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
Explanatory Notes continued
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
Explanatory Notes continued
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
Explanatory Notes continued
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
Installation continued
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.
Installation continued
Attention
Makesurethatweldingand,ifnecessary,annealingworkdoesnotdamagethesealsandgaskets!Checkand,ifnecessary,cleansealingsurfaces.
Alwaysreplacegasketwhenremovingtheactuatingcylinder.
Thespecifiedtorquesmustbestrictlyobserved.
Note:Donotusethepushrod9ashandle!
9
Bottom valve HWV 205/1 - DN 80 continued
Installation continued
,
6
20/2xM6 46
Manifold 88.9
M278
6.5
292
2
turnedthrough90 turnedthrough90
Torque20Nm
Torque20Nmturnedthrough5
Torque50Nmturnedthrough45
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
Installation continued
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.
Thespecifiedtorquesmustbestrictlyobserved.
2
Bottom valve HWV 215/1 - DN 80 continued
Installation continued
Attention
Makesurethatweldingand,ifnecessary,annealingworkdoesnotdamagethesealsandgaskets!Checkand,ifnecessary,cleansealingsurfaces.
Alwaysreplacegasketwhenremovingtheactuatingcylinder.
Thespecifiedtorquesmustbestrictlyobserved.
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
Bottom valve HWV 215/1 - DN 80 continued
Installation continued
Attention
Thespecifiedtorquesmustbestrictlyobserved.
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
Bottom valve HWV 215/1 - DN 80 continued
Installation continued
6
20/2xM6 46
Manifold 88.9
M2
78
6.5
292
2turnedthrough90
turnedthrough90
Torque20Nm
Torque20Nmturnedthrough5
Torque50Nmturnedthrough45
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
Installation continued
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
Installation continued
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
Installation continued
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
Installation 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
Installation continued
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
Installation continued
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
Installation continued
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
Installation continued
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
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Checkconnectionbetweenactuatingcylinderandbody.Ifyoudetectanoilleak
replacethePTFEsealandtheO-ringasdescribedinsectionMaintenance.
Checktorqueof50Nm$
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Checkthetorquesofthefourhexagon-headcapscrewsoftheactuatingcylinderand,ifnecessary,retightenthe
screwstoatorqueof50Nm.
Checktorqueof20Nmb
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Checkand,ifnecessary,re-tightenthesixhexagon-headcapscrewsofthebodyandthetwohexagonnutsthatfix
thecontrolunittothebodywithatorqueof20Nm.
Checksmoothnessofoperationofballvalveshaft
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Checksmoothoperationgofswitchingshaft.Iftheswitchingshaftdoesnotmovesmoothlyapply
acommerciallyavailablelubricant.
Replacepistonseal(
Whennecessary,every8yearsatthelatest
ReplacepistonsealasdescribedinsectionMaintenance.
31
34
31
36
35
Operating device BV 110
Maintenance continued
Type of maintenance Time interval Activity
Checkoillevel
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Thelevelinthetankofthehydraulichandpumpmustbeabovethelowermarkingonthedipstick.
Checktightness
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Makesurethatoilcannotescapeatconnections,jointsandT-typescrewedunions.
Ifnecessary,retightenrespectiveconnections.
Checkvalvelift
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Withthehydraulicsystemclosed,afterapprox.6liftsofthehydraulichandpumpbothindicatingpistons
mustbecompletelyextended(heightapprox.46mm).
Checkholdingpressure
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Withthehydraulicsystemclosed,bothbottomvalvesmustwithstandaconstantpressurefortwohours
withoutclosing.
Checkrapid-actionclosing
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Whendisengagingthetensionropetherapid-actionclosingmusttakeplacewithinonesecondand
theindicatingpistonsmustbeatthelowermarking.
Checkcompleteness
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
Bothoperatingdevicesmusthavetwoemergencyoperatingscrewseach.Theseemergencyoperatingscrewsmustbe
screwedintherearwall.
Connecting lines
Type of maintenance Time interval Activity
Checktightness
Whennecessary,duringmaininspection
atthelatest(every4yrs.)
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
Thespecifiedtorquesmustbestrictlyobserved.
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
Thespecifiedtorquesmustbestrictlyobserved.
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
Thespecifiedtorquesmustbestrictlyobserved.
42 41
36 37 38 39 40
43
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
Top Related