GESTRA-Flowserve

t

GESTRA Steam Systems

HV 215Installation Instructions 818480-01HydraulicLoadingandUnloadingSystemHV25

2Contents

Usagefortheintendedpurpose.................................................................................................................................. 8Safetynotes............................................................................................................................................................... 8Danger....................................................................................................................................................................... 8Legalregulations........................................................................................................................................................ 9

Important NotesPage

Scopeofsupply........................................................................................................................................................ 0Description............................................................................................................................................................... 0Function................................................................................................................................................................... Technicaldata.................................................................................................................................................... ,2Fluidlist.............................................................................................................................................................. 3,4

Explanatory Notes

Hydraulicloading&unloadingsystemHV25.......................................................................................................... 5Mountingflange.................................................................................................................................................. 5,6BottomvalveHWV205/-DN80......................................................................................................................7-9BottomvalveHWV25/-DN80......................................................................................................................20-23Cablerouting............................................................................................................................................................ 24OperatingdeviceBV0.......................................................................................................................................... 25Connectinglines................................................................................................................................................. 26,28AttachingoperatingplatesHV25............................................................................................................................ 29Attachinglistindicatingfluids................................................................................................................................... 29Fillingandventingofhydraulicsystem...................................................................................................................... 30Fillingandventingofhydraulicactuatingsystem...................................................................................................... 30Fillingandventingofhydraulicindicatingsystem...................................................................................................... 3Performancetest...................................................................................................................................................... 3

Installation

Service..................................................................................................................................................................... 32Emergencyoperation................................................................................................................................................ 33

Operation

BottomvalvesHWV205/-DN80/HWV25/-DN80.......................................................................................... 34OperatingdeviceBV0........................................................................................................................................... 35Connectinglines....................................................................................................................................................... 35

Maintenance

3Hydraulicloading&unloadingsystemHV25.......................................................................................................... 36Replacingvalveplugseal...................................................................................................................................36-38Reworkingseatflange.............................................................................................................................................. 39Replacinggasketsofactuactingcylinder............................................................................................................ 40,4Replacingcontrolunitofbottomvalve...................................................................................................................... 42

Servicing

Contents continued Page

4Components

F

Y

S

K

L GRP

X

PRG

F

D

HWV205/

EWV

HWV25/

BV0

HZ

EC

A

Tensionropewithwirecableclamp

B

K

KJ

IB

NO

Q

M

S

F

U

T

gas phase liquid phaseopen

closed

YL

5Key

A Shut-offvalvesB ActuatingcylinderC RailhookD RingE OperatingdevicesF PumpleverofhydraulichandpumpG LineleadingtotheindicatingcylinderofthegasphaseH IndicatingcylinderI FillingconnectionJ SealingplugK ScrewforsealingoffopeningforemergencyunloadingL LineleadingtotheindicatingcylinderoftheliquidphaseM BoltforoperatingdeviceN PlateshowingvalvepositionofindicatingpistonsO IndicatingpistonsP PressurelineQ Screw-inplugforventingfacilityR ReturnlineS Screwforoilfillingconnection(withdipstick)T HydraulichandpumpU Non-returnvalveV Transversepipe-runW FrameX ControlunitY GuidebushingZ Fluidlist

6Basic Components of Bottom Valves

Mountingflange

Valvehead

Body

Actuatingcylinder

1234567

8ji h g dc

e

f

b

a=)(/

&%$

"

!0

9

31

7Key

1 Hexagonheadcapscrew2 Lockingwasher3 Springplate4 Staybolt5 Sleeve6 Gasket7 Seatflange8 Gasket9 Pushrod0 Bellows! Gasket" Piston Pistonseal$ Hexagonheadcapscrew% Sealingplug& Jointring/ Retainingring( O-ring) O-ring= Bushinga Sealringb Hexagonheadcapscrewc Socket-headcapscrewd Lockingwashere Valveplugf Compressionspringg Washerh Retainingringi Socket-headcapscrewj Washer Valveplugseal31

8Important Notes

ThehydraulicallyoperatedloadingandunloadingsystemHV25isintendedsolelyforfillinganddrainingstationaryandmobiletankscontainingpressureliquefiedgases.

Itsuseispermissibleonlywithintheallowablepressureandtemperatureratingsandonlyifthechemicalandcorrosiveinfluencesontheequipmentaretakenintoaccount.Beforeinstallingtheequipmentmakesurethattheloading&unloadingsystemissuitablefortheintendedapplicationandthefluidtobeused(corrosionresistanceandchemicalsuitability).

Modificationstothedesignmayonlybemadeifthemanufacturerswrittenpermissionisobtained.

Anytypeofusedifferingfromtheusagedescribedabovemustbeconsideredasimproper.Theresultingriskwillhavetobebornebytheuseralone.Themanufacturerherebyexpresslyrejectsanyclaimsforanyresultingdamage.

Theuseofexternalpumpsforopeningorclosingthebottomvalvesisnotpermitted.

Usage for the intended purpose

Theloadingandunloadingsystemmustnotbeinstalledorcommissionedbyanyoneotherthanqualifiedstaff.

Maintenanceandserviceworkmustonlybeperformedbyadequatelytrainedpersonswhohavearecognisedlevelofcompetence.

Forinstallation,removal,commissioning,operationandmaintenance,everypersonwhoworkswiththeloadingandunloadingsystemmusthavereadandunderstoodthecompleteinstallationmanual.Furthermore,responsibilitiesmusthavebeendefinedclearlyandunambiguouslyandmustbeadheredto.

Theoperatingcompanymustensurethat,whenevertheloadingandunloadingsystemisbeingoperated,itisinperfectcondition.

Safety notes

Workingmethodsthatjeopardisesafetymustnotbeused!

Attention

Iftheloadingandunloadingsystemisusedinaninexpertorimpropermannerbyunqualifiedstaff,itcancausedangertolifeandlimbfortheuserorforthirdparties,possiblyresultingindeath.

Duringoperation,thebottomvalvesoftheloadedandunloadedtanksareunderpressure.Duringtheloadingandunloadingprocedureallothercomponentsarealsounderpressure.Inthiscondition,screwsaswellasnutsandboltsoftheloadingandunloadingsystemmustnotbeslackened.Liquidorvaporizingfluidsmightescapeandcouldcauseseverecasesofpoisoningandenvironmentalpollution.

Duringtheloadingandunloadingproceduredonotleavetheinstallationunattended.

Theshut-offvalvesmightbecoldduringtheloadingandunloadingprocedure.Makesurethattheoperatorwearsprotectivegloveswhenoperatingthehandwheels.

Anyinstallationorremovalworkmayonlybeperformedwhenthetankisatzeropressureandcompletelyfreeofgas.Whencarryingoutinstallationandmaintenancework,makesurethatthetankcannotbeoperatedaccidentally.

Danger

9Important Notes continued

TheconfigurationoftheloadingandunloadingsystemHV25mountedtothetankcarcarryingpressurizedgasmeetstherequirementsofDIN26026orofEN256-3.ThebottomvalvesHWV205/-DN80andHWV25/-DN80fulfillthelegalrequirementsoftheRID/GGVSEsec-tion6,constitutingthefirstinnershut-offasdefinedintheseregulations.

Legal regulations

Anyuseofnakedflamesisexpresslyforbidden!

Beforeperfomringanyserviceworkinsidethetankmakesurethatthetankissufficientlyventilatedandallgaseshavebeencompletelyvented.TherulesconcerningMAC(=maximumallowableconcentration)valuesatplaceofworkmustbestrictlyapplied!

Warning

0

Explanatory Notes

BottomvalveHWV205/-DN80BottomvalveHWV25/-DN80withtensionrope2HydraulicoperatingdevicesBV02OperatingplatesHV252Platesindicatingfluids(onlyforbottomvalveswithvalveplugsealmadeofCR)Installationmanualforloading&unloadingsystemHV25Setofacceptancecertificates

Thefollowingitemsarenotscopeofthesupplybutcanbeorderedseparately:

Setofconnectinglinesasaccessorykit4Shut-offvalvesDN802Valvemountingflanges

Scope of supply

ThehydraulicallyoperatedloadingandunloadingsystemHV25isdesignedforfillinganddrainingstationaryandmobiletankscontainingpressureliquefiedgases.

Itismainlyusedintankcarscarryingpressurizedgases.Thesetankcars(TC)requireahighdegreeofreliability,easeofoperationandmaintenanceandalongservicelifeoftheassociatedvalves.

Theloadingandunloadingsystemconsistsofthetworapid-actionbottomvalves,thetwooperatingdevices,theshut-offvalves,therailhookandthetensionrope.Theconnectinglinesrequiredforoperatingtheloadingandunloadingsystemareeithermadeofhydraulictubesandhydraulichosesorentirelyofhydraulichoses.

ThebottomvalvestypeHWV205/-DN80andtypeHWV25/-DN80(withcontrolunit)aredesignedforinstallationinthevalve-mountingflangeslocatedatthebottomofthevessel.Bothbottomvalvesarealwaysopenedorclosedtogether.Amanifoldconnectsthebottomvalvesdirectlywiththeshut-offvalves.Bothvalvescaneitherbeusedfortheliquidphaseorthegasphase.

Theoperatingdevicesconsistofahydraulichandpumpandoneindicatingpistonfortheliquidphaseandoneforthegasphase.Theyareattachedtotheleftandrighthandsideofthetankcar,whichmeansthatthebottomvalvescanbeopenedfromeithersideofthetankcarbyactuatingtherespectiveoperatingdevice.

Duringtheloading/unloadingprocesstherailhookconnectedtothetensionropekeepsthebottomvalvesintheopenposition.Intheeventofanemergency,e.g.emergencyshut-offorinadvertentmovingofthetankcar,therailhookisdisengagedfromtherailandthebottomvalvescloseinstantaneously(rapid-actionclosing).

Description

Explanatory Notes continued

TheloadingandunloadingsystemHV25isdesignedforfillinganddrainingtanksthatcontainpressure-liquefiedgases.

Onebottomvalveopensfortheliquidphaseandtheotheropensforthegasphase.Bothopeningprocessesalwaystakeplacesimultaneously.

Theoperatingdeviceofthetensionrope(e.g.railhookVZ0)engagedtooneoftherailsprovidestherequiredtensionoftherope.Thistensionkeepstheballvalveofthecontrolunitofthehydraulicsystemclosed.

ThehydraulichandpumpoftheoperatingdeviceBV0canthenbeusedtoapplypressuretothehydraulicsystem.Thepressureactsontheactuatingcylindersofthebottomvalves,forcingthepistontogoupandtherebycausingthebottomvalvestoopen.

ThecurrentliftpositionofbothbottomvalvesisindicatedseparatelybytheindicatingcylindersoftheoperatingdeviceBV0.

Whentherailhookisdisengaged,i.e.whentheloadonthetensionropeisreduced,thehydraulicsystemopens,leadingtotherapid-actionclosingofthebottomvalveswithinlessthansecond.

Thenon-returnvalveintegratedintheoperatingdeviceBV0preventstheprematureclosingofthebottomvalvescausedbyleakingfluidsinthehydraulichandpumpandthepressure-reducingvalve.

Function

Technical data

Forpressure/temperatureratingsofthebottomvalvesseenameplate.

Attention

Nameplatedrawing Nameplatespecifications

Typeofbottomvalve

Typeapproval

GESTRAmanufacturingno.

Testpressure

Typeofvalveplugsealusedinvalvehead

T. AGG.

Manu.-no.:

Ptest : 37.5barTmin. : - 50C valve plug seal PTFE

Tmin. : - 40C valve plug seal CR

GESTRA HWV

MADE BY GESTRA

2

Pressure/Temperature Ratings of Bottom Valves

NominalpressurePN[bar] 25

Testpressure[bar] 37.5

TemperaturerangeforvalveplugsealCR[C] 40to+50

TemperaturerangeforvalveplugsealPTFE[C] 50to+50

ConnectionofbottomvalvebodySocket-weldendsformanifold

withO.D.88.9mm

Springpressureonvalveplug[N] 32230

Liftofvalveplug[mm] >2.2

DragcoefficientLoading Unloading

3.3 2.8


Technical data continued

Item no. Component Material

Body .0566

b HexagonheadcapscrewM6 A2-70orA4-70$ HexagonheadcapscrewM2 A2-707 Seatflange .457e Valveplug .457f Compressionspring .4303 Springplate .4304 Staybolt .4300 Bellows,complete .454and.45768! Gasket PTFE

Valveplugseal PTFEorCR

c Socket-headcapscrew A2-70() O-ring NBR70Shore5 Sleeve .433

31

Weight [kg] HWV 205/1 HWV 215/1 BV 110

Body 20 20

Valvehead 9 9

Hydraulicactuator 7 7

Controlunit 3

Total 36 39 2x6

3


Fluid list

Media ClassClassification

codeUN No.

Valve plug seal PTFE down to

-50 C

Valve plug seal CR down

to

Propane 2 2F 978 X X

Butane 2 2F 0 X X

Propene 2 2F 077 X X

Butene- 2 2F 02 X X

Butadiene-.3 2 2F 00 X X

Ammonia 2 2TC 005 X X

Ethylchloride 2 2F 037 X

Methylchloride 2 2F 063 X

Vinylchloride 2 2F 086 X

GasR2 2 2A 028 X

GasR2 2 2A 029 X

GasR22 2 2A 08 X

GasR4 2 2A 958 X

GasR5 2 2A 020 X

GasR2B 2 2A 974 X

Methylbromide 2 2T 062 X

Methylamine(freefromwater) 2 2F 06 X

Dimethylamine(freefromwater) 2 2F 032 X

Trimethylamine(freefromwater) 2 2F 083 X

Ethylamine(freefromwater) 2 2F 036 X

HexafluoropropyleneR26 2 2A 858 X

Dimethylether 2 2F 033 X

ChlorotrifluoroethaneR33a 2 2A 983 X

Ethyleneoxidewithmax.0%carbondioxide

2 2TF 040 X

Ethyleneoxidewithnitrogenupto0barat50C

2 2TF 040 X

MixtureF 2 2A 078 X

MixtureF2 2 2A 078 X

MixtureP 2 2F 060 X

4


Fluid list continued

Media ClassClassification

codeUN No.

Valve plug seal PTFE down to

-50 C

Valve plug seal CR down

to

MixtureA(tradenamebutane) 2 2F 965 X X

MixtureAO(tradenamebutane) 2 2F 965 X X

MixtureA 2 2F 965 X X

MixtureB 2 2F 965 X X

MixtureC(tradenamepropane) 2 2F 965 X X

Mixturesofhydrocarbonswithbutadiene-.3

2 2F 00 X X

Isobutane 2 2F 969 X

Isobutene 2 2F 055 X

Cis-2-butene 2 2F 02 X X

Trans-2-butene 2 2F 02 X X

Cyclopropane 2 2F 027 X

GasmixtureR500 2 2A 2602 X

GasmixtureR502 2 2A 973 X

Carbondioxide 2 3A 287 X

Ethylene 2 3F 038 X

5

Installation

Hydraulic loading & unloading system HV 215

Wehighlyrecommendthatonlyqualifiedstaffshouldcarryoutinstallationworkinaccordancewiththeseinstallationinstructions.Themanufacturerexpresslyrejectsanyclaimsfordamagecausedbyimproperinstallation.

Allpartstobefittedmustmeetthetechnicalrequirementsspecifiedbythemanufacturer.Allgenuinepartsareguaranteedtocomplywiththeserequirements.

Forinstallationworkchooseliftingdevicesthatarespecifiedfortherespectiveweights.Useonlysuitableandproperliftingdevices.

Whenweldingobservelegalregulationsandin-houseguidelinesconcerningweldedconnections.Beforeweldingcleanallspotstobewelded.

Makesurethatthegasketsoftheflangedconnectionsareexactlyplacedbetweentheflanges.Cleanallseatingsurfacesbeforeinstallingtheequipment.

Beforeinstallingthevalvesremovethetransportpackingandalltransitprotectionplugsforendconnections.

Installtheequipmentinthefollowingorder:

n Mountingflangesn BottomvalveHWV205/-DN80n BottomvalveHWV25/-DN80n Cableroutingn OperatingdevicesBV0n Connectinglinesn AttachingoperatingplatesHV25n Attachingplatesindicatingfluids

Mounting flange

ThemountingflangesforbottomvalvestypeHWV205/-DN80andHWV25/-DN80havethesameformandcanbeinstalledinthesameway.

Theyarenotscopeofsupplyoftheloading&unloadingsystemHV25butcanbeorderedfromGestra.

Valvemountingflangesmadefromthefollowingmaterialsareavailable:

n P355NL(.0566,old:TStE355)n S420NL(.892,old:TStE420)n P460NL(.895,old:TStE460)Furthermaterialsareavailableonrequest.

Gestrasuppliesvalvemountingflangeswithastandarddiameterof430+6mm.Toavoidawallthicknessmisalignmentbetweenthevalvemountingflangeandthetankwall,adjusttheoutsidediameterDtothethicknessSofthetankcar(seedrawingonpage6).Makesurethattheweldjointproducedisincompliancewiththespecificationsofthetankmanufacturer.

Thevalvemountingflangesareweldedintothebottomofthevesselaccordingtothespecificationsofthelocalweldingauthority.

TocalculatethedimensionsofthepressurevesseltoAD-B/B9,refertothedrawing(seepage6)inwhichthedimensionsofthereinforcementareindicated.

6

Mounting flange continued

Attention

Installation continued

Aftertheannealingprocesschecktheseatingsurfacesand,ifnecessary,clean,reworkorcutthem.

ThereferencedimensionSvariesasafunctionofthedropforgingtoleranceandmustbecompensatedforbythediameterDofthevalvemountingflange.

Longitudinalaxisofboiler

Valvejointasspecifiedbylocalauthority

Referencedimensionvariesasafunctionofthedropforgingtolerance

S+4.3

-.6

0+

4.3

-.6

3532

430 +6

D 365 55

7

Bottom valve HWV 205/1 - DN 80


Thesuppliedbottomvalveconsistsoftwocomponentparts-thevalveheadandthebodywiththeactuatingcylinder.Thevalvecomeswithasetofassemblyparts.

Theassemblypartsofthevalveheadcomprise:

n Gasket25n 2Lockingwashersn 2SocketheadcapscrewsM6x30Firstattachthevalveheadfromtheoutsidetothevalvemountingflange.Seedrawingonpage9

. Putthegasket6ontothevalvehead.2. Placethevalveheadontothemountingflangeandinsertthesuppliedsocket-headcapscrewscandlocking washersdinthevalvemountingflangeandtightenthemwithatorqueof20Nm.Applyacommerically availablelubricanttothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.

3. Checkspacingbetweenbottomofvalveplugeandseatflange7(referencedimensionseepage9).Forthis purposeyoucanholdatrysquaretothebottomofthevalveheadandreadoffthedistancetothebottomofthe valveplug.Adistanceof7mmisrequired.Ifthereadingexceedsthistolerancecheckthepositionofthe sealofthevalvepluge.Ifnecessarypushthevalveplugeslightlyupwards. Dirtysealsortheincorrectpositionofthevalveplugsealmayhavecausedthisproblem.Shouldevenafter thisexaminationtheactualreadingsstillexceedthespecifiedtolerances,pleasecontactourTechnicalServicein yourcountry,statingtheGestramanufacturingnumberindicatedonthenameplate.

31

31

Attention

Checkand,ifnecessary,cleansealingsurfaces.

Thespecifiedtorquesmustbestrictlyobserved.

8

Bottom valve HWV 205/1 - DN 80 continued

Afterthevalveheadinstallthebodywiththeactuatingcylinder.

Theassemblypartsofthevalvebodycomprise:

n Gasket25n 6HexagonheadcapscrewsM6x40n Gasket(sparepartforreplacement)Thebodyissuppliedtogetherwiththeactuatingcylinderasacompletecomponentpart.Seedrawingsonpage4andpage9

. Firstweldthemanifoldtothebody,takingthespecificationsofthelocalweldingauthorityintoaccount.Thebody endissizedforapipehavinganoutsidediameterof88.9mm.Toweldthemanifolditmightbenecessaryto removetheactuatingcylinderBfromthebody.Forthispurposeunscrewthehexagonheadcapscrews$and carefullypushtheactuatingcylinderBdownwards.Removethegasket!.Donotre-usethisgasket!Insertthe suppliedsparegasket!.2. Checkthetorque(50Nm)requiredfortighteningthehexagonheadcapscrews$.IftheactuatingcylinderB hasbeenremoved,tightenthehexagonheadcapscrews$withatorqueof50Nm.Applyacommerically availablelubricanttothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.

3. Thenchecktheliftofthepushrod9inthebodywithactuatingcylinderB.Forthispurposemeasurethe referencedimension2and3(seepage9)fromtheupperedgeofthepushrod9tothesealingsurfaceofthe unloadedbellows0andtothelowerstopofthebellows0.Ifthedistanceexceedstheadmissibletolerance, checkthepushrod9forsmoothoperation.Ifthepushrodisjammed,firsteliminatethecauseandthengently knockwithyourhandagainstthepushrod9untilitcanmovefreely.Ifyoucannotfindafaultpleasecontactour TechnicalServicesinyourcountry,statingtheGESTRAmanufacturingnumber.

4. Insertthesuppliedgasket8inthebottomofthevalveheadandusethehexagonheadcapscrewsbtoscrew thebodytothemountingflange,applyingatorqueof20Nm.Applyacommericallyavailablelubricanttothe screwsandtightentheminseveralstepsindiagonallyoppositepairs.


Attention

Makesurethatweldingand,ifnecessary,annealingworkdoesnotdamagethesealsandgaskets!Checkand,ifnecessary,cleansealingsurfaces.

Alwaysreplacegasketwhenremovingtheactuatingcylinder.


Note:Donotusethepushrod9ashandle!

9



,

6

20/2xM6 46

Manifold 88.9

M278

6.5

292

2

turnedthrough90 turnedthrough90

Torque20Nm

Torque20Nmturnedthrough5


Referencedimensiononvalvehead

Referencedimension2onbodywithactuatingcylinder(bellowsunloaded)

Referencedimension3onbodywithactuatingcylinder(bellowsatlowerstop)

7 6

+9

!

31

0

8

$

7

9 d

c

6e

b

32

20

Bottom valve HWV 215/1 - DN 80


Thesuppliedbottomvalveconsistsofthreecomponentparts-thevalvehead,thebodywiththeactuatingcylinderandthecontrolunit.Thevalvecomeswithasetofassemblyparts.

Theassemblypartsofthevalveheadcomprise:

n Gasket25n 2Lockingwashersn 2SocketheadcapscrewsM6x30Firstattachthevalveheadfromtheoutsidetothevalvemountingflange.Seedrawingonpage23

. Putthegasket6ontothevalvehead.2. Placethevalveheadontothemountingflangeandinsertthesuppliedsocket-headcapscrewscandlocking washersdinthevalvemountingflangeandtightenthemwithatorqueof20Nm.Applyacommerically availablelubricanttothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.

3. Checkthespacingbetweenthebottomofthevalveplugeandtheseatflange7(cf.referencedimension onpage23).Forthispurposeyoucanholdatrysquaretothebottomofthevalveheadandreadoffthe distancetothebottomofthevalvepluge.Aspacingof7mmisrequired.Ifthereadingexceedsthis tolerance,checkthepositionofthesealofthevalvepluge.Ifnecessarypushthevalveplugeslightly upwards.Dirtysealsortheincorrectpositionofthevalveplugsealmayhavecausedthisproblem.

Shouldevenafterthisexaminationtheactualreadingsstillexceedthespecifiedtolerances,pleasecontactour TechnicalServicesinyourcountry,statingtheGestramanufacturingnumberindicatedonthenameplate.

31

31

Attention

Checkand,ifnecessary,cleansealingsurfaces.


2



Attention

Makesurethatweldingand,ifnecessary,annealingworkdoesnotdamagethesealsandgaskets!Checkand,ifnecessary,cleansealingsurfaces.

Alwaysreplacegasketwhenremovingtheactuatingcylinder.


Afterthevalveheadinstallthebodywiththeactuatingcylinder.

Theassemblypartsofthevalvebodycomprise:

n Gasket25n 6HexagonheadcapscrewsM6x40n Gasket(sparepartforreplacement)Thebodyissuppliedtogetherwiththeactuatingcylinderasacompletecomponentpart.Seedrawingsonpage4andpage23

. Firstweldthemanifoldtothebody,takingthespecificationsofthelocalweldingauthorityintoaccount.Thebody endissizedforapipehavinganoutsidediameterof88.9mm.Toweldthemanifolditmightbenecessaryto removetheactuatingcylinderBfromthebody.Forthispurposeunscrewthehexagonheadcapscrews$and carefullypushtheactuatingcylinderBdownwards.Removethegasket!.Donotre-usethisgasket!Insertthe suppliedsparegasket!.2. Checkthetorque(50Nm)requiredfortighteningthehexagonheadcapscrews$.IftheactuatingcylinderB hasbeenremoved,tightenthehexagonheadcapscrews$withatorqueof50Nm.Applyacommerically availablelubricanttothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.

3. Thenchecktheliftofthepushrod9inthebodywithactuatingcylinderB.Forthispurposemeasurethe referencedimension2and3(seepage23)fromtheupperedgeofthepushrod9tothesealingsurfaceofthe unloadedbellows0andtothelowerstopofthebellows0.Ifthedistanceexceedstheadmissibletolerance, checkthepushrod9forsmoothoperation.Ifthepushrodisjammed,firsteliminatethecauseandthengently knockwithyourhandagainstthepushrod9untilitcanmovefreely.Ifyoucannotfindafaultpleasecontactour TechnicalServicesinyourcountry,statingtheGESTRAmanufacturingnumber.

4. Insertthesuppliedgasket8inthebottomofthevalveheadandusethehexagonheadcapscrewsbtoscrew thebodytothemountingflange,applyingatorqueof20Nm.Applyacommericallyavailablelubricanttothe screwsandtightentheminseveralstepsindiagonallyoppositepairs.

5. EngagetheloopofthetensionspringofthecontrolunitXtothehexagonheadcapscrewb.42

22



Attention


Inadditionmakesurethatthestemoftheballvalvecanalwaysrunsmoothly.Ifthestemdoesnotmovesmoothly,applyacommerciallyavailablelubricant.Donottreatorpaintthesurface!

Makesurethatthecableroutingdoesnottouchthemanifold!

Note:Donotusethepushrod9ashandle!

Attachthecontrolunittothebody.

Theassemblypartsofthecontrolunitcomprise:

n 2StudboltsM6x35n 2Lockingwashersn 2NutsM6Thecontrolunitscomeswiththeballvalve.Seedrawingsonpage4

. Screwstudboltsintothebody,applyingatorqueof20Nm.

2. UsethelockingwashersandnutstofitthecontrolunitXtothebodywithatorqueof20Nm.3. Engagethetensionspringintheleveroftheballvalve.42 36

35

33 34

23



6

20/2xM6 46

Manifold 88.9

M2

78

6.5

292

2turnedthrough90

turnedthrough90

Torque20Nm



Referencedimensiononvalvehead

Referencedimension2onbodywithactuatingcylinder(bellowsunloaded)

Referencedimension3onbodywithactuatingcylinder(bellowsatlowerstop)

7 6

9

!

31

0

8

$

9 d

c

6e

b

32

3334

35 36 37 38 39 40

Torque20Nm

42 41

24

Cable routing


ProvidetankcarwithaguidesleeveYforthetensionrope.ThepositionoftheguidesleeveYmustenablethetensionropetoleavethecontrolunitXofthebottomvalveatanangleof45.Seedrawingonpage4

. Thetensionropesuppliedbythemanufactureris500mmlongandmustbecuttotherequiredlength.

2. ToconnectthetensionropewiththerailhookCorthetensionropeoperatingdevice,providethetension ropewitharingDaccordingtoDIN26026. NotethatthisringDisnotscopeoftheGESTRAsupply! UsethesuppliedwireclamptoattachtheringD.Fastenthescrewsofthewireclampwithatorqueof2Nm.

Attention

Donotpassthetensionropeoversharpedges.

Thelay-outofthetensionrope,theguidesleeveYandtheringDforattachingthetensionropeoperatingdevicemustcomplywithDIN26026andEN256-3.

520270

Tensionrope

Guidesleeve

Ifthevalveisopen

Atdamperlevel060

Upperedgeofrail

Ringforattachingthetensionropeoperatingdevice

25

Operating device BV 110


Fittheoperatingdevicestobothsidesofthevesselsuchthattheyareeasilyaccessible.

Eachoperatingdeviceconsistsof:

n Handlevern Adhesivelabelforvalveposition(no.04856)Theoperatingdevicesaresuppliedcompletelymounted.Seedrawingonpage4

. WeldorscrewtheoperatingdevicesEtotheframeW. ThebodyoftheoperatingdeviceEisprovidedwithtwoboreholes(diameter3mm)forscrewedunions. TheassociatedscrewsandlockingwashersarenotscopeoftheGESTRAsupply. Notethatweldingprocessesmustbesupervisedbythelocalweldingauthority.

2. Whenyouhavefinishedweldingandpainting,sticktheadhesivelabelNindicatingthevalvepositionto thebackofthebodybehindtheindicatingpistonO.

Dimensionsindicatedinmm Depth64

Attention

ThehandleversuppliedbyGestraprotrudesapprox.300mmoutoftherearwallofthebodywhentheflapisclosed.

Ifnecessaryyoucanshortenthehandlevelbymax.50mm.

Iftheweldingprocesshasaffectedthecoatofpaint,makesurethatthedamagedpaintworkisrepaired.

260

27020032

2538

4

3

26

Connecting lines


Theconnectinglineshavedifferentlengthsduetothedifferentdimensionsofthevesselsortanks.Usethetableonpage28toascertaintherequiredlengths.

Hydraulictubesincombinationwithhydraulichosesoronlyhydraulichosescanbeusedasconnectinglines.

Thespecificlay-outoftheconnectinglinesdependsonthedesignofthetankcar.Seedrawingsonpage4andpage28

. Foronepossiblearrangementweldatransversepipe-runV(sectionalsteel,e.g.L-typesteeltoEN0056- withdimensions00x50x6mm)betweenthetwoframesWoftheoperatingdeviceE. InthiscaseyoucanprovidearecessattheleftsideofthetransversesupportVfortheinstallationofthe hydrauliclineswithoutanykinks. Therequirementsandspecificationsofthelocalweldingauthoritymustbeobserved.

2. Thelengthandformofthehydraulictubeshavetobematchedtothetransversepipe-runV.Installthehydraulic tubesattheinside(thesidefacingthebottomvalves)ofthetransversepipe-runV.Thetransversepipe-runV canthenalsoprotectthetubes.3. Usepipeclampstofixthehydraulictubestothetansversepipe-runV.4. Toconnectthelinestothelongitudinalpipe-runuseT-typescrewjoints.5. ForaflexibleconnectionbetweenthehydraulictubesandtheoperatingdevicesEuseprefabricatedhydraulic hoseswithalengthofapprox.280mm. AtthesideforconnectingtheoperatingdeviceEtheyareprovidedwitha90bendandaunionnutM6x.5 andatthesideforconnectingthehydraulictubestheyhaveastubM6x.5forconnectingthehydraulictubes.

6. Severalconnectinglinesfromthetransversepipe-runVtothebottomvalvescanbemadebyusingthe hydraulictubes,,,.7. UseflexiblehydraulichoseswithscrewedendconnectionsM6x.5asconnectinglines,,tothe controlunit.

8. Ifnecessaryusepipeclampstoconnecttheconnectinglines.Recommendeddistancebetweenpipeclamps: approx.500mm.Duetothelengthofthelinemostconnectinglines,willthereforerequiretheseclamps.Ifonlyhydraulichosesareusedadaptthelengthsaccordinglyandusesuitableendconnections.

g

a

c

p q r s

d e f

g

r s

27

Connecting lines continued


IfthedesignoftheinstallationmakesitdifficultorimpossibletoruntheconnectinglinestotheendattachmentsoftheactuatingcylindersofthebottomvalvesHWV205/-DN80orHWV25/-DN80,youcanswoptheendconnectionsoftheactuatingcylinderswiththefillingconnections.

Forthispurposeuseaspanner9mmA.F.Applyatorqueof40Nmtofastentheconnections(seebelow).

Attention

ThehydraulictubesmustmeettherequirementsofDIN239andmustbemadeofSt37.4NBKwithawallthicknessof0xmm.

ThehydraulichosesmustbeinaccordancewithEN853-SN8.

Wheninstallingtheconnectinglinesmakesurethatthelineshaveaslightinclinationtowardsthemiddlesuchthatthehydraulicsystemcanbevented.

Ifnecessarytakeadditionalprecautionstopreventthetransversepipe-runfromswinging.

Thehydraulictubesleadingtotheactuatingcylindersmustbeprovidedwithexpansionloopsinordertoabsorbvibrations.

Checkthesoftsealsoftheconnectionsfordamage.Onlysoftsealsthatarenotdamagedcanbeusedagain.Replacedamagedgasketsandseals.

P P

Socket-weldendformanifold

Connectionforindicatingcylinder

HWV205/Standardarrangementwhensupplied

HWV25/Standardarrangementwhensupplied

Fillingconnection

Fillingconnection

28

Reference Designation Qty.

T-typescrewjointe.g.CompanyWalterscheid,

CompanyErmeto5

AdjustableT-typescrewjoint

e.g.CompanyWalterscheid,CompanyErmeto

Hydraulichosewith90pipebendandconnectingstub

8

Hydraulichosewith2xunionnuts

each

Dual-typepipeclamp, e.g.CompanyStauff 0

Hydraulic connecting lines for loading & unloading system HV 215


fe

g

d

c

b

a

Item Length [mm] Item Length [mm] Item Length [mm]

Itemsh-s:PermanentpipingwithO.D.ofpipe=0mmpossible.ThetubessuppliedbyGESTRAarenotbent.

h

ij

k

lm

nop

q

rs

de

f

lh

p

R

c

Provideexpansionbendforliquidphase(onlywithhydraulictubes)

ControlunitHV25

BV0

Provideexpansionloopforgasphase(onlywithhydraulictubes)

f

e

g

dc

b

a

r

qs

g

h i

j kGL

RP

C pg

G

PRL

l

n o

ma

29

Attaching operating plates HV 215


Attachtheoperatingplatesatbothsidesofthetankcarnearthevalvessothattheyareclearlyvisible.

. Makesurethatthesurfaceontowhichyouwanttosticktheadhesivelabelisclean,dryandfreeofgrease.

2. Removetheprotectivepaper(Controltacprintedonit)fromtheadhesivelabel.

3. Attachtheoperatingplateatthedesiredpositionbutdonotyetstickitfirmlytoit. Aslongastheoperatingplateisnotfirmlypressedagainstdiesurfaceyoucanstillchangeitsposition.

4. Tofixtheoperatingplatepermanentlyuseaplasticspatulatopresstheadhesivelabelfirmlyagainstthesurface. Startinthemiddleofthelabelandmakesurethatnoairgetstrappedin.

5. Carefullystripofftheprotectivesheetand,ifnecessary,pressthecornersoftheoperatingplateagainfirmly againstthesurface.

6. Ifthereareairblistersprickaneedleintothemandthenpressthelableagainfirmlyagainstthesurface.

Attaching list indicating fluids

ThefluidlistmustonlybeattachedifbottomvalvesareusedwithavalveplugjointCRatbothoperatingdevices.Seedrawingonpage4

AttachthefluidplatesZatthemiddleoftheinsideofbothflapsoftheoperatingdevicesEsothattheyareclearlyvisible.

GESTRA

30

Filling and venting of hydraulic system


Tofillthewholehydraulicsystemoftheloadingsystemcarryoutthefollowingtwosteps:

. Fillingthehydraulicactuatorsystem Sequence:Bothsidesseparatelyoneaftertheother.

2. Fillingthehydraulicindicatingsystem Sequence: .Liquidphase 2.Gasphase

Thehydraulicsystemhastobefilledafterinstallingtheloadingsystemorwhenmaintenanceworkorrepairshavebeencarriedout.

Attention

Useonlyoilsthatarerecommendedbythemanufacturer.RecommendedoilsareESSOZerice22,ARALVitamol4004orotheroilswithsimilarproperties.

Filling and venting of hydraulic actuating system

Depressurisesystembeforefillingthehydraulicsystem.

Seedrawingsonpage4andpage23

. Releasethetensionrope-theballvalveofthecontrolunitXofthebottomvalveHWV25/-DN80 willautomaticallyopenthehydraulicsystem.

2. UnscrewtheredplugSandthedipstickoftheoilfillingconnectionofthehydraulichandpumpT andfilloilintothetank.

3. PullthetensionropeinordertoclosetheballvalveofthecontrolunitXofthebottomvalve HWV25/-DN80.

4. OperatethehydraulichandpumpTuntiltheresistancefirstincreasesperceptibly,thepressurelimitingvalve responsesaudiblyandthenthereisadistinctpressurerelief.Thencarryout20to30strokeswiththepump leverFofthehydraulichandpumpTinordertodischargetheairinthehydraulicsystemviathepressure- limitingvalve.

5. UsetheoildipstickSinthecovertochecktheoillevel.IfnecessaryrefilloilandscrewinplugSofoilfilling connectionwithatorqueof20Nm.

6. Finallyloosenthetensionropeinordertore-openthehydraulicsystem.

RepeatthewholeprocedurewiththesecondhydraulichandpumpT.

36

36

3

Filling and venting of hydraulic indicating system


Openbothbottomvalvesbeforefillingthehydraulicindicatingsystem.Seedrawingonpage4

. UsetheoperatingdeviceEtoopenthebottomvalves.2. LoosentheventingplugQoftheactuatingcylinderHoftheliquidphaseintheoperatingdeviceE byhalfaturn.

3. Tofillthehydraulicindicatingsystemconnectanexternaloilhandpumpwithapressuregauge (measuringrange:0-20bar)tothefillingconnectionIofthebottomvalvefortheliquidphase. OperatethepumpuntiltheoilleavestheventingplugQoftheindicatingcylinderHwithoutanybubbles.4. ThenfastentheventingplugQtightly.5. ContinuetooperatetheexternaloilhandpumpuntiltheindicatingpistonOiscompletelymovedout andapressureofapprox.0to20barisindicatedbythepressuregauge.

6. FinallyremovetheexternaloilhandpumpfromthefillingconnectionIofthebottomvalveandopen thehydraulicsystembylooseningthetensionrope.Thebottomvalveclosesautomatically.

Followthesamestepswhenfillingthebottomvalveforthegasphase.

Performance test

UsebothoperatingdevicesEfortheperformancetest.Seedrawingsonpage4andpage23

. Toclosethehydraulicsystem,pullthetensionropethatclosestheballvalveofthecontrolunitX ofthebottomvalveHWV25/-DN80.

2. UsethepumpleverFofthehydraulichandpumpTintheoperatingdeviceEandperformapprox. sixstrokesuntilyoudetectaslightresistance.TheindicatingpistonsOofbothbottomvalvesmustnow beintheopenpositionandtheymustbeextendedbyapprox.46mm.

3. Duringtheholdtimeofapprox.2hoursthepressuremustnotdecrease.

4. Checkallconnectionsandscrewedunionsforoilleaks.Ifnecessaryre-tightentheconnections.

5. Thenre-openthehydraulicsystembylooseningthetensionrope.

6. BothbottomvalvesmustcloseautomaticallyandtheindicatingpistonsOintheoperatingdevicesE mustbeatthelowerposition.

36

32

Service

Operation

Duringtheloadingprocessthefollowingactionswilltakeplace:

n Openingofbottomvalven ClosingofbottomvalveToopen/closethebottomvalvesoperateoneoftheoperatingdevicesEateithersideofthetank.Seedrawingonpage4

WhenopeningtheoperatingdeviceEremove-ifnecessary-thecustomsleadsealfromtheboltM.. ToopentheoperatingdeviceEpushtheboltMupwardsandthenturnitby90tooneside. Youcannowswingdownthelid.

2. MakesurethatthepumpleverofthehydraulicpumpFiscompletelyextendedtowardsthefront.3. ConnecttherailhookC(e.g.railhookVZ0)tothetensionropeandengageitintherail. TheballvalveofthecontrolunitXofthebottomvalewillcloseandthehydraulicsystemisreadyforoperation.4. Theup-strokesanddown-strokesoftheleverofthehydraulichandpumpFintheoperatingdeviceE builduppressureinthehydraulicsystem,causingthetwobottomvalvestoopensimultaneously. Afterapprox.sixstrokesofthepumpleverbothbottomvalveswillbecompletelyopen.Checkposition ofbottomvalves:Theopeningpositionofthebottomvalvesisindicatedbythetwocompletelyextended indicatingpistonsOoftheindicatingcylindersH(liftofindicatingpistonsapprox.46mm).5. Openthelateralshut-offvalvesAtostarttheloading/unloadingprocess.6. ThepumpleverofthehydraulicpumpFisnolongerrequiredandmustbereturnedtoitsoriginalposition.

Attention

Ifonlyoneoperatingdevicefortheloadingsystemwasopened,thelidoftheotheroperatingdevicecannotbeopenedwhenthebottomvalvesareopen.

Closebottomvalvesimmediatelyafterloadingorunloadingthetank.Seedrawingonpage4

7. ToclosethebottomvalvesdisengagethetherailhookCfromtherail.Thiswillloosenthetensionrope. TheballvalveofthecontrolunitXopensthehydraulicsystemandbothrapid-actionbottomvalveswillbe closedinstantaneously.BesurethatbothbottomvalvesareclosedbycheckingtheindicatingpistonsO oftheindicatingcylindersH.Bothindicatingpistonsmustberetracted.8. ThencloseandlatchtheoperatingdeviceE.9. Tofinishtheloading/unloadingprocessclosetheshut-offvalvesAandattachthesealingplugstothe shut-offvalves.

Attention

Note:Ifthelidcannotbeclosed,oneorbothbottomvalvesarestillopen!

Theinsideofthelidoftheoperatingdevicefeaturesabracket.Thisbracketpreventstheclosingofthelidwhenoneorbothbottomvalvesareopen.Thelidcanonlybeclosedwhentheindicatingpistonsareretracted.Thecauseofthismalfunctionmustbeascertainedandeliminated!

Ifonlyoneoperatingdevicefortheloadingsystemwasopened,thelidoftheotheroperatingdevicecannotbeopenedwhenthebottomvalvesareopen.

33

Emergency operation

Operation continued

Duringemergencyunloadingthefollowingactionswilltakeplace:

n Openingofbottomvalven ClosingofbottomvalveIfbothbottomvalvesaretobeopened,openfirstthebottomvalveforthegasphaseandthentheonefortheliquidphase.Seedrawingonpage4

. UnscrewthesealingplugJofthebottomvalvelocatedinthebottomoftheactuatingcylinderB. Asmallamountofoilmightescape.PutthesealingplugJintheoperatingdeviceE.2. UnscrewoneortwooftherequiredscrewsforsealingofftheopeningforemergencyunloadingKfrom oneofthetwooperatingdevicesEandapplyasmearofcommerciallyavailablelubricanttothem. TheyarescrewedonebelowtheotheratthebackoftheoperatingdeviceE.4. Screwthesealing-offscrewKintothethreadatthebottomoftheactuatingcylinderBinordertoopen thebottomvalve.

5. Openthelateralshut-offvalvesAtostarttheloading/unloadingprocess.

Usetheemergencyoperationofthebottomvalvesonlyifbothhydraulichandpumpshavefailedor,foranyotherreason,thereisnotenoughpressureforopeningoneorbothbottomvalves.

Incaseofemergencyoperationarapid-actionclosingofthebottomvalveisnotpossible.

Warning

Ifbothbottomvalvesaretobeclosedviaemergencyoperation,firstclosethebottomvalvefortheliquidphaseandthentheoneforthegasphase.Seedrawingonpage4

. Toclosethebottomvalveunscrewthesealing-offscrewforemergencyunloadingKoutofthebottom oftheactuatingcylinderB.Thespringinthebottomvalveeffectstheclosing.2. Oncetheemergencyloading/unloadingprocesshasbeenaccomplished,screwthesealing-offscrewsK backintotherearwalloftheoperatingdeviceE.3. Tofinishtheloading/unloadingprocess,closetheshut-offvalvesAandattachthesealingplugsto theshut-offvalves.

4. Defectivebottomvalvesmustbepermanentlymarkedinordertoavoidinadvertentre-commissioning. DonotscrewsealingplugsJintodefectivebottomvalves.5. Thecauseofthemalfunctionmustbeascertainedandeliminatedbyqualifiedpersonnel!

Incaseofemergencyoperationarapid-actionclosingofthebottomvalveisnotpossible.

Whentheemergencyoperationofoneorbothbottomvalvesisfinished,findandeliminatethecauseforthemalfunction.Notethattherepeatedorcontinuousapplicationoftheemergencyoperationisconsideredasimproperusage.Theresultingriskwillhavetobebornebytheuseralone.Themanufacturerherebyexpresslyrejectsanyclaimsforanyresultingdamage.

Warning

34

Bottom valves HWV 205/1 - DN 80/ HWV 215/1 - DN 80

Maintenance

Type of maintenance Time interval Activity

Checkvalveplugseal

Whennecessary,duringmaininspection

atthelatest(every4yrs.)

Checkvalveheadforleaks.IfaleakisdetectedreplacevalveplugsealasdescribedinsectionMaintenance.

Replacevalveplugseal

Maininspection(every4yrs.)

ReplacevalveplugsealasdescribedinsectionMaintenance.

CheckactuatingcylinderB



Checkconnectionbetweenactuatingcylinderandbody.Ifyoudetectanoilleak

replacethePTFEsealandtheO-ringasdescribedinsectionMaintenance.

Checktorqueof50Nm$



Checkthetorquesofthefourhexagon-headcapscrewsoftheactuatingcylinderand,ifnecessary,retightenthe

screwstoatorqueof50Nm.

Checktorqueof20Nmb



Checkand,ifnecessary,re-tightenthesixhexagon-headcapscrewsofthebodyandthetwohexagonnutsthatfix

thecontrolunittothebodywithatorqueof20Nm.

Checksmoothnessofoperationofballvalveshaft



Checksmoothoperationgofswitchingshaft.Iftheswitchingshaftdoesnotmovesmoothlyapply

acommerciallyavailablelubricant.

Replacepistonseal(

Whennecessary,every8yearsatthelatest

ReplacepistonsealasdescribedinsectionMaintenance.

31

34

31

36

35

Operating device BV 110

Maintenance continued


Checkoillevel



Thelevelinthetankofthehydraulichandpumpmustbeabovethelowermarkingonthedipstick.

Checktightness



Makesurethatoilcannotescapeatconnections,jointsandT-typescrewedunions.

Ifnecessary,retightenrespectiveconnections.

Checkvalvelift



Withthehydraulicsystemclosed,afterapprox.6liftsofthehydraulichandpumpbothindicatingpistons

mustbecompletelyextended(heightapprox.46mm).

Checkholdingpressure



Withthehydraulicsystemclosed,bothbottomvalvesmustwithstandaconstantpressurefortwohours

withoutclosing.

Checkrapid-actionclosing



Whendisengagingthetensionropetherapid-actionclosingmusttakeplacewithinonesecondand

theindicatingpistonsmustbeatthelowermarking.

Checkcompleteness



Bothoperatingdevicesmusthavetwoemergencyoperatingscrewseach.Theseemergencyoperatingscrewsmustbe

screwedintherearwall.

Connecting lines


Checktightness



MakesurethatnooilcanescapeatconnectingjointsandT-typescrewedunions.Ifnecessary,retightenrespectiveconnections.

36

Hydraulic loading & unloading system HV 215

Servicing

Observethefollowingservicinginstructionswhenevercarryingout:

n Visualexaminationsaspartofthemaininspectionn RepairworkduetoleaksorothermalfunctionsThebottomvalvesHWV205/-DN80andHWV25/-DN80requiremaintenanceandservicing.TheoperatingdeviceBV0ismaintenancefree.

WerecommendremovingthebottomvalvesHWV205/-DN80andHWV25/-DN80andcheckingthemforwearanddamagewhenperformingvisualinspections.

Donotre-usepartssubjecttowear,suchasgasketsandseals.Wornordamagedpartsmustbereplacedafterascer-tainingandeliminatingthecauseofthedamage.UseonlygenuineGESTRAparts.

GESTRAsuppliesthefollowingsealkits:

. Stockcode049387

n ValveplugsealPTFEn 2Gaskets25682. Stockcode049395

n ValveplugsealCRn 2Gaskets25683. Stockcode049563

n Pistonsealn Sealringan 2O-rings()n Gasket!n Gasket&Modificationstothedesignmayonlybemadeifthemanufacturerswrittenpermissionisobtained.

31

31

Replacing valve plug seal

Thevalveheadcanberemoveddirectlyinsidethetank.Thisoptionishighlyrecommendedsinceinthiscasethebottomvalves,theconnectinglinesandthehydraulicsystemdonotrequireanyadditionalpreparation.

If,however,thevalveheadcanonlyberemovedfromtheoutside,pleaseproceedasfollows:Seedrawingsonpage4,page6andpage38

. FirstdisconnectallconnectionsoftheactuatingcylinderB.Asmallamountofoilmightescape. Collecttheoilanddisposeofitcorrectly.

2. Ifpossibleseparatethemanifoldfromthebody.

3. ToremovethebodyandtheactuatingcylinderBunscrewthesixhexagon-headcapscrewsbofthebody andremovethebodyandtheassociatedactuatingcylindertogether.Removegasket8.4. Undothe2socket-headcapscrewscandtakethevalveheadfromthemountingflange.Forthispurpose youcanscrewtwohexagon-headcapscrewsM0intothetwothroughthreadsoftheseatflange. Notethatthesescrewsarenotscopeofthesupply.

37

Replacing valve plug seal continued

Servicing continued

Removegasket6.Toremovethevalveheadproceedasfollows:Seedrawingonpage38

. Securethepreloadedcompressionspringf.Forthispurposeyoucanuseadevice(notscopeofthesupply) thatbearstheloadofthespringbymeansofleveragesothatthe6hexagon-headcapscrewscanbesafely loosened.

2. Thenunscrewthesixhexagon-headcapscrews1withthelockingwasher2outofthestaybolt4. Takethevalveplugetogetherwiththespringplate3andthecompressionspringfoutof theseatflange.7.3. Thenremovetheretainingringhandthewasherg.4. Unscrewthefoursocket-headcapscrewsi,takeoutthewasherjandremovethevalveplugseal.Carefullycleanallremovedanddismantledparts.

31

Anyuseofnakedflamesisexpresslyforbidden!

Beforeperforminganyserviceworkinsidethetankmakesurethatthetankissufficientlyventilatedandallgaseshavebeencompletelyvented.TherulesconcerningMAC(=maximumallowableconcentration)valuesatplaceofworkmustbestrictlyapplied!

Notethataninadequatelysecuredcompressionspringcanleadtopartsflyingaround,causingseriousinjuries.

Warning

Tomountthevalveheadproceedinreverseorderoftheremovingprocedure:Seedrawingfurtherdown

. Putthevalveplugsealontotovalveplugeandscrewinthefoursocket-headcapscrewsitogether withthewasherj,applyingatorqueof5Nm.Applyacommerciallyavailablelubricanttothescrews andtightentheminseveralstepsindiagonallyoppositepairs.

2. Thensecurethewashergbyusingtheretainingringh.3. Screwthesixhexagon-headcapscrews1togetherwiththelockingwashers2intothestaybolts3, usingatorqueof25Nm.Applyacommericallyavailablelubricanttothescrewsandtightentheminseveral stepsindiagonallyoppositepairs.

TomountthebottomvalvesfromtheoutsidefollowtheinstructionsgiveninsectionInstallation(seepage7forHWV205/-DN80andpage20forHWV25/-DN80).

31

Attention


38

Replacing valve plug seal continued

Servicing continued

1234567

ji h g dc

ef

31

39

Reworking seat flange

Iftheseatingssurfaceoftheseatflangeisslightlydamagedyoucanremoveandreworktheseatflange.Formoredetailsseedrawingbelow.

Toremovetheseatflangepleaseproceedasfollows:Seedrawingonpage38

. Removebodyandactuatingcylinder.

2. Unscrewthe2socket-headcapscrewscandtheirassociatedlockingwashersdandremove theseatflange.Takeoutthegasket6.3. Unscrewthesixstaybolts4togetherwiththeirsleeves5outoftheseatflange7.Re-assemblyinreverseorder:Seedrawingonpage42

. Firstpushthesleeves5ontothesixstaybolts4andthenscrewthemwithatorqueof25Nm totheseatflange7.Applyacommericallyavailablelubricanttothescrewsandtightenthem.2. Tomountthevalveheadfollowtheindicatedsteps(seepage38).

3. Thenputanewgasket6ontotheseatflange7.4. Usethe2socket-headcapscrewsctogetherwiththeirlockingwashersdtomountthevalvehead tothemountingflange.Tightenthemwithatorqueof20Nm.Applyacommerciallyavailablelubricant tothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.

Servicing continued

Attention


85

Ra0.8

max.5x45

40

Replacing gaskets of actuating cylinder

Servicing continued

Toremovetheactuatingcylinderproceedasfollows:Seedrawingsonpage6andpage4

. Ifconnectinglinesarestillattachedtotheactuatingcylinder,youhavetodetachtheseconnectionsfirst. Asmallamountofoilmightescape.Collecttheoilanddisposeofitcorrectly.

2. Unscrewthefourhexagon-headcapscrews$inthebottomoftheactuatingcylinderandremove theactuatingcylinder.

3. Firsttakeoutthesealingplug%andthejointring&.Usethisopeningtocarefullypullthepiston", thepushrod9andthebellows0outoftheactuatingcylinder.4. Takeoutthepistonseal.5. Pullthepiston"outofthebellows0.6. Removetheretainingring/ofthelowerpartofthebellows0andpulloutthebushing=. TakeouttheO-ring)andthesealringa.7. ThenremovetheO-ring(fromtheactuatingcylinder.ToinstalltheactuatingcylinderBproceedasfollows:Seedrawingonpage4

. FirstinsertanewO-ring(intheactuatingcylinder.2. InsertfirstthesealringaandtheO-ring)inthelowerpartofthebellows0.Thenputthebushing= intothebellows0andsecureitwiththeretainingring/.3. Thenplacethepistonsealontothepiston".4. Putthepiston"intothebellows0.Applyalightsmearofhydraulicoiltothepistonseal. Thenputthiscomponentintotheactuatingcyclinder.

5. Screwthesealingplug%withthejointring&intotheactuatingcylinder.

32

4

Replacing gaskets of actuating cylinder continued

Servicing continued

a

=

)

(

/

&%

"

!0

9

32

32

42

Replacing control unit of bottom valve

Servicing continued

Inthecontrolunittheballvalvewiththetensionropewillbereplaced.

Toremovetheitemproceedasfollows:Seedrawingfurtherdown

. Disengagethespringfromtheleveroftheballvalve.

2. Detachthehydraulichoses.

3. Unscrewthetwohexagonnutsandtheirlockingwashersandremovetheballvalve.

Toinstalltheitemproceedasfollows:

. Usetwohexagon-headcapscrewsandhexagonnutswithwashinglockerstofixtheballvalve tothesupportwithatorqueof25Nm.

2. Attachtheconnectionsforthehydraulichoses.

3. Engagethespringintheleveroftheballvalve.

42 36

41

39 40 36

38 39 40 36

37

41

42 36

Attention


42 41

36 37 38 39 40

44

Great Britain

Flowserve Flow Control (UK) Ltd.BurrelRoad,HaywardsHeathWestSussexRH6TLTel. 0044444/34400Fax 0044444/34557E-mail: [email protected]

Italia

Flowserve S.p.A.FlowControlDivisionViaPrealpi,30l-20032Cormano(MI)Tel. 003902/66325Fax 003902/66325560E-mail: [email protected]

GESTRA ESPAOLA S.A.LuisCabrera,86-88E-28002MadridTel. 00349/552032Fax 00349/436747;552036E-mail: [email protected]

Espaa

Flowserve DALCO Steam Products260GrasslandDriveLouisville,KY40299Tel. 00502/495054,495788Fax 00502/495608E-mail: [email protected]

USA

Portugal

Flowserve Portuguesa, Lda.Av.Dr.AntunesGuimares,59Porto400-082Tel. 0035 22/698770Fax 0035 22/607575E-mail: [email protected]

Polska

GESTRA POLONIA Spolka z.o.o.Ul.Schuberta04PL-80-72GdanskTel. 004858/3060-02od0Fax 004858/3063300E-mail: [email protected]

Agenciesallovertheworld:

www.gestra.de

GESTRA AGP.O.Box05460, D-28054BremenMnchenerStr.77, D-2825BremenTelephone +49(0)423503 - 0Fax +49(0)423503 - 393E-Mail [email protected] www.gestra.de

88480-0/005cm 2003GESTRAAGBremenPrintedinGermany

GESTRA-Flowserve

Documents

Transcript of GESTRA-Flowserve