Maintenance Instructions VV 10

Transcription

1 Maintenance Instructions VV 10 Safety Notes Installation Maintenance Component Parts Key Spare Parts

2 Contents Important Notes Usage for intended purpose... 3 Safety note... 3 Danger... 3 Seite Explanatory Notes Scope of supply... 3 System description... 3 Function... 3 Maintenance intervals... 3 Technical data... 4 Corrosion resistance... 4 Sizing... 4 Installation Danger... 4 Tools... 5 Installing TC airline valve VV Operation Opening TC airline valve VV Closing TC airline valve VV Maintenance Danger... 5 Tools... 5 External inspection... 6 Detaching TC airline valve VV Internal inspection... 6 Mounting TC airline valve VV Component Parts TC airline valve VV Key TC airline valve VV Spare Parts TC airline valve VV Accessories TC airline valve VV

3 Important Notes Usage for intended purpose Use TC airline valve VV 10 only for venting hazardous tank containers (TC) of IMO classes 1 and 2. Use this pressure equipment only within the specified pressure and temperature ratings and check chemical resistance and suitability for the application in question. Safety note The airline valve must only be installed by qualified staff. Qualified staff are those persons who through adequate training in engineering, the use and application of safety equipment in accordance with regulations concerning tank containers, and first aid & accident prevention have achieved a recognised level of competence appropriate to the installation and commissioning of this device. Danger The valve is under pressure during operation. When loosening sealing plugs, corrosive, toxic, flammable or contaminant liquids or gases may escape. This presents the risk of severe cases of poisoning, severe burns to the whole body or even death. Do not carry out any installation or maintenance work until it is verified that the tank container has been depressurized and thoroughly cleaned. All relevant safety precautions and environmental regulations concerning the handling of hazardous substances must be observed when cleaning or servicing the equipment. Sharp edges on internals present a danger of cuts to hands. Always wear industrial gloves for installation and maintenance work. Explanatory Notes Scope of supply Tank container (TC) airline valve VV 10 1 TC airline valve type VV 10 1 Installation and maintenance manual Description The airline valve VV 10 is designed for venting hazardous tank containers (TC) of IMO classes 1 and 2. The VV 10 meets the following requirements: Sea transport: IMDG Code: General introduction/ggv Sea Rail transport: RID/GGVE, Annex X Road transport: ADR/GGVS, Annex B 1b as well as the associated TR Technical Directives of the German Federal Ministry of Transport AD Bulletin For the airline valve VV 10 an Inspection Certificate issued by Lloyd s Register is available. Function The TC airline valve VV 10 is part of the loading and unloading system for hazardous tank containers of IMO classes 1 and 2. The VV 10 is operated manually by a lever equipped with a sealing device for customs according to TIR. Maintenance intervals The airline valve VV 10 must be inspected and checked every 2.5 years. 3

4 Technical data Nominal size DN/NPS 40 mm (1½" BSPP*) Operating pressure 10 barg (145 psig) Operating temperature 30 C to C Test pressure 15 barg (218 psig) Tank connection Flat face square flange Hose connections 1½" BSPP* male thread ¼" NPT or BSPP*) for connecting pressure gauge Materials 316 SS Body: /316C16-BS 1504 (identical) CF8M Wetted parts: austenitic steel with molybdenum / austenitic-ferritic steel Seat: PTFE Stem seal: PTFE Dimensions and connections See data sheet Kv value (flow coefficient) Based at DN 40: 219 m³/h Weight Approx. 2.3 kg Operating forces Handlever: approx. 10 N Operating angle of handlever Standard design: approx. 90 *) BSPP = British Standard Pipe Parallel Thread Corrosion resistance When used for its intended purpose the safe functioning of the valve will not be impaired by corrosion. Sizing The valve body must not be subjected to sharp increases in pressure. Flanges are designed to withstand dynamic loading (bending and alternating stress). The dimensional allowances for corrosion reflect the latest state of technology. Installation Danger After removing the transit protection the valve ball and seals might drop out of the valve body. This presents the risk of injuries to arms, hands and feet. For installation place the airline valve in the OPEN position onto the valve-mounting flange of the tank container. 4

5 Tools The following tools are required for mounting the valve: Spanner 19 mm A. F. to DIN 3113 B / ISO 3318, 7738 Torque spanner 6-50 Nm to DIN ISO 6789 Mounting airline valve VV Remove transit protection from valve flange P. 2. Put airline valve in the OPEN position onto the mounting flange of the tank container. 3. Use hexagon nuts or bolts to fix the valve in place. 4. Turn handlever A to position CLOSED. 5. Tighten hexagon nuts or bolts at room temperature in diagonally opposite pairs with a torque of 36 Nm. Operation Opening airline valve VV Turn valve handlever A through 90 to the OPEN position. Closing airline valve VV Turn valve handlever A through 90 to the CLOSED position. Maintenance Tools Danger When opening airline valve VV 10 or loosening flanged connections and sealing plugs, corrosive, toxic, flammable or contaminant liquids or gases may escape. This presents the risk of severe cases of poisoning, severe burns to the whole body or even death. Do not carry out maintenance work until it is verified that the tank container has been depressurized and thoroughly cleaned. Do not carry out maintenance work unless the airline valve is completely drained and thoroughly cleaned. All relevant safety precautions and environmental regulations concerning the handling of hazardous substances must be observed when cleaning or servicing the equipment. Sharp edges on internals present a danger of cuts to hands. Always wear industrial gloves for installation and maintenance work. The following tools are required for maintenance work: Key for hexagon socket screws 3 mm A. F. to ISO 2936 Spanner 17 mm A. F. to DIN 3113 B / ISO 3318, 7738 Spanner 22 mm A. F. to DIN 3113 B / ISO 3318, 7738 Torque spanner 6-50 Nm to DIN ISO 6789 Torque spanner 4-12 Nm to DIN ISO 6789 Open-end spanner 14 x 17 A. F. to DIN 3110 / ISO 3318 Circlip pliers 2.3/220 to DIN ISO 5256 C 5

6 External inspection 1. Check torques and, if necessary, re-tighten fixing nuts and bolts. Item Designation Torque [Nm] S Hexagon nut M T Grub screw M 6 x 10 9 U Grub screw M 6 x Check airline valve VV 10 for smooth operation. 2. Check pressure gauge H for damage. 3. Check wire cable B. 4. Check cap seal E for damage. 5. Check filter gauze G for damage. Detaching airline valve VV Turn handlever A to position OPEN. 2. Unscrew hexagon nuts from fixing studs or bolts. 3. Remove valve from mounting flange. 4. Unscrew and check fixing studs or bolts, replace if necessary. 5. Clean seating areas. Internal inspection 1. Turn handlever A to position OPEN. 2. Remove PTFE seat rings O, M and valve ball N from valve body. 3. Remove pressure gauge H if fitted or gauge plug I with seal J. 4. Unscrew sealing cap C and, if fitted, cap seal E. 5. Take out circlip F with circlip pliers. 6. Remove filter gauze G. 7. Unscrew grub screws T and U. 8. Detach handlever A. 9. Unscrew hexagon nut S. 10. Remove disc springs R and press stem L and PTFE seal K out of valve body. 11. Take gland ring Q and PTFE rings K out of the valve body. 12. Clean valve body and component parts thoroughly. Check parts for damage. 13. Insert new PTFE seals K and gland ring Q into the valve body. Apply a light smear of silicone (e. g. DOW Molykote 111) to PTFE rings. 14. Fit PTFE ring K over stem L and insert it from the inside into the valve body. Apply a light smear of silicone (e. g. DOW Molykote 111) to the PTFE ring K. 15. Insert new disc springs R. Note: Arrange disc springs such that the convex sides are on the outside. Fit hexagon nut S and tighten with 18 Nm. 16. Insert new PTFE seat ring M into the valve body. Rotate the stem L to the CLOSED position, insert valve ball N, making sure that the small hole is positioned at the mounting flange end. Insert new PTFE seat ring O. 17. Position handlever A onto stem L and fix in place with grub screws U and T. Tighten grub screw U and T with 9 Nm. 18. Turn handlever A to position OPEN. 19. Insert new filter gauze G into valve body and fit circlip F. 20. Insert new PTFE seal E into sealing cap C. 21. Install pressure gauge H if fitted or gauge plug I with new seal J. 22. To prevent the ball N and seat ring O from falling out of the valve, ensure the handlever is OPEN during transit. If required a plastic cable tie may be used to retain these components. Mounting airline valve VV Place airline valve in OPEN position onto tank container mounting flange. 2. Fasten valve by means of hexagon nuts or bolts. 3. Turn handlever A to position CLOSED. 4. Tighten hexagon nuts or bolts at room temperature in diagonally opposite pairs with a torque of 36 Nm. Molykote is a registered trademark of DOW Corning GmbH, Wiesbaden. 6

7 Component Parts A U S R T B Q C P K G F E D Fig. 1 O N M L K J I H Key A Handlever B Wire cable C Sealing cap D Gauge protection bar E PTFE cap seal 46 x 32 x 2.5 F Circlip G Filter gauze H Pressure gauge I Gauge plug J PTFE gauge plug seal 21 x 13 x 2 K PTFE stem seal 20 x 15 x 1 L Stem M Inner seat ring PTFE N Valve ball O Outer seat ring PTFE P Valve body Q Gland ring 20 x 14.5 x 4.7 R Disc spring 27 x 14 x 1 S Hexagon nut M 14 T Grub screw M 6 x 10 U Grub screw M 6 x 6 7

8 Spare Parts Item Designation Stock code Price E M O K R Spare parts kit T U E B M O K R T Spare parts kit U R B G D Prices on request Prices on request Accessories Item Designation Stock code C Sealing cap B Wire cable E PTFE cap seal 46 x 32 x H Pressure gauge customer supply D Gauge protection bar /1001 8