installation instructions 818480-01 - flowserve · 5 key a shut-off valves b actuating cylinder c...

�

t

GESTRA Steam Systems

HV 215Installation Instructions 818480-01HydraulicLoadingandUnloadingSystemHV2�5

2

Contents

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

Important NotesPage

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

Explanatory Notes

Hydraulicloading&unloadingsystemHV2�5.......................................................................................................... �5Mountingflange.................................................................................................................................................. �5,�6BottomvalveHWV205/�-DN80......................................................................................................................�7-�9BottomvalveHWV2�5/�-DN80......................................................................................................................20-23Cablerouting............................................................................................................................................................ 24OperatingdeviceBV��0.......................................................................................................................................... 25Connectinglines................................................................................................................................................. 26,28AttachingoperatingplatesHV2�5............................................................................................................................ 29Attachinglistindicatingfluids................................................................................................................................... 29Fillingandventingofhydraulicsystem...................................................................................................................... 30Fillingandventingofhydraulicactuatingsystem...................................................................................................... 30Fillingandventingofhydraulicindicatingsystem...................................................................................................... 3�Performancetest...................................................................................................................................................... 3�

Installation

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

Operation

BottomvalvesHWV205/�-DN80/HWV2�5/�-DN80.......................................................................................... 34OperatingdeviceBV��0........................................................................................................................................... 35Connectinglines....................................................................................................................................................... 35

Maintenance

3

Hydraulicloading&unloadingsystemHV2�5.......................................................................................................... 36Replacingvalveplugseal...................................................................................................................................36-38Reworkingseatflange.............................................................................................................................................. 39Replacinggasketsofactuactingcylinder............................................................................................................ 40,4�Replacingcontrolunitofbottomvalve...................................................................................................................... 42

Servicing

Contents – continued –

Page

4

Components

F

Y

S

K

L GRP

X

PRG

F

D

HWV205/�

EWV

HWV2�5/�

BV��0

HZ

EC

A

Tensionropewithwirecableclamp

B

K

KJ

IB

NO

Q

M

S

F

U

T

gas phase liquid phaseopen

closed

YL

5

Key

A Shut-offvalves

B Actuatingcylinder

C Railhook

D Ring

E Operatingdevices

F Pumpleverofhydraulichandpump

G Lineleadingtotheindicatingcylinderofthegasphase

H Indicatingcylinder

I Fillingconnection

J Sealingplug

K Screwforsealingoffopeningforemergencyunloading

L Lineleadingtotheindicatingcylinderoftheliquidphase

M Boltforoperatingdevice

N Plateshowingvalvepositionofindicatingpistons

O Indicatingpistons

P Pressureline

Q Screw-inplugforventingfacility

R Returnline

S Screwforoilfillingconnection(withdipstick)

T Hydraulichandpump

U Non-returnvalve

V Transversepipe-run

W Frame

X Controlunit

Y Guidebushing

Z Fluidlist

6

Basic Components of Bottom Valves

Mountingflange

Valvehead

Body

Actuatingcylinder

1234567

8ji h g d

c

e

f

b

a=)(/

&%$

§"

!0

9

31

7

Key

1 Hexagonheadcapscrew

2 Lockingwasher

3 Springplate

4 Staybolt

5 Sleeve

6 Gasket

7 Seatflange

8 Gasket

9 Pushrod

0 Bellows

! Gasket

" Piston

§ Pistonseal

$ Hexagonheadcapscrew

% Sealingplug

& Jointring

/ Retainingring

( O-ring

) O-ring

= Bushing

a Sealring

b Hexagonheadcapscrew

c Socket-headcapscrew

d Lockingwasher

e Valveplug

f Compressionspring

g Washer

h Retainingring

i Socket-headcapscrew

j Washer

Valveplugseal31

8

Important Notes

ThehydraulicallyoperatedloadingandunloadingsystemHV2�5isintendedsolelyforfillinganddrainingstationaryandmobiletankscontainingpressureliquefiedgases.

Itsuseispermissibleonlywithintheallowablepressureandtemperatureratingsandonlyifthechemicalandcorrosiveinfluencesontheequipmentaretakenintoaccount.Beforeinstallingtheequipmentmakesurethattheloading&unloadingsystemissuitablefortheintendedapplicationandthefluidtobeused(corrosionresistanceandchemicalsuitability).

Modificationstothedesignmayonlybemadeifthemanufacturer‘swrittenpermissionisobtained.

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

9

Important Notes – continued –

TheconfigurationoftheloadingandunloadingsystemHV2�5mountedtothetankcarcarryingpressurizedgasmeetstherequirementsofDIN26026orofEN�256�-3.ThebottomvalvesHWV205/�-DN80andHWV2�5/�-DN80fulfillthelegalrequirementsoftheRID/GGVSEsec-tion6,constitutingthefirstinnershut-offasdefinedintheseregulations.

Legal regulations

Anyuseofnakedflamesisexpresslyforbidden!

Beforeperfomringanyserviceworkinsidethetankmakesurethatthetankissufficientlyventilatedandallgaseshavebeencompletelyvented.TherulesconcerningMAC(=maximumallowableconcentration)valuesatplaceofworkmustbestrictlyapplied!

Warning

�0

Explanatory Notes

�BottomvalveHWV205/�-DN80�BottomvalveHWV2�5/�-DN80withtensionrope2HydraulicoperatingdevicesBV��02OperatingplatesHV2�52Platesindicatingfluids(onlyforbottomvalveswithvalveplugsealmadeofCR)�Installationmanualforloading&unloadingsystemHV2�5�Setofacceptancecertificates

Thefollowingitemsarenotscopeofthesupplybutcanbeorderedseparately:

�Setofconnectinglinesasaccessorykit4Shut-offvalvesDN802Valvemountingflanges

Scope of supply

ThehydraulicallyoperatedloadingandunloadingsystemHV2�5isdesignedforfillinganddrainingstationaryandmobiletankscontainingpressureliquefiedgases.

Itismainlyusedintankcarscarryingpressurizedgases.Thesetankcars(TC)requireahighdegreeofreliability,easeofoperationandmaintenanceandalongservicelifeoftheassociatedvalves.

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

ThebottomvalvestypeHWV205/�-DN80andtypeHWV2�5/�-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 –

TheloadingandunloadingsystemHV2�5isdesignedforfillinganddrainingtanksthatcontainpressure-liquefiedgases.

Onebottomvalveopensfortheliquidphaseandtheotheropensforthegasphase.Bothopeningprocessesalwaystakeplacesimultaneously.

Theoperatingdeviceofthetensionrope(e.g.railhookVZ�0)engagedtooneoftherailsprovidestherequiredtensionoftherope.Thistensionkeepstheballvalveofthecontrolunitofthehydraulicsystemclosed.

ThehydraulichandpumpoftheoperatingdeviceBV��0canthenbeusedtoapplypressuretothehydraulicsystem.Thepressureactsontheactuatingcylindersofthebottomvalves,forcingthepistontogoupandtherebycausingthebottomvalvestoopen.

ThecurrentliftpositionofbothbottomvalvesisindicatedseparatelybytheindicatingcylindersoftheoperatingdeviceBV��0.

Whentherailhookisdisengaged,i.e.whentheloadonthetensionropeisreduced,thehydraulicsystemopens,leadingtotherapid-actionclosingofthebottomvalveswithinlessthan�second.

Thenon-returnvalveintegratedintheoperatingdeviceBV��0preventstheprematureclosingofthebottomvalvescausedbyleakingfluidsinthehydraulichandpumpandthepressure-reducingvalve.

Function

Technical data

Forpressure/temperatureratingsofthebottomvalvesseenameplate.

Attention

Nameplatedrawing Nameplatespecifications

Typeofbottomvalve

Typeapproval

GESTRAmanufacturingno.

Testpressure

Typeofvalveplugsealusedinvalvehead

TÜ. AGG.

Manu.-no.:

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

Tmin. : - 40°C 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] 322±30

Liftofvalveplug[mm] >2�.2

DragcoefficientζLoading Unloading

3.3 2.8


Technical data – continued –

Item no. Component Material

– Body �.0566

b HexagonheadcapscrewM�6 A2-70orA4-70

$ HexagonheadcapscrewM�2 A2-70

7 Seatflange �.457�

e Valveplug �.457�

f Compressionspring �.43�0

3 Springplate �.430�

4 Staybolt �.430�

0 Bellows,complete �.454�and�.457�

68! Gasket PTFE

Valveplugseal PTFEorCR

c Socket-headcapscrew A2-70

() O-ring NBR70Shore

5 Sleeve �.43�3

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 2x�6

�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 �0�2 X X

Butadiene-�.3 2 2F �0�0 X X

Ammonia 2 2TC �005 X X

Ethylchloride 2 2F �037 X

Methylchloride 2 2F �063 X

Vinylchloride 2 2F �086 X

GasR�2 2 2A �028 X

GasR2� 2 2A �029 X

GasR22 2 2A �0�8 X

GasR��4 2 2A �958 X

GasR��5 2 2A �020 X

GasR�2B� 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

HexafluoropropyleneR�2�6 2 2A �858 X

Dimethylether 2 2F �033 X

ChlorotrifluoroethaneR�33a 2 2A �983 X

Ethyleneoxidewithmax.�0%carbondioxide

2 2TF �040 X

Ethyleneoxidewithnitrogenupto�0barat50°C

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 �0�0 X X

Isobutane 2 2F �969 X

Isobutene 2 2F �055 X

Cis-2-butene 2 2F �0�2 X X

Trans-2-butene 2 2F �0�2 X X

Cyclopropane 2 2F �027 X

GasmixtureR500 2 2A 2602 X

GasmixtureR502 2 2A �973 X

Carbondioxide 2 3A 2�87 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 Mountingflanges

n BottomvalveHWV205/�-DN80

n BottomvalveHWV2�5/�-DN80

n Cablerouting

n OperatingdevicesBV��0

n Connectinglines

n AttachingoperatingplatesHV2�5

n Attachingplatesindicatingfluids

Mounting flange

ThemountingflangesforbottomvalvestypeHWV205/�-DN80andHWV2�5/�-DN80havethesameformandcanbeinstalledinthesameway.

Theyarenotscopeofsupplyoftheloading&unloadingsystemHV2�5butcanbeorderedfromGestra.

Valvemountingflangesmadefromthefollowingmaterialsareavailable:

n P355NL�(�.0566,old:TStE355)

n S420NL(�.89�2,old:TStE420)

n P460NL�(�.89�5,old:TStE460)

Furthermaterialsareavailableonrequest.

Gestrasuppliesvalvemountingflangeswithastandarddiameterof430+6mm.Toavoidawallthicknessmisalignmentbetweenthevalvemountingflangeandthetankwall,adjusttheoutsidediameterDtothethicknessSofthetankcar(seedrawingonpage�6).Makesurethattheweldjointproducedisincompliancewiththespecificationsofthetankmanufacturer.

Thevalvemountingflangesareweldedintothebottomofthevesselaccordingtothespecificationsofthelocalweldingauthority.

TocalculatethedimensionsofthepressurevesseltoAD-B�/B9,refertothedrawing(seepage�6)inwhichthedimensionsofthereinforcementareindicated.

�6

Mounting flange – continued –

Attention

Installation – continued –

Aftertheannealingprocesschecktheseatingsurfacesand,ifnecessary,clean,reworkorcutthem.

ThereferencedimensionSvariesasafunctionofthedropforgingtoleranceandmustbecompensatedforbythediameterDofthevalvemountingflange.

Longitudinalaxisofboiler

Valvejointasspecifiedbylocalauthority

Referencedimensionvariesasafunctionofthedropforgingtolerance

S+

4.3

-�

.6

�0+

4.3

-�

.63532°

∅ 430 +6

∅ D∅ 365

∅ �55

�7

Bottom valve HWV 205/1 - DN 80


Thesuppliedbottomvalveconsistsoftwocomponentparts-thevalveheadandthebodywiththeactuatingcylinder.Thevalvecomeswithasetofassemblyparts.

Theassemblypartsofthevalveheadcomprise:

n �Gasket∅�25

n �2Lockingwashers

n �2SocketheadcapscrewsM�6x30

Firstattachthevalveheadfromtheoutsidetothevalvemountingflange.Seedrawingonpage�9

�. Putthegasket6ontothevalvehead.

2. Placethevalveheadontothemountingflangeandinsertthesuppliedsocket-headcapscrewscandlocking washersdinthevalvemountingflangeandtightenthemwithatorqueof�20Nm.Applyacommerically availablelubricanttothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.

3. Checkspacingbetweenbottomofvalveplugeandseatflange7(referencedimension�seepage�9).Forthis purposeyoucanholdatrysquaretothebottomofthevalveheadandreadoffthedistancetothebottomofthe valveplug.Adistanceof7±�mmisrequired.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 �Gasket∅�25

n 6HexagonheadcapscrewsM�6x�40

n �Gasket(sparepartforreplacement)

Thebodyissuppliedtogetherwiththeactuatingcylinderasacompletecomponentpart.Seedrawingsonpage4andpage�9

�. 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(seepage�9)fromtheupperedgeofthepushrod9tothesealingsurfaceofthe unloadedbellows0andtothelowerstopofthebellows0.Ifthedistanceexceedstheadmissibletolerance, checkthepushrod9forsmoothoperation.Ifthepushrodisjammed,firsteliminatethecauseandthengently knockwithyourhandagainstthepushrod9untilitcanmovefreely.Ifyoucannotfindafaultpleasecontactour TechnicalServicesinyourcountry,statingtheGESTRAmanufacturingnumber.

4. Insertthesuppliedgasket8inthebottomofthevalveheadandusethehexagonheadcapscrewsbtoscrew thebodytothemountingflange,applyingatorqueof�20Nm.Applyacommericallyavailablelubricanttothe screwsandtightentheminseveralstepsindiagonallyoppositepairs.


Attention

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

Alwaysreplacegasketwhenremovingtheactuatingcylinder.


Note:Donotusethepushrod9ashandle!

�9



,

6

∅ 2�0/�2xM�6

∅ �46

Manifold∅ 88.9

M�278

��6.

5

292

∅ ��2

turnedthrough90° turnedthrough90°

Torque�20Nm

Torque�20Nmturnedthrough�5°

Torque50Nmturnedthrough45°

Referencedimension�onvalvehead

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 �Gasket∅�25

n �2Lockingwashers

n �2SocketheadcapscrewsM�6x30

Firstattachthevalveheadfromtheoutsidetothevalvemountingflange.Seedrawingonpage23

�. Putthegasket6ontothevalvehead.

2. Placethevalveheadontothemountingflangeandinsertthesuppliedsocket-headcapscrewscandlocking washersdinthevalvemountingflangeandtightenthemwithatorqueof�20Nm.Applyacommerically availablelubricanttothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.

3. Checkthespacingbetweenthebottomofthevalveplugeandtheseatflange7(cf.referencedimension �onpage23).Forthispurposeyoucanholdatrysquaretothebottomofthevalveheadandreadoffthe distancetothebottomofthevalvepluge.Aspacingof7±�mmisrequired.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 �Gasket∅�25

n 6HexagonheadcapscrewsM�6x�40

n �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,applyingatorqueof�20Nm.Applyacommericallyavailablelubricanttothe screwsandtightentheminseveralstepsindiagonallyoppositepairs.

5. EngagetheloopofthetensionspringofthecontrolunitXtothehexagonheadcapscrewb.42

22



Attention


Inadditionmakesurethatthestemoftheballvalvecanalwaysrunsmoothly.Ifthestemdoesnotmovesmoothly,applyacommerciallyavailablelubricant.Donottreatorpaintthesurface!

Makesurethatthecableroutingdoesnottouchthemanifold!

Note:Donotusethepushrod9ashandle!

Attachthecontrolunittothebody.

Theassemblypartsofthecontrolunitcomprise:

n 2StudboltsM�6x35

n 2Lockingwashers

n 2NutsM�6

Thecontrolunitscomeswiththeballvalve.Seedrawingsonpage4

�. Screwstudboltsintothebody,applyingatorqueof�20Nm.

2. UsethelockingwashersandnutstofitthecontrolunitXtothebodywithatorqueof�20Nm.

3. Engagethetensionspringintheleveroftheballvalve.42 36

35

33 34

23



6

∅ 2�0/�2xM�6∅ �46

Manifold∅ 88.9

M�2

78��

6.5

292

∅ ��2turnedthrough90°

turnedthrough90°

Torque�20Nm

Torque�20Nmturnedthrough�5°

Torque50Nmturnedthrough45°

Referencedimension�onvalvehead

Referencedimension2onbodywithactuatingcylinder(bellowsunloaded)

Referencedimension3onbodywithactuatingcylinder(bellowsatlowerstop)

7±�

�6±9

�±�

!

31

0

8

$

9 d

c

6e

b

32

3334

35 36 37 38 39 40

Torque�20Nm

42 41

24

Cable routing


ProvidetankcarwithaguidesleeveYforthetensionrope.

ThepositionoftheguidesleeveYmustenablethetensionropetoleavethecontrolunitXofthebottomvalveatanangleof45°.Seedrawingonpage4

�. Thetensionropesuppliedbythemanufactureris�500mmlongandmustbecuttotherequiredlength.

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

Attention

Donotpassthetensionropeoversharpedges.

Thelay-outofthetensionrope,theguidesleeveYandtheringDforattachingthetensionropeoperatingdevicemustcomplywithDIN26026andEN�256�-3.

52027

0

Tensionrope

Guidesleeve

Ifthevalveisopen

Atdamperlevel�060

Upperedgeofrail

Ringforattachingthetensionropeoperatingdevice

25

Operating device BV 110


Fittheoperatingdevicestobothsidesofthevesselsuchthattheyareeasilyaccessible.

Eachoperatingdeviceconsistsof:

n �Handlever

n �Adhesivelabelforvalveposition(no.04856�)

Theoperatingdevicesaresuppliedcompletelymounted.Seedrawingonpage4

�. WeldorscrewtheoperatingdevicesEtotheframeW. ThebodyoftheoperatingdeviceEisprovidedwithtwoboreholes(diameter�3mm)forscrewedunions. TheassociatedscrewsandlockingwashersarenotscopeoftheGESTRAsupply. Notethatweldingprocessesmustbesupervisedbythelocalweldingauthority.

2. Whenyouhavefinishedweldingandpainting,sticktheadhesivelabelNindicatingthevalvepositionto thebackofthebodybehindtheindicatingpistonO.

Dimensionsindicatedinmm Depth�64

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-typesteeltoEN�0056-� withdimensions�00x50x6mm)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. AtthesideforconnectingtheoperatingdeviceEtheyareprovidedwitha90°bendandaunionnutM�6x�.5 andatthesideforconnectingthehydraulictubestheyhaveastubM�6x�.5forconnectingthehydraulictubes.

6. Severalconnectinglinesfromthetransversepipe-runVtothebottomvalvescanbemadebyusingthe hydraulictubes,,,.

7. UseflexiblehydraulichoseswithscrewedendconnectionsM�6x�.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/�-DN80orHWV2�5/�-DN80,youcanswoptheendconnectionsoftheactuatingcylinderswiththefillingconnections.

Forthispurposeuseaspanner�9mmA.F.Applyatorqueof40Nmtofastentheconnections(seebelow).

Attention

ThehydraulictubesmustmeettherequirementsofDIN239�andmustbemadeofSt37.4NBKwithawallthicknessof�0x�mm.

ThehydraulichosesmustbeinaccordancewithEN853-�SN8.

Wheninstallingtheconnectinglinesmakesurethatthelineshaveaslightinclinationtowardsthemiddlesuchthatthehydraulicsystemcanbevented.

Ifnecessarytakeadditionalprecautionstopreventthetransversepipe-runfromswinging.

Thehydraulictubesleadingtotheactuatingcylindersmustbeprovidedwithexpansionloopsinordertoabsorbvibrations.

Checkthesoftsealsoftheconnectionsfordamage.Onlysoftsealsthatarenotdamagedcanbeusedagain.Replacedamagedgasketsandseals.

P P

Socket-weldendformanifold

Connectionforindicatingcylinder

HWV205/�Standardarrangementwhensupplied

HWV2�5/�Standardarrangementwhensupplied

Fillingconnection

Fillingconnection

28

Reference Designation Qty.

T-typescrewjointe.g.CompanyWalterscheid,

CompanyErmeto5

AdjustableT-typescrewjoint

e.g.CompanyWalterscheid,CompanyErmeto

�

Hydraulichosewith90°pipebendandconnectingstub

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)

ControlunitHV2�5

BV��0

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(“Controltac”printedonit)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-theballvalveofthecontrolunitXofthebottomvalveHWV2�5/�-DN80 willautomaticallyopenthehydraulicsystem.

2. UnscrewtheredplugSandthedipstickoftheoilfillingconnectionofthehydraulichandpumpT andfilloilintothetank.

3. PullthetensionropeinordertoclosetheballvalveofthecontrolunitXofthebottomvalve HWV2�5/�-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 ofthebottomvalveHWV2�5/�-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 Openingofbottomvalve

n Closingofbottomvalve

Toopen/closethebottomvalvesoperateoneoftheoperatingdevicesEateithersideofthetank.Seedrawingonpage4

WhenopeningtheoperatingdeviceEremove-ifnecessary-thecustom‘sleadsealfromtheboltM.

�. ToopentheoperatingdeviceEpushtheboltMupwardsandthenturnitby90°tooneside. Youcannowswingdownthelid.

2. MakesurethatthepumpleverofthehydraulicpumpFiscompletelyextendedtowardsthefront.

3. ConnecttherailhookC(e.g.railhookVZ�0)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 Openingofbottomvalve

n Closingofbottomvalve

Ifbothbottomvalvesaretobeopened,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.Ifaleakisdetectedreplacevalveplugseal

asdescribedinsection“Maintenance”.

Replacevalveplugseal

Maininspection(every4yrs.)

Replacevalveplugsealasdescribedinsection“Maintenance”.

CheckactuatingcylinderB



Checkconnectionbetweenactuatingcylinderandbody.Ifyoudetectanoilleak

replacethePTFEsealandtheO-ringasdescribedinsection“Maintenance”.

Checktorqueof50Nm$



Checkthetorquesofthefourhexagon-headcapscrewsoftheactuatingcylinderand,ifnecessary,retightenthe

screwstoatorqueof50Nm.

Checktorqueof�20Nmb



Checkand,ifnecessary,re-tightenthesixhexagon-headcapscrewsofthebodyandthetwohexagonnutsthatfix

thecontrolunittothebodywithatorqueof�20Nm.

Checksmoothnessofoperationofballvalveshaft



Checksmoothoperationgofswitchingshaft.Iftheswitchingshaftdoesnotmovesmoothlyapply

acommerciallyavailablelubricant.

Replacepistonseal(

Whennecessary,every8yearsatthelatest

Replacepistonsealasdescribedinsection“Maintenance”.

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 Visualexaminationsaspartofthemaininspection

n Repairworkduetoleaksorothermalfunctions

ThebottomvalvesHWV205/�-DN80andHWV2�5/�-DN80requiremaintenanceandservicing.TheoperatingdeviceBV��0ismaintenancefree.

WerecommendremovingthebottomvalvesHWV205/�-DN80andHWV2�5/�-DN80andcheckingthemforwearanddamagewhenperformingvisualinspections.

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

GESTRAsuppliesthefollowingsealkits:

�. Stockcode049387

n �ValveplugsealPTFE

n 2Gaskets∅�25682. Stockcode049395

n �ValveplugsealCR

n 2Gaskets∅�25683. Stockcode049563

n �Pistonseal§n �Sealringan 2O-rings()n �Gasket!n �Gasket&Modificationstothedesignmayonlybemadeifthemanufacturer‘swrittenpermissionisobtained.

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. Undothe�2socket-headcapscrewscandtakethevalveheadfromthemountingflange.Forthispurpose youcanscrewtwohexagon-headcapscrewsM�0intothetwothroughthreadsoftheseatflange. 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,applyingatorqueof�5Nm.Applyacommerciallyavailablelubricanttothescrews andtightentheminseveralstepsindiagonallyoppositepairs.

2. Thensecurethewashergbyusingtheretainingringh.

3. Screwthesixhexagon-headcapscrews1togetherwiththelockingwashers2intothestaybolts3, usingatorqueof25Nm.Applyacommericallyavailablelubricanttothescrewsandtightentheminseveral stepsindiagonallyoppositepairs.

Tomountthebottomvalvesfromtheoutsidefollowtheinstructionsgiveninsection“Installation”(seepage�7forHWV205/�-DN80andpage20forHWV2�5/�-DN80).

31

Attention


38

Replacing valve plug seal – continued –


1234567

ji h g dc

ef

31

39

Reworking seat flange

Iftheseatingssurfaceoftheseatflangeisslightlydamagedyoucanremoveandreworktheseatflange.Formoredetailsseedrawingbelow.

Toremovetheseatflangepleaseproceedasfollows:Seedrawingonpage38

�. Removebodyandactuatingcylinder.

2. Unscrewthe�2socket-headcapscrewscandtheirassociatedlockingwashersdandremove theseatflange.Takeoutthegasket6.

3. Unscrewthesixstaybolts4togetherwiththeirsleeves5outoftheseatflange7.

Re-assemblyinreverseorder:Seedrawingonpage42

�. Firstpushthesleeves5ontothesixstaybolts4andthenscrewthemwithatorqueof25Nm totheseatflange7.Applyacommericallyavailablelubricanttothescrewsandtightenthem.

2. Tomountthevalveheadfollowtheindicatedsteps(seepage38).

3. Thenputanewgasket6ontotheseatflange7.

4. Usethe�2socket-headcapscrewsctogetherwiththeirlockingwashersdtomountthevalvehead tothemountingflange.Tightenthemwithatorqueof�20Nm.Applyacommerciallyavailablelubricant tothescrewsandtightentheminseveralstepsindiagonallyoppositepairs.


Attention


∅ 85

Ra0.8

max.5x45°

40

Replacing gaskets of actuating cylinder


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. Thenplacethepistonseal§ontothepiston".

4. Putthepiston"intothebellows0.Applyalightsmearofhydraulicoiltothepistonseal§. Thenputthiscomponentintotheactuatingcyclinder.

5. Screwthesealingplug%withthejointring&intotheactuatingcylinder.

32

4�

Replacing gaskets of actuating cylinder – continued –


a

=

)

(

/

&%

§"

!0

9

32

32

42

Replacing control unit of bottom valve


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,HaywardsHeathWestSussexRH�6�TLTel. 0044�444/3�4400Fax 0044�444/3�4557E-mail: [email protected]

Italia

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

GESTRA ESPAÑOLA S.A.LuisCabrera,86-88E-28002MadridTel. 00349�/5�52032Fax 00349�/4�36747;5�52036E-mail: [email protected]

España

Flowserve DALCO Steam Products260�GrasslandDriveLouisville,KY40299Tel. 00�502/4950�54,495�788Fax 00�502/495�608E-mail: [email protected]

USA

Portugal

Flowserve Portuguesa, Lda.Av.Dr.AntunesGuimarães,��59Porto4�00-082Tel. 0035� 22/6�98770Fax 0035� 22/6�07575E-mail: [email protected]

Polska

GESTRA POLONIA Spolka z.o.o.Ul.Schuberta�04PL-80-�72GdanskTel. 004858/306�0-02od�0Fax 004858/3063300E-mail: [email protected]

Agenciesallovertheworld:

www.gestra.de

GESTRA AGP.O.Box�05460, D-28054BremenMünchenerStr.77, D-282�5BremenTelephone +49(0)42�3503 - 0Fax +49(0)42�3503 - 393E-Mail [email protected] www.gestra.de

8�8480-0�/�005cm·© 2003GESTRAAG·Bremen·PrintedinGermany

installation instructions 818480-01 - flowserve · 5 key a shut-off valves b actuating cylinder c...

Documents