Flowserve HV 205 User Manual
HV 205
Maintenance Instructions 818458-00
Hydraulic Loading & Unloading System HV 205
For your notes
2
Contents
Page
Important Notes
Usage for the intended purpose ...................... ................................................................8
Safety Notes ....................................................................................................................8
Danger.............................. ...............................................................................................9
Legal Regulations...................................................... ......................................................9
Explanatory Notes
Descripti on.....................................................................................................................10
Function............................ .............................................................................................11
Technical Data...............................................................................................................12
Checking
Hydraulic Loading & Unloading System HV 205 ...........................................................14
Bottom Valves HWV 205/1-DN 80 ................................................................................15
Connecting Lines...........................................................................................................15
Operating Devic e BV 100 ..............................................................................................16
Control Unit XV100........................................................................................................16
Maintenance
Hydraulic Loading & Unloading System HV 205 ...........................................................17
Replacing valve plug seal..............................................................................................18
Mounting bottom valve HWV 205/1-DN 80...................................................................20
Reworking seat flange .................................................................... ...............................23
Replacing gaskets of actuating cylinder ........................................................................24
Replacing control unit....................................................................................................26
Filling and venting of the hydraul ic system ................................................ ....................27
Filling and venting of hydraulic actuating system ..........................................................27
Filling and venting of hydraulic indicating system........................... ...............................28
Performance test ................................................................................................. ..........28
Operation
Operation .......................................................................................................................29
Emergency Operation....................................................................................................31
Annex
Revision............................................................................................................... ..........33
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Components
E
A
B
C
D
R
P
X
F
H
I
B
K
J
Y
P
R
G
L
M
H
W
liquid phaseopengas phase
closed
N
O
D
Q
V
Y
U
T
S
4
Key
A
Bottom valves HWV 205/1
B
Operating device BV 100
C
Control unit XV 100
D
Actuating cylinder
E
Shut-off valves
F
Tension rope with wire rope clamp
G
Line leading to the indicating cylinder of the gas phase
H
Ring
I
Rail hook
J
Pump lever of hydraulic hand pump
K
Indicating cylinder
L
Line leading to the indicating cylinder of the liquid ph ase
M
Bolt for operating device
N
Plate showing valve position of indicating pistons
O
Indicating pistons
P
Pressure line
Q
Screw-in plug for venting facility
R
Return line
S
Plug for oil filling connection (with dip stick)
T
Hydraulic hand pump
Non-return valve
U
Sealing plug
V
Filling connection
W
X
Connections
Screw for sealing off opening for emergency unloading
Y
5
Basic Components of Bottom Valves
Mounti ng flange
Valve head
Body
1
2
3
4
5
6
7
29
3031
8
28
27
26
25
24
23
22
Actuating cylinder
10
11
12
13
14
21
9
15
16
20
19
18
17
6
Key
1
Hexagon-head cap screw
2
Locking washer
3
Spring plate
4
Stay bolt
5
Sleeve
6
Gasket
7
Seat flange
8
Gasket
9
Push rod
10
Bellows
11
Gasket
12
Piston
13
Piston seal
14
Hexagon-head cap screw
15
Sealing plug
16
Joint ring
17
Retaining ring
18
O-ring
19
O-ring
20
Bushing
21
Seal ring
22
Hexagon-head cap screw
23
Socket-head cap screw
24
Locking washer
25
Valve plug
26
Compression spring
27
Washer
28
Retaining ring
29
Socket-head cap screw
30
Washer
31
Valve plug seal
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Important Notes
Usage for the intended purpose
The hydraulically operated loading and unloading system HV 205 is intended solely for
filling and draining stationary and mobile tanks containing pressure liquefied gases.
Its use is permissible only within the allowable pressure and temperature ratings and only
if the chemical and corrosive influences on the equipment are taken into account.
Changes in the design may only be performed if the manufacturer's written permission is
obtai ned.
Any type of use differing from the usage described above must be considered as
improper. The resulting risk will have to be borne by the user alone. The manufacturer
hereby expressly rejects any claims fo r any resulting damage.
Safety Notes
The loading and unloading system must not be installed, removed, commissioned,
operated or maintained by anyone other than qualified staff. Qualified staff are thos e
persons who - through adequate training, the use and applicatio n of safety equipment in
accordance with regulations concerning safety systems, and first aid & accident
preventi on - have achieved a recognised level of competence appropriate to the
installation and commissioning of this device.
For installation, removal, commissioning, operation and maintenance, every person who
works with the loading and unloading system must have read and understood the
complete installation manual. Furthermore, responsibilities must have been defined
clearly and unambiguously and must be adhered to.
Usage of the system for the intended purpose includes compliance with the rules and
notes in these installation instructions for installation, removal, commissioning, operation
and mai ntenance.
The operating company must ensure that, whenever the loading and unloading system
is being operated, it is in perfect condition.
Attention
Working methods that jeopardise safety must not be used!
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Important Notes – continued –
Danger
If the load ing and unloading system is used in an inexpert or improper manner by
unqualified statt, it can cause danger to life and limb for the use r or for third parties,
possibly resulting in d eath.
During oper ation, the bottom valves of the loaded and unloaded tanks are under
pressure. During the loading and unloading procedure all other components are also
under pressure. In this condition, screws as well as nuts and bolts of the loading and
unloading system must not be slackened. Liquid or vaporizing fluids might escape and
could cause severe cases of poi soning and environmental pollution.
During the loading and unloading procedure do not leave the installation unattended.
The shut-off valves might be cold during the loading and unloading procedure. Make sure
that the operator wears protective gloves when operating the handwheels.
Any installation or removal work may only be performed when the tank is at zero pressure
and completely free of gas.
When carrying out installation and maintenance work, make sure that the tank cannot be
operated accidentally.
Attention
Any use of naked flames is expressly forb idden!
Whene ver carrying out work inside the tank ensure su fficient ventilation
and gas venting. The rules concerning MAC (= maximum allowable
concentration) values at place of work mu st be strictly applied!
Legal Regulations
The configuration of the loading and unloading system HV 205 mounted to tank cars
carrying p ressurized gas meets the requirements of prEN 12561-3.
The two bottom valves HWV 205/1-DN80 fulfill the legal requirements of RID/GGVSE,
section 6.8, constituting the fi rst inner shut-off as defined in these regulations.
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Explanatory Notes
Description
The hydraulically operated loading and unloading system HV 205 is designed for filli ng
and draining stationary and mobile tank s containing pressure liquefied gases.
It is mainly used in tank cars carrying pressurized gases. These tank cars (TC) require a
high degree of reliability, ease of operation and maintenance and a long service life of the
associated valves.
The l oading and u nloadin g syste m c o nsist s of t he tw o r api d-a ction bott om va l ves, th e two
operating devices, the control unit, the shut-off valves, the rail hook and the tension rope.
The connecting lines required for operating the loading and unloading system are either
made of hydraulic tubes a nd hydraulic hoses or entirely of hydraulic hoses.
The bottom valves HWV 205/1-DN80 are fitted to the valve-mounting flanges at the
bottom of the vessel. Both bottom valves are always opened or closed together.
A manifold connects the bottom valves directly with the shut-off valves. Both valves can
eithe r be used for the liquid phase or the gas phase.
The operating devices consist of a hydraulic hand pump and one indicating piston for the
liquid phase and one for the gas phase. They are attached to the left and right hand side
of the tank car, which means that the bottom valves can be opened from either side of
the tank car by actuating t he respective operating device.
During the loading/unloading process the rail hook connected to the tensio n rope keeps
the bottom valves in the open positio n. In the event of an emergency, e. g. emergency
shut -off or inadvertent movi ng of the tank car, the rail hook is disengaged from the rail
and the bottom valves close instantaneously (rapid-action cl osing).
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Explanatory Notes – continued –
Function
The loading and unloading system HV 205 is designed for filling and draining tanks that
contain pr essure-liquefied gases.
One bottom valve opens for the liquid phase and the other opens for the gas phase. Both
opening p rocesses always take place simultaneously.
The operating device of the tension rope (e. g. rail hook VZ 10) engaged to one of the
rails provides the required tens ion of the rope. This tension keeps the ball valve of the
control unit of the hydraulic system closed.
The hydraulic hand pump of the operating device BV 100 can then be used to apply
pressure to the hydraulic system. The pressure acts on the actuating cylinders of the
bottom valves, forcing the piston to go up and thereby causing the bottom valves to open.
The current lift position of both bottom valves is indicated separately by the indicating
cylinders of the operating device BV 100.
When the rail hook is disengaged, i. e. when the load on the tension rope is reduced, the
hydraulic system opens, leading to the rapid-action closing of the bottom valves within
less than 1 second.
The integrated non-return valve prevents the premature closing of the bottom valves
caused by leaking fluids in the hydraulic hand pump and the pressure-reducing valve.
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