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HV 215
User Manual
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Flowserve HV 215 User Manual

GESTRA Steam Systems
HV 215
Installation Instructions 818480-01
Hydraulic Loading and Unloading System HV 215
t
1
Contents
Page
Important Notes
Usage for the intended purpose .................................................................................................................................. 8
Danger .......................................................................................................................................................................8
Explanatory Notes
Function ...................................................................................................................................................................11
Technical data .................................................................................................................................................... 11, 12
Installation
Hydraulic loading & unloading system HV 215 .......................................................................................................... 15
Mounting flange .................................................................................................................................................. 15, 16
Bottom valve HWV 205/1 - DN 80 ......................................................................................................................17 - 19
Bottom valve HWV 215/1 - DN 80 ......................................................................................................................20 - 23
Cable routing ............................................................................................................................................................24
Connecting lines ................................................................................................................................................. 26, 28
Attaching operating plates HV 215 ............................................................................................................................29
Filling and venting of hydraulic indicating system...................................................................................................... 31
Performance test ...................................................................................................................................................... 31
Operation
Service ..................................................................................................................................................................... 32
Maintenance
Bottom valves HWV 205/1 - DN 80 / HWV 215/1 - DN 80 .......................................................................................... 34
2
Contents – continued –
Page
Servicing
Hydraulic loading & unloading system HV 215 .......................................................................................................... 36
Replacing valve plug seal ...................................................................................................................................36 - 38
Reworking seat flange .............................................................................................................................................. 39
Replacing gaskets of actuacting cylinder ............................................................................................................ 40, 41
Replacing control unit of bottom valve ......................................................................................................................42
3
Components
F
Y
S
K
Tension rope with wire cable clamp
A
B
HWV 205/1
X
Y
G
L
HWV 215/1
BV 110
R
P
E
C
D
E
W
V
F
H
L G R P
Z
K
M
F
gas phase liquid phaseopen
N
B
closed
O
I
Q S
U
J
K
T
4
Key
A Shut-off valves B Actuating cylinder C Rail hook D Ring E Operating devices F Pump lever of hydraulic hand pump G Line leading to the indicating cylinder of the gas phase H Indicating cylinder I Filling connection J Sealing plug K Screw for sealing off opening for emergency unloading L Line leading to the indicating cylinder of the liquid phase 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 Screw for oil filling connection (with dip stick) T Hydraulic hand pump U Non-return valve V Transverse pipe-run W Frame X Control unit Y Guide bushing Z Fluid list
5
Basic Components of Bottom Valves
Mounting flange
Valve head
Body
1 2
3 4
5 6
7
8
31
j i h g
f
e
d c
b
Actuating cylinder
6
9
0 !
"
§
$
a = )
( /
&%
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 0 Bellows ! Gasket " Piston
§ Piston seal $ Hexagon head cap screw % Sealing plug & Joint ring / Retaining ring ( O-ring ) O-ring = Bushing a Seal ring b Hexagon head cap screw c Socket-head cap screw d Locking washer e Valve plug f Compression spring g Washer h Retaining ring i Socket-head cap screw j Washer
31
Valve plug seal
7
Important Notes
Usage for the intended purpose
The hydraulically operated loading and unloading system HV 215 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. Before installing the equipment make sure that the loading & unloading system is suitable for the intended application and the fluid to be used (corrosion resistance and chemical suitability).
Modifications to the design may only be made if the manufacturer‘s written permission is obtained.
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 for any resulting damage.
The use of external pumps for opening or closing the bottom valves is not permitted.
Safety notes
The loading and unloading system must not be installed or commissioned by anyone other than qualified staff.
Maintenance and service work must only be performed by adequately trained persons who have a recognised level of competence.
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.
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!
Danger
If the loading and unloading system is used in an inexpert or improper manner by unqualified staff, it can cause danger to life and limb for the user or for third parties, possibly resulting in death.
During operation, 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 poisoning 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.
8
Important Notes – continued –
Warning
Any use of naked flames is expressly forbidden!
Before perfomring any service work inside the tank make sure that the tank is sufficiently ventilated and all gases have been completely vented. The rules concerning MAC (= maximum allowable concentration) values at place of work must be strictly applied!
Legal regulations
The configuration of the loading and unloading system HV 215 mounted to the tank car carrying pressurized gas meets the requirements of DIN 26026 or of EN 12561-3. The bottom valves HWV 205/1- DN 80 and HWV 215/1- DN 80 fulfill the legal requirements of the RID / GGVSE sec­tion 6, constituting the first inner shut-off as defined in these regulations.
9
Explanatory Notes
Scope of supply
1 Bottom valve HWV 205/1 - DN 80 1 Bottom valve HWV 215/1 - DN 80 with tension rope 2 Hydraulic operating devices BV 110 2 Operating plates HV 215 2 Plates indicating fluids (only for bottom valves with valve plug seal made of CR) 1 Installation manual for loading & unloading system HV 215 1 Set of acceptance certificates
The following items are not scope of the supply but can be ordered separately:
1 Set of connecting lines as accessory kit 4 Shut-off valves DN 80 2 Valve mounting flanges
Description
The hydraulically operated loading and unloading system HV 215 is designed for filling and draining stationary and mobile tanks 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 loading and unloading system consists of the two rapid-action bottom valves, the two operating devices, 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 and hydraulic hoses or entirely of hydraulic hoses.
The bottom valves type HWV 205/1 - DN 80 and type HWV 215/1 - DN 80 (with control unit) are designed for installation in the valve-mounting flanges located 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 either 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 the respective operating device.
During the loading/unloading process the rail hook connected to the tension rope keeps the bottom valves in the open position. In the event of an emergency, e. g. emergency shut-off or inadvertent moving of the tank car, the rail hook is disengaged from the rail and the bottom valves close instantaneously (rapid-action closing).
10
Explanatory Notes – continued –
TÜ. AGG. Manu.-no.:
P
test
: 37.5bar
T
min.
: - 50°C valve plug seal PTFE
T
min.
: - 40°C valve plug seal CR
GESTRA HWV
MADE BY GESTRA
Function
The loading and unloading system HV 215 is designed for filling and draining tanks that contain pressure­liquefied gases.
One bottom valve opens for the liquid phase and the other opens for the gas phase. Both opening processes 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 tension 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 110 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 110.
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 non-return valve integrated in the operating device BV 110 prevents the premature closing of the bottom valves caused by leaking fluids in the hydraulic hand pump and the pressure-reducing valve.
Technical data
Attention
For pressure / temperature ratings of the bottom valves see name plate.
Name plate drawing
Name plate specifications
Type of bottom valve
Type approval
GESTRA manufacturing no.
Test pressure
Type of valve plug seal used in valve head
11
Explanatory Notes – continued –
Technical data – continued –
Pressure/Temperature Ratings of Bottom Valves
Nominal pressure PN [bar]
Test pressure [bar]
Temperature range for valve plug seal CR [°C] – 40 to + 50
Temperature range for valve plug seal PTFE [°C] – 50 to + 50
Connection of bottom valve body
Spring pressure on valve plug [N] 322 ± 30
Lift of valve plug [mm] > 21.2
Drag coefficient
ζ
Item no. Component Material
– Body 1.0566
b $
Hexagon head cap screw M16 A2-70 or A4-70
Hexagon head cap screw M12 A2-70
Socket-weld ends for manifold
with O. D. 88.9 mm
Loading Unloading
3.3 2.8
25
37.5
7 e f 3 4 0
68!
31
c
()
5
Weight [kg] HWV 205/1 HWV 215/1 BV 110
Body 20 20 –
Valve head
Seat flange 1.4571
Valve plug 1.4571
Compression spring 1.4310
Spring plate 1.4301
Stay bolt 1.4301
Bellows, complete 1.4541 and 1.4571
Gasket PTFE
Valve plug seal PTFE or CR
Socket-head cap screw A2-70
O-ring NBR 70 Shore
Sleeve 1.4313
9 9 –
Hydraulic actuator
Control unit
Total 36 39 2 x 16
12
7 7 –
– 3 –
Explanatory Notes – continued –
Fluid list
Media Class
Propane 2 2F 1978 X X
Butane 2 2F 1011 X X
Propene 2 2F 1077 X X
Butene-1
Butadiene-1.3
Ammonia 2 2TC 1005 X X
Ethyl chloride
Methyl chloride
Vinyl chloride
Gas R12
Gas R21
Gas R22
Classification
code
2 2F 1012 X X
2 2F 1010 X X
2 2F 1037 X
2 2F 1063 X
2 2F 1086 X
2 2A 1028 X
2 2A 1029 X
2 2A 1018 X
UN No.
Valve plug seal
PTFE down to
-50 °C
Valve plug
seal CR down
to
Gas R114
Gas R115
Gas R12 B1
Methyl bromide
Methylamine (free from water)
Dimethylamine (free from water)
Trimethylamine (free from water)
Ethylamine (free from water)
Hexafluoropropylene R1216
Dimethyl ether
Chlorotrifluoroethane R133a
Ethylene oxide with max. 10% carbon dioxide
Ethylene oxide with nitrogen up to 10 bar at 50 °C
2 2A 1958 X
2 2A 1020 X
2 2A 1974 X
2 2T 1062 X
2 2F 1061 X
2 2F 1032 X
2 2F 1083 X
2 2F 1036 X
2 2A 1858 X
2 2F 1033 X
2 2A 1983 X
2 2TF 1040 X
2 2TF 1040 X
Mixture F1
Mixture F2
Mixture P1
2 2A 1078 X
2 2A 1078 X
2 2F 1060 X
13
Explanatory Notes – continued –
Fluid list – continued –
Media Class
Mixture A (trade name butane)
Mixture AO (trade name butane)
Mixture A1
Mixture B
Mixture C (trade name propane)
Mixtures of hydrocarbons with butadiene -1.3
Iso butane
Iso butene
Cis -2-butene
Trans -2-butene
Cyclopropane 2 2F 1027 X
Classification
code
2 2F 1965 X X
2 2F 1965 X X
2 2F 1965 X X
2 2F 1965 X X
2 2F 1965 X X
2 2F 1010 X X
2 2F 1969 X
2 2F 1055 X
2 2F 1012 X X
2 2F 1012 X X
UN No.
Valve plug seal
PTFE down to
-50 °C
Valve plug
seal CR down
to
Gas mixture R500
Gas mixture R502
Carbon dioxide
Ethylene 2 3F 1038 X
2 2A 2602 X
2 2A 1973 X
2 3A 2187 X
14
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