various options are denoted by a marking on the valve body. 'W' - Without spring - Metal disc seat 'V' - Standard spring - Viton disc seat 'E' - Standard spring - EPDM disc seat 'WV' - Without spring - Viton disc seat 'WE' - Without spring - EPDM disc seat FMDCV (ANSI) 7

10 4. Product Working Principle: Forbes Marshall Disc Check Valve ensures unidirectional fluid flow in pipes by restricting the back flow of fluids. Valve are opened by the pressure of the flow of the fluid and closed by spring as soon as the flow ceases and before the reverse flow occurs. Fig. 3: Operation of Forbes Marshall Disc Check Valve 8 Forbes Marshall Disc Check Valve

11 5. Installation Guidelines: Before implementing any installations observe the 'Important Safety Notes' in Section 2. Referring to the Limiting conditions check the product is suitable for the intended installation. Check materials, pressure and temperature and their maximum values. Determine the correct installation situation and the direction of fluid flow. Remove packing covers from the product. Forbes Marshall Disc Check Valve must only be installed where 'weld neck' flanges are used. Other flanges types may restrict operation. Spring loaded check valves simply fit between two pipe flanges as shown in fig. 4. Standard gaskets are used either side of the valve together with longer bolts or studs. Note: Flanges, bolts (or studs), nuts and joint gaskets to be provided by the installer. Normal sensible flange bolting practice should be followed e.g. torque tightening the bolts in opposite sequence. The FMDCV (ANSI) can be installed in any plane with the exception of valve is supplied without an integral spring. These must be fitted in a vertical flow line with the flow from bottom-to- top i.e. upward flow (see fig. 4b). FMDCV (ANSI) must be fitted in accordance with the direction of the flow arrow on the body, indicating correct fluid flow direction. Note: Forbes Marshall Disc Check Valve are not suitable for use where heavily pulsating flow exists, such as close to a compressor. a b c 'b' is the only acceptable orientation when a FMDCV (ANSI) is supplied without an internal spring d e Fig. 4: FMDCV (ANSI) installation without internal spring FMDCV (ANSI) 9

12 6. Start-up and Commissioning: 6.1 Flushing of lines: As part of pre-installation all fluid handling equipment particularly piping should be thoroughly cleaned of scale and the internal debris which accumulates during construction. This is accomplished by blowing or flushing with air, steam, water and other suitable medium. Follow these steps to carry out the flushing. Note: For a detailed procedure on flushing of lines please visit Forbes Marshall website. 6.2 Commissioning: After installation or maintenance ensure that the system is fully functioning by confirming fluid is passing through it. 1. After flushing of lines is complete, ensure that upstream isolation valve is opened. 2. Check for leaks and attend if any. 10 Forbes Marshall Disc Check Valve

13 7. Maintenance Guidelines: Before undertaking any maintenance on the product it must be isolated from both supply line and return line as it is under pressure during operation. When re-assembling ensure that product if are clean. Once completed open isolation valves slowly and check for leaks. Unscrew the nuts from the flange remove the gasket, to remove the dirt deposits rinse the equipment with fresh water and wipe the disc with a clean, lint free cloth. Any minor or major damage / scratch on the disc surface of the metal disc or body seat will cause failure in the Forbes Marshall Disc Check Valve with standard metal disc to resist back flow of condensate. The spring retainer should be unlocked using bend tool if not use mallet to apply light strokes on locked side of spring retainer to remove disc form the body to repair the scratch / damage part of the disc. Since the disc is less hardened than the body seat, fine particle passing through the spring loaded check valve (along with the condensate) could damage the disc. This damage will be in the form of scratches on the disc surface area. If the scratch depth is not much this can be cured by lapping the disc and the steam trap can be made functional. If the body seat is slightly worn out it can be refaced by lapping individual on a glass surface plate. The amount of material to be removed by lapping should not exceed 0.25mm (0.010 ). Note: Viton / EPDM soft faced disc cannot be lapped. If scratches or damage on Viton /EPDM soft faced disc the product should be replaced. Lapping Procedure: Requirement: Emery paper, glass surface plate, lapping paste (Aluminum Oxide slurry) and oil. First, lap the disc on a piece of emery paper (grade 220) to eliminate scratches on the disc and to prepare the surface for further fine lapping. Apply the lapping paste and oil on to the glass surface and rotate the disc in the shape of the numeric 8 (Eight). Lapping should be done till all scratches on the disc disappear. Note: If the scratches on the disc are not curable then the product should be replaced. When re-assembling the spring retainer, place the lapped side of the metal disc in contact with the body seating face. New gasket should be used either side of the spring loaded check valve together with longer bolts or studs when fit between two pipe flanges. Ensure the spring retainer is locked using bend tool if not use screw driver to lock the spring retainer. Note: Great care must be taken if the Forbes Marshall Disc Check Valve with a heavy duty spring is taken apart since the strength of the spring can cause the retainer to spring out the body. FMDCV (ANSI) 11

14 8. Troubleshooting: If the expected performance is unachievable after installation of the Forbes Marshall Disc Check Valve, check the following points for appropriate corrective measures. Failure Mode Possible Cause Remedy No Fluid discharge Forbes Marshall Disc Check Valve installed in reverse direction of the fluid discharge Foreign material deposits between the disc and body seat have accumulated. Forbes Marshall Disc Check Valve should be installed with arrow on the body pointing in direction of fluid discharge. Rinse the Forbes Marshall Disc Check Valve with fresh water and wipe the disc with a clean, lint free cloth. Fluid leak through spring loaded check valve. The spring is damage or worn out. The disc / seat of body are damaged. Replace damage spring with standard / Heavy duty spring as per the product requirement Replace the spring loaded check valve with the new one. Spring retainer is unlocked Spring retainer should be locked using bend tool. The gasket is worn or damaged. Replace with new gasket during maintenance to avoid further leakage. Note: Never attempt to modify the product. When replacing part with new part, use the spare parts listed in Section Forbes Marshall Disc Check Valve

15 9. Available Spare Parts: DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 STD Spring SPARE-15FMDCV-SSKIT SPARE-20FMDCV-SSKIT SPARE-25FMDCV-SSKIT SPARE-32FMDCV-SSKIT SPARE-40FMDCV-SSKIT SPARE-50FMDCV-SSKIT SPARE-65FMDCV-SSKIT SPARE-80FMDCV-SSKIT SPARE-100FMDCV-SSKIT How to order spares by using the description and P. C. No. given in the column headed available spares and stating the size & type of the FMDCV-A Example : 1 Standard spring for 15NB Forbes Marshall Disc Check Valve, FMDCV-A & P.C. No. SPARE-15FMDCV-SSKIT How to order a new product: Forbes Marshall FMDCV(ANSI) austenitic stainless steel Disc check valve for fitting between 25NB, ANSI Warranty Period: As per ordering information and agreements in the contract. FMDCV (ANSI) 13

16 Disclaimer: This information is strictly proprietary and legally privileged. All contents herein shall be the property of Forbes Marshall Pvt Ltd and having protection under the intellectual property rights. No part of this information or data may be distributed or disclosed in any form to any third party. Any dissemination, use, review, distribution, printing or copying is strictly prohibited, if you are not the intended recipient or user of this information. Forbes Marshall Pvt Ltd Manufacturing: B-85, Phase II Chakan Indl Area, Sawardari, Chakan Tal. Khed, Dist, Pune Tel: +91(0) Sales: Opp 106th Milestone, Bombay Pune Road, Kasarwadi, Pune Tel.: +91 (0) CIN No: U28996PN1985PTC seg@forbesmarshall.com Doc# FMSS/09/16/UM-FMDCVA/V2.R0