595-K/L and 596-K/L Series Self Operated Valves Installation and Maintenance Instructions

Transcription

1 CH Issue K/L and 596-K/L Series Self Operated Valves Installation and Maintenance Instructions 1. Safety information 2. General product information 3. Installation 4. Maintenance 5. Spares parts 6. Fault finding E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y Copyright 2016

2 1. Safety information Safe operation of these products can only be guaranteed if they are properly installed, commissioned, used and maintained by qualified personnel (see Section 1.11) in compliance with the operating instructions. General installation and safety instructions for pipeline and plant construction, as well as the proper use of tools and safety equipment must also be complied with. 1.1 Intended use Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended use / application. The products listed below comply with the requirements of the European Pressure Equipment Directive 2014/68/EU, carry the, mark when so required and fall within the Pressure Equipment Directive categories: Unit Group 1 Gases Group 2 Gases Group 1 Liquids Group 1 Liquids Actuator SEP - SEP Actuator SEP - SEP Water pot IT - SEP - SEP For valve bodies please refer to relevant Installation and Maintenance Instructions IM-S i) The products have been specifically designed for use with liquids and gases which are in Groups 1 and 2 of the above mentioned Pressure Equipment Directive. The products use on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the product for the application being considered. ii) Check material suitability, pressure and temperature and their maximum and minimum values. If the maximum operating limits of the product are lower than those of the system in which it is being fitted, or if malfunction of the product could result in a dangerous overpressure or overtemperature occurrence, ensure a safety device is included in the system to prevent such over-limit situations. iii) Determine the correct installation situation and direction of fluid flow. iv) Spirax Sarco products are not intended to withstand external stresses that may be induced by any system to which they are fitted. It is the responsibility of the installer to consider these stresses and take adequate precautions to minimise them. v) Remove protection covers from all connections and protective film from all name-plates, where appropriate, before installation on steam or other high temperature applications. 1.2 Access Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting to work on the product. Arrange suitable lifting gear if required. 1.3 Lighting Ensure adequate lighting, particularly where detailed or intricate work is required. 1.4 Hazardous liquids or gases in the pipeline Consider what is in the pipeline or what may have been in the pipeline at some previous time. Consider: flammable materials, substances hazardous to health, extremes of temperature. 1.5 Hazardous environment around the product Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery. 1.6 The system Consider the effect on the complete system of the work proposed. Will any proposed action (e.g. closing isolation valves, electrical isolation) put any other part of the system or any personnel at risk? Dangers might include isolation of vents or protective devices or the rendering ineffective of controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system shocks

3 1.7 Pressure systems Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that the system has depressurised even when the pressure gauge indicates zero. 1.8 Temperature Allow time for temperature to normalise after isolation to avoid the danger of burns and consider whether protective clothing (including safety glasses) is required. 1.9 Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine Spirax Sarco replacement parts Protective clothing Consider whether you and/or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and dangers to eyes and face Permits to work All work must be carried out or be supervised by a suitably competent person. Installation and operating personnel should be trained in the correct use of the product according to the Installation and Maintenance Instructions. Where a formal permit to work system is in force it must be complied with. Where there is no such system, it is recommended that a responsible person should know what work is going on and, where necessary, arrange to have an assistant whose primary responsibility is safety. Post warning notices if necessary Handling Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling, carrying or supporting a load by bodily force can cause injury particularly to the back. You are advised to assess the risks taking into account the task, the individual, the load and the working environment and use the appropriate handling method depending on the circumstances of the work being done Residual hazards In normal use the external surface of the product may be very hot. If used at the maximum permitted operating conditions the surface temperature of some products may reach temperatures of 300 C (572 F). Many products are not self-draining. Take due care when dismantling or removing the product from an installation (refer to Maintenance instructions ) Freezing Provision must be made to protect products which are not self-draining against frost damage in environments where they may be exposed to temperatures below freezing point Safety information - Product specific This valve contains a PTFE component. When PTFE is heated to its sintering temperature it gives rise to gaseous decomposition products or fumes which can produce unpleasant effects if inhaled. Smoking should be prohibited in workshops where PTFE is handled and It is extremely important to avoid contamination of clothing, especially the pockets, with PTFE and to maintain a reasonable standard or personal cleanliness by washing hands and removing any PTFE particles lodged under the fingernails. Gaskets should be carefully handled because they contain thin stainless steel support ring which may cause physical injury Disposal Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable and no ecological hazard is anticipated with its disposal providing due care is taken. However, if the valve is fitted with a PTFE seat, special care must be taken to avoid potential health hazards associated with decomposition / burning of these seats; PTFE can only be disposed of by approved methods, not incineration. - Keep PTFE waste in a separate container, do not mix it with other rubbish, and consign it to a landfill site

4 1.17 Returning products Customers and stockists are reminded that under EC Health, Safety and Environment Law, when returning products to Spirax Sarco 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. Attention If the product is not used in the manner specified by these instructions, the protection provided may be impaired Working safely with cast iron products on steam Cast iron products are commonly found on steam and condensate systems. If installed correctly using good steam engineering practices, it is perfectly safe. However, because of its mechanical properties, it is less forgiving compared to other materials such as SG iron or carbon steel. The following are the good engineering practices required to prevent waterhammer and ensure safe working conditions on a steam system. Safe Handling Cast Iron is a brittle material. If the product is dropped during installation and there is any risk of damage the product should not be used unless it is fully inspected and pressure tested by the manufacturer. Please remove label before commissioning. Prevention of water hammer Steam trapping on steam mains: m. intervals Steam Gradient 1:100 Gradient 1:100 Steam Trap set Trap set Trap set Condasate Condasate Condasate

5 Steam Mains - Do s and Dont s: Prevention of tensile stressing Pipe misalignment: Installing products or re-assembling after maintenance: Do not over tighten. Use correct torque figures. Flange bolts should be gradually tightened across diameters to ensure even load and alignment

6 Thermal expansion: Examples showing the use of expansion bellows. It is highly recommended that expert advise is sought from the bellows manufacturer. Guides Axial movement Short distance Fixing point Guides Axial movement Guides Limit rods Small lateral movement Large lateral movement Medium distance Fixing point Limit rods Guides Small lateral movement Large lateral movement

7 2. Product information 2.1 General description Self-operated diaphragm pressure control valves Series 595K/L-596K/L is a range of robust directacting valves designed to operate under arduous conditions being ideal to control the pressure in liquid, steam and inert gases systems. A soft-seated version in PTFE is available (suffix G ) for air / gas applications that require tight shut-off (limited to 200 C). It is recommended that for these applications, a maximum pressure turndown ratio of 10:1 is observed. The valve is controlled by the downstream pressure which acts directly on the diaphragm, opposing the force to which the spring is calibrated. Under stable conditions diaphragm force and spring force are in a state of balance, but an increase or decrease in demand raises or lowers the downstream pressure which in turn acts against the spring to close or open the valve to adjust the flowrate and maintain a constant downstream pressure. The 595K/L-596K/L range requires no periodic maintenance. Note: when operating a pressure reduction on liquids, it is possible that cavitation occurs. In such situations, it is essential to use control valves which are specifically designed to avoid damages that cavitation may cause both to the valve internal parts and to the components mounted immediately downstream. Fig K/L Pressure Reducing Valve Fig K/L Pressure Relief Valve

8 Fig. 3 - Cross sectional views of the 595-K/L Pressure Reducing Valve Fig. 4 - Cross sectional views of the 596-K/L Pressure Relief Valve

9 2.2 Technical Data Actuators Available types 595 Reverse-acting Cast Steel Diaphragm dimensions 150/ Direct-acting SG Iron Diaphragm dimensions 150/250 For valve body characteristics please refer to monographic Installation and Maintenance Instructions IM-S Pressure/temperature limits 595/ / PMA - Maximum design pressure 15 bar 4,5 bar TMA - Maximum design temperature 110 C* Minimum design temperature 0 C 0 C For valve body characteristics please refer to monographic Installation and Maintenance Instructions IM-S Technical Data - Water seal pot Versions IT maximum pressures up to 15 bar DN Filling connection Connection to the pipeline DN Filling liquid DN DN Actuator pressure signal Max level Fig. 5 - IT Water seal pot Note: Water seal pot is used for temperatures > 110 C. Water seal pot is filled to the maximum level as indicated in the figure. For use on steam, it is suggested to use water as the liquid filling. For other working fluids is suggested to use water or glycerine, consistent with the nature of the process fluid. Warning: the filling fluid should have a density greater than the process fluid

10 2.5 Connection sizes Version IT Inlet Screwed - Butt weld 3 /8 BW Outlet Screwed 1 /8 gas 2.6 Materials Pot housing Carbon steel 2.7 Pressure/temperature limits Body design conditions PN16 PMA - Maximum design 250 C 15 bar g TMA - Maximum design 15 bar g 250 C Minimum design temperature 0 C PMO - Maximum operating pressure on saturated steam 15 bar g TMO - Maximum operating temperature* 250 C Minimum operating temperature 0 C Maximum cold hydraulic test pressure of: 24 bar g IT 250 Temperature C IT Steam saturation curve Pressure bar g The IT Water seal pot can be used in the entire area of the chart

11 2.8 Materials N Item Material 1 Yoke Carbon steel 2 Bottom adaptor Carbon steel 3 Screw M5x16 UNI 5931 Carbon steel 4 Nut M5 Nylon Carbon steel 5 Front Clamp Carbon steel 6 Rear Clamp NBR 7 Top adaptor NBR 8 Nut M10x1 UNI 5589 NBR 9 Spring stretcher Carbon steel 10 Spring Case-back Cast iron GG25 DIN a Upper rod Galvanized carbon steel 11b Upper rod Stainless steel Gr Spring Spring steel 13 Stud T.S.E.I. M8x25 UNI5933 Carbon steel Gr.8.8 Zn 14a Bottom bonnet 595 Cast iron GG25 DIN b Bottom bonnet 596 Carbon steel ASTM A Nut M10 UNI5588 Carbon steel Gr.8 Zn 16 Stud T.C.E.I. M10x40 UNI5931 Carbon steel Gr.8.8 Zn 17 Diaphragm plate Cast iron GG25 DIN Stud T.C.E.I. M10x40 UNI5739 Carbon steel Gr.8.8 Zn 19 Diaphragm NBR 20 Upper bonnet Cast iron GG25 DIN Stud T.E. M12x40 UNI5739 Carbon steel Gr.8.8 Zn 22 OR-123 NBR 23 OR-4400 NBR 24 OR-112 NBR 25 Washer D48x12.5xSp.4 Galvanized carbon steel 26 Nut M12 UNI5589 Carbon steel Gr.8 Zn 27 Lifting eye Galvanized carbon steel 28 Stud M24x55 UNI Carbon steel Gr.8.8 Zn 29 Nut M24 UNI5588 Carbon steel Gr.8 Zn

12 a 13 11a Fig. 6 - Mod

13 b b Fig. 7 - Mod

14 3. Installation Note: Before actioning any installation, observe the Safety information in Section 1. Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended installation. 3.1 General information The valve should be installed upright in a horizontal pipeline. For operating temperatures below 110 C the valve can be installed with the actuator positioned either vertically upwards or vertically downwards as shown in Fig. 8. For operating on steam or temperatures above 110 C, the valve must be installed vertically downwards with the spring/actuator below the pipework with a water seal pot fitted on the downstream control signal line to the actuator, a typical installation is shown in Figure in Fig. 9. It is essential to pay close attention to properly install the valve according to the direction of flow, as indicated by the arrow on the valve body. * * *1 m (3 ft) or 15 pipe diameters minimum Fig. 8 - Typical installation for downstream temperatures below 110 C in which the valve can also be installed with the actuator upwards. * 1 m (3 ft) or 15 pipe diameters minimum * * IT Water seal pot Fig. 9 - Typical installation for downstream temperatures above110 C

15 3.2 Downstream pressure inlet piping The signal line of the actuator should be connected directly to the downstream pipeline. To provide a good control signal, the sensitive point downstream must be at a distance by at least 1 m or 15 times the diameter of the pipe from the valve or by changes in the flow direction. It is recommended that the actuator signal pipe should be 8 mm diameter copper or stainless steel of 1 m minimum length. 3.3 Preventing from dirt Before installing the valve, all piping shall be cleaned with compressed air to remove dirt and deposits. The valve must be protected by a filter that has the same size of upstream piping. To prevent water buildup in applications with steam or air, filter should be installed with the basket on a horizontal plane. 3.4 Condensate removal To ensure that the pipework is adequately drained, in steam lines installations is also required to install a condensate separator upstream of the valve provided with a suitable steam trap. 3.5 Pressure gauges To assist in commissioning the valve and monitoring operating conditions it is essential to fit pressure gauges on both upstream and downstream sides of the valve. 3.6 Safety valve A safety valve should be fitted to protect the downstream equipment from over-pressure. Safety valve should be set to lift below the safe working pressure of the downstream equipment, and will normally be sized to pass the full capacity of the K/L PRV, should the PRV fail in the fully open position. Discharge pipework should be taken to a protected and safe place. 3.7 Isolating valves In order to provide for the maintenance and cleaning, it is recommended to install two manual shutoff valves, one downstream and one upstream of the pressure reducing assembly. 3.8 Water seal pot If fitted, before operating the valve, Water seal pot should be charged with water. Remove the water seal pot filling plug and fully charge the vessel with soft water. Replace the filling plug. To commission the valve, slowly open the upstream manual isolating valve to avoid waterhammer. The pressure reducing valve is now ready for operation. 3.9 Setting the desired downstream pressure The valve is supplied un-calibrated and with the bottom spring plate at its lowest position. The required downstream pressure is to be calibrated under zero-flow conditions or under ordinary operation, according to application needs and taking into account the proportional deviation. The required downstream pressure is obtained by rotating the bottom spring plate until the pressure gauge indicates the desired value. The adjustment can be done using a standard open ended spanner size 32 mm. Compressing the pressure adjustment spring, the downstream calibration pressure will raise; while, conversely, relaxing the spring tension reduces the downstream set pressure (See Fig. 10)

16 Reduce set pressure Spring adjuster (9) Increase set pressure Fig

17 4. Maintenance Note: Before actioning any maintenance program observe the Safety information in Section 1. Safety information - Product specific This product should not be dismantled without first releasing the compression on the control spring. Important Note: To avoid the risk of damaging the sealing bellows, by performing maintenance work on the 596K/L valve, never turn the setting nut (28) without first releasing the lock-nut (25). Failure to do this will result in sealing bellows damage. 4.1 General information The valve is not subject to routine maintenance, but it is recommended to disassemble it every months for a precautionary check of the components. Any item which show signs of wear should be replaced. Details of the Spare Parts are provided in Section 5. Before carrying out any control or mount spares, make sure that the valve is intercepted and the pressure upstream and downstream is vented to zero value; then rotate the Spring-adjuster (9) to fully discharge the spring (or springs) and reduce its compression to zero. The piping downstream of the sensing line must be disconnected from the actuator. Note: given that this product contains composite elements made of PTFE / steel, precautions stated in paragraph 1.15 should be taken. 4.2 Recommended tightening torques (N m) Valvola K Series L Series Please refer to the relevant installation and maintenance instructions IM-S24-42 Please refer to the relevant installation and maintenance instructions IM-S24-42 Attuatore 15, 16 Actuator bolts and nuts 35 N m 18 Diaphragm Plate clamping bolt 35 N m 26 Diaphragm clamping nut 40 N m Water seal pot Filling plug = tighten up to ensure a tight seal

18 4.3 Mounting Spares How to renew the actuator diaphragm and the sealing washer (Fig ) - Before replacing spare parts, separate the actuator from the valve. - Rotate the spring adjuster (9) to fully discharge the spring (12). - Remove bolts and nuts (15,16), the cover (20) and the diaphragm (19) from the actuator. - Fit the new diaphragm (19). - Replace the cover (20) of the actuator. - Refit bolts and nuts (16,15) and tighten to the recommended torque as indicated in Section 4.2. Secure the actuator to the valve actuator and tighten the locknut ring to the torque recommended in Section Reconnect the line of the pulse inlet. - Before operating the valve, water seal pot should be filled with water (when installed). - Re-commission the valve As indicated in Sections 3.8 and a 13 11a Fig How to renew or change the control spring(s) (Fig. 11) - Rotate the spring adjuster (9) to fully discharge the compression of the spring (12). - Disconnect the downstream pressure signal piping. - Undo the actuator mounting nuts and separate the actuator from the valve. - Remove bolts and nuts (15,16), the cover (20) and the diaphragm (19) from the actuator. - Undo the locking screw (18) and remove the diaphragm plate (17). - Replace the spring and reassemble in reverse order the plate, and the locking screw. - Reassemble the diaphragm, cover, screws and nuts. - Adjust the stroke of the valve and reconnect the inlet pulse piping as indicated in section Re-commission the valve As indicated in Sections 3.8 and

19 5. Spare parts Note: When placing an order for spare parts please clearly specify the full product description as found on the label of the valve body, as this will ensure that the correct spare parts are supplied Actuators Available spares for DN15 and DN20 (1 2 and 3 4 ) valves are indicated below. Other replacement parts are not available as spares. Available spares Diaphragm Spring Set of gaskets Stem O-ring, Cover O-ring, diaphragm plate O-ring A B C, D, E How to order spares Always order spares by using the description given in the column headed Available spares, and state the size and type of valve including the full product description of the product. Example: N 1 off - Diaphragm for a Mod Actuator. A B Fig Mod

20 E A D C B Fig Mod

21 6. Fault finding Preliminary check Before investigating any fault ensure that both upstream and downstream isolating valves are shut. Symptom Causa Remedy Downstream pressure increases above it s set pressure. Under full load condition, downstream pressure drop is in excess of the required pressure control. Valve is correctly sized but is not supplying full load. On low flow conditions, downstream pressure is hunting. Unable to adjust downstream set pressure. 1. Blockage of the pressure signal pipe or coupling. 2. Leakage across actuator diaphragm or actuator diaphragm clamp gasket. 3. Damage or erosion to valve head / seat. 4. Failure of the balancing bellows assembly (DN25 to DN100, 1 to 2 valves only). 5. Leakage of sealing bellows. The valve is achieving maximum lift, but is undersized for the duty required. The valve is not achieving full lift position at maximum load. 1. Over sensitive pressure control signal. 2. High pressure turndown ratios. 3. Downstream pressure tapping is too close to valve. The actuator is not being subjected to downstream pressure. 1. Disconnect the pressure signal pipe from the actuator coupling and blow through the pipe and coupling to clear obstruction. It is recommended that for causes 2 to 5, components are checked in the following sequence, using the relevant data from Section Remove the actuator housing and inspect the diaphragm and diaphragm clamp washer, replacing as necessary. 3. Remove the bonnet/spring/ actuator assembly and inspect the valve head and seat for damage or wear and replace as necessary. 4. Remove the balancing bellows assembly (DN25 to DN100, 1 to 2 valves only) and inspect for failure of the balancing bellows. Replace as necessary. 5. Remove the stem sealing bellows assembly, examining for failure. Replace as necessary. Check maximum installed load condition required and valve size selected and installed. Check full lift setting as described in Section Remove 8 mm pressure signal pipe and actuator/ water seal pot couplings and replace with 6 mm signal pipe and couplings. 2. Consider two valves in series to reduce turn down ratios. 3. Ensure the downstream pressure signal tapping is not located within a turbulent area and is at least 1 m (40 ) from any valve or fitting. Remove the signal pipe from the actuator and check for sludge build-up and blockage

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24 SERVICE For technical support, please contact our local Sales Engineer or our Head Office directly: Spirax Sarco S.r.l. - Technical Assistance Via per Cinisello, Nova Milanese (MB) - Italy Tel.: (+39) (+39) Fax: (+39) support@it.spiraxsarco.com LOSS OF GUARANTEE Total or partial disregard of above instructions involves loss of any rights to guarantee. Spirax-Sarco S.r.l. - Via per Cinisello, Nova Milanese (MB) - Tel.: Fax: CH Issue