Installation Instructions 818480-01 - Flowserve
GESTRA Steam SystemsHV 215Installation Instructions 818480-01tHydraulic Loading and Unloading System HV 215
ContentsPageImportant NotesUsage for the intended purpose. 8Safety notes. 8Danger. 8Legal regulations. 9Explanatory NotesScope of supply. 10Description. 10Function. 11Technical data. 11, 12Fluid list. 13, 14InstallationHydraulic loading & unloading system HV 215. 15Mounting flange. 15, 16Bottom valve HWV 205/1 - DN 80.17 - 19Bottom valve HWV 215/1 - DN 80.20 - 23Cable routing. 24Operating device BV 110. 25Connecting lines. 26, 28Attaching operating plates HV 215. 29Attaching list indicating fluids. 29Filling and venting of hydraulic system. 30Filling and venting of hydraulic actuating system. 30Filling and venting of hydraulic indicating system. 31Performance test. 31OperationService. 32Emergency operation. 33MaintenanceBottom valves HWV 205/1 - DN 80 / HWV 215/1 - DN 80. 34Operating device BV 110. 35Connecting lines. 35
Contents– continued –PageServicingHydraulic loading & unloading system HV 215. 36Replacing valve plug seal.36 - 38Reworking seat flange. 39Replacing gaskets of actuacting cylinder. 40, 41Replacing control unit of bottom valve. 42
ComponentsHWV 205/1HWV 215/1BV 110AXBGYYTension rope withwire cable clampCDERPEWVLFFHL G RPZKKFBIJ gas phase open liquid phaseclosedUKMTNOQSS
KeyABCDEFGHIJKLMNOPQRSTUVWXYZShut-off valvesActuating cylinderRail hookRingOperating devicesPump lever of hydraulic hand pumpLine leading to the indicating cylinder of the gas phaseIndicating cylinderFilling connectionSealing plugScrew for sealing off opening for emergency unloadingLine leading to the indicating cylinder of the liquid phaseBolt for operating devicePlate showing valve position of indicating pistonsIndicating pistonsPressure lineScrew-in plug for venting facilityReturn lineScrew for oil filling connection (with dip stick)Hydraulic hand pumpNon-return valveTransverse pipe-runFrameControl unitGuide bushingFluid list
Basic Components of Bottom ValvesMounting flangeValve headBody12345678fe31jihgdcba )(/Actuating cylinder90!"§ % &
Key1234567890!"§ %&/() abcdefghij31Hexagon head cap screwLocking washerSpring plateStay boltSleeveGasketSeat flangeGasketPush rodBellowsGasketPistonPiston sealHexagon head cap screwSealing plugJoint ringRetaining ringO-ringO-ringBushingSeal ringHexagon head cap screwSocket-head cap screwLocking washerValve plugCompression springWasherRetaining ringSocket-head cap screwWasherValve plug seal
Important NotesUsage for the intended purposeThe hydraulically operated loading and unloading system HV 215 is intended solely for filling and draining stationaryand mobile tanks containing pressure liquefied gases.Its use is permissible only within the allowable pressure and temperature ratings and only if the chemical andcorrosive influences on the equipment are taken into account. Before installing the equipment make sure that theloading & unloading system is suitable for the intended application and the fluid to be used (corrosion resistanceand 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 willhave 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 notesThe 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 recognisedlevel of competence.For installation, removal, commissioning, operation and maintenance, every person who works with the loading andunloading system must have read and understood the complete installation manual. Furthermore, responsibilitiesmust 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 inperfect condition.AttentionWorking methods that jeopardise safety must not be used!DangerIf the loading and unloading system is used in an inexpert or improper manner by unqualified staff, it can causedanger 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 andunloading procedure all other components are also under pressure. In this condition, screws as well as nuts andbolts of the loading and unloading system must not be slackened. Liquid or vaporizing fluids might escape andcould 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 wearsprotective 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.
Important Notes– continued –WarningAny use of naked flames is expressly forbidden!Before perfomring any service work inside the tank make sure that the tank is sufficiently ventilatedand all gases have been completely vented. The rules concerning MAC ( maximum allowableconcentration) values at place of work must be strictly applied!Legal regulationsThe configuration of the loading and unloading system HV 215 mounted to the tank car carrying pressurizedgas 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.
Explanatory NotesScope of supply1 Bottom valve HWV 205/1 - DN 801 Bottom valve HWV 215/1 - DN 80 with tension rope2 Hydraulic operating devices BV 1102 Operating plates HV 2152 Plates indicating fluids (only for bottom valves with valve plug seal made of CR)1 Installation manual for loading & unloading system HV 2151 Set of acceptance certificatesThe following items are not scope of the supply but can be ordered separately:1 Set of connecting lines as accessory kit4 Shut-off valves DN 802 Valve mounting flangesDescriptionThe hydraulically operated loading and unloading system HV 215 is designed for filling and draining stationaryand 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, theshut-off valves, the rail hook and the tension rope. The connecting lines required for operating the loading andunloading 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 forinstallation in the valve-mounting flanges located at the bottom of the vessel. Both bottom valves are alwaysopened or closed together. A manifold connects the bottom valves directly with the shut-off valves. Both valvescan 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 onefor the gas phase. They are attached to the left and right hand side of the tank car, which means that the bottomvalves 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 theopen position. In the event of an emergency, e. g. emergency shut-off or inadvertent moving of the tank car, therail hook is disengaged from the rail and the bottom valves close instantaneously (rapid-action closing).10
Explanatory Notes– continued –FunctionThe 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 processesalways take place simultaneously.The operating device of the tension rope (e. g. rail hook VZ 10) engaged to one of the rails provides the requiredtension 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 hydraulicsystem. The pressure acts on the actuating cylinders of the bottom valves, forcing the piston to go up and therebycausing the bottom valves to open.The current lift position of both bottom valves is indicated separately by the indicating cylinders of the operatingdevice 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 bottomvalves caused by leaking fluids in the hydraulic hand pump and the pressure-reducing valve.Technical dataAttentionFor pressure / temperature ratings of the bottom valves see name plate.Name plate drawingGESTRA HWVName plate specificationsType of bottom valveTÜ. AGG.Type approvalManu.-no.:GESTRA manufacturing no.Ptest : 37.5barT min. : - 50 C valve plug seal PTFETest pressureT min. : - 40 C valve plug seal CRType of valve plug seal usedin valve headMADE BY GESTRA11
Explanatory NotesTechnical data– continued –– continued –Pressure/Temperature Ratings of Bottom Valves25Nominal pressure PN [bar]37.5Test pressure [bar]Temperature range for valve plug seal CR [ C]– 40 to 50Temperature range for valve plug seal PTFE [ C]– 50 to 50Connection of bottom valve bodySocket-weld ends for manifoldwith O. D. 88.9 mmSpring pressure on valve plug [N]322 30Lift of valve plug [mm] 21.2Drag coefficient ζItem no.–b 7ef34068!31c()5Weight .0566Hexagon head cap screw M16A2-70 or A4-70Hexagon head cap screw M12A2-70Seat flange1.4571Valve plug1.4571Compression spring1.4310Spring plate1.4301Stay bolt1.4301Bellows, complete1.4541 and 1.4571GasketPTFEValve plug sealPTFE or CRSocket-head cap screwA2-70O-ringNBR 70 ShoreSleeve1.4313HWV 205/1HWV 215/1BV 110Body2020–Valve head99–Hydraulic actuator77–Control unit–3–Total36392 x 16
Explanatory Notes– continued –Fluid listClassClassificationcodeUN No.Valve plug sealPTFE down to-50 CValve plugseal CR 2TC1005XXEthyl chloride22F1037XMethyl chloride22F1063XVinyl chloride22F1086XGas R1222A1028XGas R2122A1029XGas R2222A1018XGas R11422A1958XGas R11522A1020XGas R12 B122A1974XMethyl bromide22T1062XMethylamine (free from water)22F1061XDimethylamine (free from water)22F1032XTrimethylamine (free from water)22F1083XEthylamine (free from water)22F1036XHexafluoropropylene R121622A1858XDimethyl ether22F1033XChlorotrifluoroethane R133a22A1983XEthylene oxide withmax. 10% carbon dioxide22TF1040XEthylene oxide withnitrogen up to 10 bar at 50 C22TF1040XMixture F122A1078XMixture F222A1078XMixture P122F1060XMedia13
Explanatory NotesFluid list– continued –– continued –UN No.Valve plug sealPTFE down to-50 CValve plugseal CR downto2F1965XX22F1965XXMixture A122F1965XXMixture B22F1965XXMixture C (trade name propane)22F1965XXMixtures of hydrocarbons withbutadiene -1.322F1010XXIso butane22F1969XIso butene22F1055XCis -2-butene22F1012XXTrans -2-butene22F1012XXCyclopropane22F1027XGas mixture R50022A2602XGas mixture R50222A1973XCarbon codeMixture A (trade name butane)2Mixture AO (trade name butane)Media14
InstallationHydraulic loading & unloading system HV 215We highly recommend that only qualified staff should carry out installation work in accordance with theseinstallation instructions. The manufacturer expressly rejects any claims for damage caused by improper installation.All parts to be fitted must meet the technical requirements specified by the manufacturer. All genuine parts areguaranteed to comply with these requirements.For installation work choose lifting devices that are specified for the respective weights. Use only suitable andproper lifting devices.When welding observe legal regulations and in-house guidelines concerning welded connections. Before weldingclean all spots to be welded.Make sure that the gaskets of the flanged connections are exactly placed between the flanges. Clean all seatingsurfaces before installing the equipment.Before installing the valves remove the transport packing and all transit protection plugs for end connections.Install the equipment in the following order:n Mounting flangesn Bottom valve HWV 205/1 - DN 80n Bottom valve HWV 215/1 - DN 80n Cable routingn Operating devices BV 110n Connecting linesn Attaching operating plates HV 215n Attaching plates indicating fluidsMounting flangeThe mounting flanges for bottom valves type HWV 205/1 - DN 80 and HWV 215/1 - DN 80 have the sameform and can be installed in the same way.They are not scope of supply of the loading & unloading system HV 215 but can be ordered from Gestra.Valve mounting flanges made from the following materials are available:n P355NL1 (1.0566, old: TStE 355)n S420NL (1.8912, old: TStE 420)n P460NL1 (1.8915, old: TStE 460)Further materials are available on request.Gestra supplies valve mounting flanges with a standard diameter of 430 6 mm. To avoid a wall thicknessmisalignment between the valve mounting flange and the tank wall, adjust the outside diameter D to thethickness S of the tank car (see drawing on page 16). Make sure that the weld joint produced is in compliancewith the specifications of the tank manufacturer.The valve mounting flanges are welded into the bottom of the vessel according to the specifications of thelocal welding authority.To calculate the dimensions of the pressure vessel to AD-B1/ B9, refer to the drawing ( see page 16) in whichthe dimensions of the reinforcement are indicated.15
InstallationMounting flange– continued –– continued –AttentionAfter the annealing process check the seating surfaces and, if necessary, clean, rework or cut them.The reference dimension S varies as a function of the drop forging tolerance and must becompensated for by the diameter D of the valve mounting flange.Reference dimension varies as a function of the drop forging tolerance 430 6 4.3-1.61032 Valve joint as specifiedby local authorityLongitudinal axis of boiler1635S 4.3-1.6 D 365 155
Installation– continued –Bottom valve HWV 205/1 - DN 80The supplied bottom valve consists of two component parts - the valve head and the body with the actuatingcylinder. The valve comes with a set of assembly parts.The assembly parts of the valve head comprise:n 1 Gasket 125n 12 Locking washersn 12 Socket head cap screws M16 x 30First attach the valve head from the outside to the valve mounting flange.See drawing on page 191. Put the gasket 6 onto the valve head.2. Place the valve head onto the mounting flange and insert the supplied socket-head cap screws c and lockingwashers d in
The non-return valve integrated in the operating device BV 0 prevents the premature closing of the bottom valves caused by leaking fluids in the hydraulic hand pump and the pressure-reducing valve. Function Technical data For pressure / temperature ratings of the bottom valves see name plate. Attention Name plate drawing Name specifications
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used
- Engineering (hydraulic calculations, design, Flowserve) - Delivery of two new pumps, with modified hydraulics, as per API 610, 12th edition, ATEX certified (Flowserve) - Delivery of two API 53B/23 seal support systems (Flowserve) - Delivery of two dual, metal bellow mechanical seals (Flowserve) - Delivery of new couplings (John Crane)
Flowserve Pump Division to provide sound and all necessary information the content of this manual may appear insufficient and is not guaranteed by Flowserve as to its completeness or accuracy. Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance .
In 2004 Flowserve Pump Division (FPD) acquired Thompsons, Kelly & Lewis Pty. Ltd. (TKL) which was formed in 1987 by the merger of two long-established pump companies, Thompsons at Castlemaine (Vic) and Kelly & Lewis in Melbourne. FPD is a division of Flowserve Corporation of the USA, a global company manufacturing centrifugal
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