IOM RSD-BB

8/17/2019 IOM RSD-BB

http://slidepdf.com/reader/full/iom-rsd-bb 1/15

Page 1 o

SC FEPA SA

BÂRLAD

CE 2295-PED-H-FEP-001-09-ROM

INSTALLATION, OPERATION&MAINTENANCEBALL VALVE TYPE RSD-BB

SC FEPA SAStr.REPUBLICII nr.316, Cod postal 731120, Bârlad-RomâniaTel.+40 0235 411812Fax +40 0235 421 618/0235 413729 Rev 0Be-mail: [email protected] / [email protected] 09.03.2015

FIRE SAFE !

API 607

API 6FA

mailto:marketing:@fepa.ro





Page 2 o

1. INTRODUCTIONThe manual is designed to give the user complete information regarding installation, operation, adjustment,

perform periodic inspections and maintenance of valves type RSD-BB producer is FEPA Barlad. READ THE INSTRUCTIONS CAREFULLY BEFORE INSTALLING AND USING THE PRODUCT !

For any further information it is recommended to contact the manufacturer.User's responsibility to know all the information presented in this manual and the specific application for which it waspurchased valve.It is also the responsibility of the user to use for installation, operation and maintenance only qualified and trainedOn request the valve manufacturer can provide training to its headquarters or beneficiary.The user is obliged to ensure all measures for safe operation, the health of staff, environment and function of theequipment.Before delivery valves are tested by the manufacturer .If the instructions are not clear, please contact us addressS.C.FEPA SA str.Republicii nr.316cod 731120BARLAD, or [email protected].

At www.fepa.ro can find other information about the products FEPA.

1.1ApplicationBall valves distributor RSD-BB type fall into the category of valves for pipes (may be used in piping systemsunderground or over ground) in oil and gas industry.The products fall into the category of accessories for pressure regulation and essential requirements related to

ensuring the safety of users of pressure equipment covered by Government 584/2004 amended (Directive97 / 23 / ECPED)

1.2Technical characteristicThe valves can be classified:Construction: -monoblock type(wlded body) -demontable type(split body)

Installation : -overground

-underground

Type of connection to the process:-with welding ends

-with flanges -with threaded

Nominal diameter or NPS 50-1400 or 2’’-56’’Nominal pressure: 6;10;16;25;40;60;100;150 bar; 600bar ANSI 150, ANSI 300; ANSI 600;ANSI 900Standard temperature ranges : -30C +110C and 0C +200CDimensions according to API 6D or SR EN558-1Standard working environment: neutral or potential corrosive gases and liquids, filtrated, without any solid

particles bigger than 0,1 mm.Special orders: fluids with suspensions; the nature of suspensions and the size of particles has to be mentioned.

Sealing area-The primary sealing is assured by the metal gasket. After the primary gasket is wear the sealing is provided by theViton gasket.Basically the force that assures the pressing of the gaskets is provided only by springs, the gaskets’ sealing diameterlower, in fact equal with the sealing diameter of the metal and the O-ring gaskets.The metal gasket assures the sealing if the O-ring gasket is damaged, at least till the injection of the emergencymoulded gaskets.The force produced by (pressure x valve section) is taken by the bearing system of the ball



Page 3 o

1.3Features

]

Anti blow-aut proof stemconstruction

The stem cannot beextracted or expelledpressure

Antistatic constructionConstant contact betweenmetal parts.

Full bore

Double block and bleedBoth gasket are sealing the bal landthe valve’s chamber can be

depressurized

Fire seif design

Matal/metal sealingAfter fire exposure

Trunnion mounted ballBall with bearing

SEAT SEALAT INJECTION

Emergensy tertiarysealing injection



Page 4 o

2 FUNCTIONAL DESCRIPTION

Shut valve – both sides of the Open valve – the valve’s chamber may becomeball are under the pressure, depressurized to verify the tightness degree the valve’s chamber maybecome depressurized

3. CORROSION PROTECTION

-primer coat- Zinc-rich primer -with special paint which corresponds to a voltage of 25kV verification for valves installed underground-with high strength epoxy for valves mounted above ground

4.ACTUATION-manually with a lever up tp DN100 /over DN 100with reducer or, or electrically, pneumatically, hidro-pneumatically,electro-hidraulically actuator.

5.TESTS- Products are tested by the manufacturer

- Test pressure and loss rates are allowable according to SR EN12266 (without losses) / API598/API6D

6. CODIFICATION

-Coding RSD-BB top entry type is presented in the general product specification 839/2008

Rev.2

7.IDENTIFICATIONEach valve is equipped with label (identification card) that includes:



Page 5 o

-*Depending on the requirements of the technical specification of the beneficiary may appear on the nameplate - nomarking API 6D. License / no marking CE/fire marking test API607 or API 6FA.

8. PACKING, TRANSPORT, STORAGE,8.1 Packing

Each valve must be drained of fluid test.The ends of the body must be covered to prevent foreign bodies and moisture-protective covers are removed onlywhen installing.

The valves are delivered with the obturator in the open position!The packing is designed,made and marked according to the transport and storage conditions contractually agreed,and provide good protection for equipment.

8.2. TransportationDuring transportation, environmental conditions that have influence on the valves are described, according to SR EN60721-3-2, the next series of classes of environmental conditions:2K4/2B2/2C2/2M2(IE23).

8.3. Storage conditionsThe valves should be stored in a clean dry environment and should be left on shipping pallets or in original packingprior to installation.

All flange protectors should remain in place until installation of RSD-BB Valve.

The Valves should be stored in the “FULLY OPEN” position (prevents damage to ball and seats).For the storage of products applies IE12 from Table 7 and described in Annex B of SR.EN 60721-3-1

9. INSTALLATION-OPERATION9.1 Unpacking

All valves should be inspected on receipt for lost or damaged components.

9.2 HandlingBecause of physical dimensions and heavy equipment will be used properly and lifting methods for transport, storageand installation.-valves are furnished in open position, in order to minimize the effect of mechanical loads and impurities on seats,gaskets, and other pressure parts.



Page 6 o

Before handling the valve, verify it is open position. Lift valve with sling suitable for its weight. Never use lever, actuatoor gear operator to lift the valve

9.3Installation.

Inspect the piping system prior to valve installation whenever possible, to insure that it has been properlyflushed and cleared of construction and fabrication debris. The seating surfaces in soft seated valves are particularlysusceptible to weld slag and sand blasting grit. Pipe scale, metal chips and other foreign materials should be removed

Verify that Actuator, and mounting hardware as appropriate were included with the valve and are in goodshape, that proper tagging is in place and any warning labels are eligible and observed .Just prior to installation, remove each valve from its packing and remove any end covers.

Examine the flow bore for debris. All FEPA ball valves are shipped in the open position to prevent damage tothe ball surface. Any grit or foreign matter must be removed. Scratched or damage balls must be replaced. Do notinstall a damaged valve.It is also important to check for valve operation clearances. Valves may be installed in any position using standard pipfitting practices. If possible, mount the valve in such a position that the actuator can, if necessary, be detached withouremoving the valve from the pipeline. The actuator must not touch the pipeline, as pipeline vibrations may damage it o

cause disturbance.Flanged End Valve Installation

After determining that the valve is in good condition, extra attention should be given to the raised face surface. Dentsand heavy scratches should be repaired. At installation make sure that the conditions of : a. Lateral alignment-misalignment: max 2mm flange for.NPS 4”(DN100) including - 3mm misalignment flange max. for. higher NPS 4” (DN100) b. Alignment angle-difference max. Measured between flanges max 2.5mm



Page 7 o

c. Max total misalignment. for allowable holes. org. assembly -2mm flange misalignment: max for NPS 4”(DN100) including - 3mm misalignment flange: max. for higherNPS4”( DN100),are respected. - grease the bolt and nuts to get a correct bolt load. - Tighten the screws criss-cross (to avoid uneven loading gaskets and flanges)

Weld-End Valve InstallationBoth butt-weld and socket -weld valves require special consideration for installation. In addition to the general cautionalready discussed, the heat of welding may damage seats and seals. The valves are mounted in the pipeline by usingstandard welding methods and must be supported during the welding. When welding or annealing the joint, assure thathe temperature of the body in PTFE or rubber sealing material,e.g.120ºC.The increase of temperature can be preven

by wet protection cloth around the body during the welding.

After welding, binding clean compressed air network so as to be removed rust, welding, metal debrisand any foreign body.Foreign bodies of any kind, depreciation overheating welding seen through the paint may compromise thesealing group valves and get product warranty.

Threaded-End Valve Installation After removing the valve from its packing inspect the NPT threads for damage. Occasionally threads may requirechasing prior to installation to remove burrs or other minor imperfections.

Apply a good grade of pipe sealant compound to the male pipeline threads only. Do not use sealant on the femalethreads because excess compound would be forced into the valve body. This could cause sticking of the ball or

encourage the accumulation of dirt and debris that could prevent good valve shutoff.FEPA valves are shipped with a securely fastened nameplate. Information included on each is documented in next fig

Although each valve is thoroughly tested and inspected before it leaves the factory, nameplate could be lost or destroyed during shipment or while in storage. If either is missing or not legible, contact your distributor or the factoryfor assistance before operating valve.

9.4OperationBall valves are intended to be on-off devices operating through 90° rotation of the stem.Gear operated ball valves have an indicator showing the open and closed position of ball. The hand wheel rotatesclockwise to close the valve.Do not leave the ball in a partially opened position, as it will cause severe damage to the ball and seat resulting inleakage.

The most common service failures not related to the installation and start-up processes are:

-exceeding the operating temperature or pressure limits of the valve due to a process upset condition. -a chemical attack on valve components due to either misapplication, or changes in the service.

-violating temperature and pressure limits can result in immediate valve failure where chemical attack or corrosion

generally occurs overtime. Always utilize factory authorized replacement parts.Good operating procedure requires periodic inspection of valves and replacement of necessary parts to ensure propevalve function.NOTE: Valves showing through leakage or high operating torque may be damaged. DO NOT use excessive force or bars to operate valve. Disassemble valve, inspect components, and replace damaged parts.CAUTION: before attempting removal/repair, always cycle valve with system pressure isolated to relieve excepressure which may be trapped in body cavity.

10 .INSTRUCTIONS FOR USE AND MAINTENANCEWorking fluid temperature must not exceed the minimum / maximum inscribed on the valve body or on its label.Working with valves does not require specially qualified personnel.Where it is installed must meet environmental conditions imposed by the materials in valveWill open-close maneuver once a year to avoid blocking valve.Condensate drain is recommended after each actuation (when the valve is equipped with purge)Venting the body cavity is made in the body until the pressure reached atmospheric pressure(when the valve is equipped with ventilation)



Page 8 o

During venting flammable gases can be released! -Make sure that it removes any source offire. Make sure that the exhaust valve does not affect the operator.

Never attempt to open the valve PURGE AND / OR AIR WHILE valve is in the partially openValves are equipped with injection system paste the shaft seal and ball-it provide additional sealing in emergency

cases with damaged sealing surfaces.The use of a suitable injection device and only in emergencies!Position valve works / off operation allowed a position partially open / closed.The manually operated valves: -Closing the valve is rotated clockwise to 90˚. -Do not use bars, pipes, keys or other devices for amplifying lever or handwheel torque -can cause injury anddamage to the valve.We will check the operation of the valve.The manufacturer is not responsible if the valve is not used and maintained properly!

Never attempt to interfere with the valve under pressure!

Revision should be done in appropriate workshops and requires no special tools.

Any violation of instructions will void the warranty!

On stream maintenanceThis section covers maintenance and repair which can be performed without removing valve from the line.When performing any work on this valve, use normal safety precautions to protect yourself against any residual fluid otrapped pressure in the line.With the line under pressure the valve body cavity can be vented to the atmosphere and completely drained down wit

the ball in closed position only. Stem seal replacement can be made –see Annex A

10Spare partsEach valve shall be accompanied by a safety related parts, the method of replacement and specific instructions for assembly and use-Annex A.

11. HEALTH, SAFETY, ENVIRONMENT

- products are designed, manufactured, tested and equipped in the system if necessary, so as to guarantee safety of the user and the environment.- the installation shall comply with all applicable law labor protection- will wear all required personal protective equipment- do not use the valve than the designed parameters-beneficiary will not make changes without consulting the manufacturer / or if the manufacturer recommends- please check before installation if the environmental regulations , safety or other restricting use of the product.- Please firstly return to repair products that have circulated hazardous f luids decontaminated them.

Also any faucet returned must be accompanied by minimal information regarding the conditions of use, changes in th

product, operations decontamination and / or cleaning fluid and safety data sheet- used packaging and waste from the retirement harness the special without regulatory requirements.However please consider conditions of use of the product and to indicate the applicable legislation and packagingequipment.



Page 9 o

12. RISK ANALYSIS

Category risk Causes Consequences Elimination

handling Improper lifting and trasportation Damage valve -correct handling-closely inspecting the downloadand installation

storage Storage in an area

inappropriate

Damage valve -correct storage

-Inspect carefully beforeinstallationImproper installation

- Failure to follow the installation- failure to alignflanges- mounting additionalaccessories

Damage valve- additional charge bolts,gaskets, flanges- additional load risk of rupture

-Installation and preparation for installing them in the correct- check alignment flanges andpipes- do not modify without theagreement manufacturer's

Lose on the shaft O-ringuri Gas leaks in atmosphere -replacement o-rings as spaparts list

Lose to vent andpurge valves,lubricators

-lose valves Gas leaks in atmosphere Check and replace the defectivevalves

Category risk Causes Consequences Elimination

Operation-overcome workingpressure/overcomeworking temperature-external corrosion-internal corrosion-electrical charge

-installation and operating error - environmental or characteristics differ from thoseof technical sheetimproperly working fluid withparticles-electromagnetic induction.-leakage current-electrostatics charge

Damage valve-explosion hazard- bodily injury in contactwith the valveDamage valvedecrease the life of a slave.- Damage valve- electric sparks,sources of ignition

- respect pressure/temperaturecontrolClening periodically valve dustusing working fluid according todata sheetendowment valve antistatic devic

maintenanceimproper fugitive emissionsignation source

used improper spare partsdamage pressure partsused improper /operation failure

- malfunction-lossfire, explosions

design fire use proper working conditions

SC FEPA SAStr.REPUBLICII nr.316, Cod postal 731120, Bârlad-RomâniaTel.+40 0235 411812Fax +40 0235 421 618/0235 413729e-mail: [email protected] / [email protected]





Page 10 of

ANNEX A 1Ball valve RSD-BB 1.1.50.150.1.0.3.0.1.1.1.FB Ball valve RSD-BB 1.1.50.150.1.0.3.0.1.5.1.FB Ball valve RSD-BB 1.1.50.300.1.0.3.0.1.1.1.FB Ball valve RSD-BB 1.1.50.300.1.0.3.0.1.5.1.FB

A1.1 Speare parts list

Ball valve RSD-BB 1.1.50.150.1.0.3.0.1.1.1.FB Ball valve RSD-BB 1.1.50.300.1.0.3.0.1.1.1.F

Ball valve RSD-BB 1.1.50.150.1.0.3.0.1.5.1.FB Ball valve RSD-BB 1.1.50.300.1.0.3.0.1.5.1.FO-ring 20x2.65 -shaft gasket O-ring 23.81x2.65 -shaft gasket

O-ring 23,47x2.62-gland gasket O-ring 26.64x2.62-gland gasket O-ring88.57x2.62-body gasket O-ring88.57x2.62-body gasket

O-ring 53.34x5.33-seat gasket O-ring 53.34x5.33-seat gasket 4024.4350 -seat 4024.4256 -seat

3825.6811 -graphit paking 3825.6786 -graphit pakingO-ring 12.37x2.62 -trunnion gasket O-ring 22.22x2.62 -trunnion gasket

A1.2 On stream maintenanceStem seal replacement can be made on stream (Refer to Assembly drawing fig.1)

FIG.1 ASSEMBLY DRAWING



Page 11 of

The RSD-BB has2 stem seals, one primary seal(poz.38 Graphit paking ) backed up by secondindependent seal (poz19.shaft gasket)1. Turn valve to fully open position.2. Remove the action.3. Remove Extension.(42)4. Remove GLAND [17], and clean gland surfaces.5.Clean and grease GLAND BEARING(poz18)6. Check and replace if necessary GRAPHIT PAKING(poz38).

7. Check and grease if necessary Stem(poz.21)To rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it oall seals.Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions.Reassemble in reverse order ;make sure that is correct alignment of actuation components after re-assembly.

A1.3OFF STREAM MAINTENANCE

Major repairs which necessitate removing the valve from the line equipment.Handling equipment as required for the weight involved.

DISASSEMBLY PROCEDURE(Refer to Assembly Drawing)

1. If the valve is in line, isolate the valve from the line pressure.2. Release the pressure from the inlet and outlet ports.3. Place the valve in the open position. 4. Remove the valve from the line. 5. Remove the action.6.Remove the Extension 6.To disassemble the gland [17], carefully remove theGLAND SEALS[40.38)SPACER [11] , SEGMENTS[10] ,STEMsealing(9,19.20)Axial bearig(8)], then carefully remove STEM [13] 7. Position the valve so that it rests on one port/flange face.8. Remove theSTUD and NUTS [6,7] from the CLOSURE FLANGED [5], lift up the upper end9.remove from the body and place on a clean solid surface.10. Hang the BALL [37] with a strap through the bore, so that the weight of the ball is supported by the strap. Do not lthe whole valve. Remove the Trunnion [35]11. Lift the BALL [37] carefully out from the BODY [12] and place it on a clean solid surface.12. From the end CLOSURES FLANGED[5], disassemble SEAT SUBANSAMBLY [25], SEALS [26] , and SPRINGS[24].

INSPECTION AND CLEANING1. Wipe off metal parts with a soft cloth, using petroleum solvent.2. Inspect metal parts for damage or burrs on all moving surfaces.3. Replace defective parts.NOTE: O-rings are made to stretch with a certain tension around metal shoulder. Any stretching or swelling of o-ringmay cause cutting on re-assembly. Do not re-use orings unless their dimensions are carefully checked against newparts.

LUBRICATION

Lubricate all moving surfaces

RE-ASSEMBLYTo rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it oall seals. Reassemble in revers order ,make sure that is correct alignment of action components after re-assemblyTest the valve



Page 12 of

ANNEX A 2 Ball valve RSD-BB 1.1.80.150.1.0.3.0.1.1.1.FB


Ball valve RSD-BB 1.1.80.150.1.0.3.0.1.1.1.FB

O-ring 28x3.53 -shaft gasketO-ring 31.34x3.53-gland gasket

O-ring1209.24x3.53-body gasket O-ring 75,79x3.53-seat gasket

4024.4352 -seat 3825.4520-1 -graphit paking4024.3776-1 -CHEVRON paking

A2.2 On stream maintenance

Stem seal replacement can be made on stream(Refer to Assembly drawing fig.1)




Page 13 of

The RSD-BB has 3 stem seals, one primary seal(poz.22.CHEVRON paking) backed up by secondindependent seal(poz.21.Graphit paking)and third sealing (poz18.shaft gasket)1. Turn valve to fully open position.2. Remove the action3. Remove Extension(42)4. Remove GLAND [17], and clean gland surfaces.Check the GLAND SEALS (poz18.and 20)clean and replace them are damaged5.Clean and grease GLAND BEARING(poz19)

6. Check and replace if necessary GRAPHIT PAKING (poz21)and CHEVRON PAKING (poz22)7. Check and grease if necessary STEM (poz.24)To rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it oall seals.Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions.Reassemble in reverse order ;make sure that is correct alignment of actuation components after re-assembly.

A2.3 OFF STREAM MAINTENANCE


DISASSEMBLY PROCEDURE

(Refer to Assembly Drawing)1. If the valve is in line, isolate the valve from the line pressure.2. Release the pressure from the inlet and outlet ports.3. Place the valve in the open position. 4. Remove the valve from the line. 5. Remove the action.6.Remove the Extension 6.To disassemble the gland [17], carefully remove theGLAND SEALS[18,20)SPACER [11] , SEGMENTS[10] , ,STEMTHRUST WASHER[23], then carefully remove STEM [24] 7. Position the valve so that it rests on one port/flange face.8. Remove theSTUD and NUTS [6,7] from the CLOSURE FLANGED [5], lift up the upper end9.remove from the body and place on a clean solid surface.10. Hang the BALL [35] with a strap through the bore, so that the weight of the ball is supported by the strap. Do not lthe whole valve. Remove the plate[37]11. Lift the BALL [35] carefully out from the BODY [12] and place it on a clean solid surface.12. From the end CLOSURES FLANGED[5], disassemble SEAT SUBANSAMBLY [30], SEALS [27] , and SPRINGS[29].


LUBRICATIONLubricate all moving surfaces




Page 14 of

ANNEX A 3Ball valve RSD-BB 1.1.50.150.1.0.5.0.1.1.1.FB


Ball valve RSD-BB 1.1.50.150.1.0.3.0.1.1.1.FB

O-ring 20x2.65 -shaft gasketO-ring 23,47x2.62-gland gasket

-Ø95x Ø 90.5 h=3.6 body gaskets(spring energized PTFE seal)-Ø65x Ø 58.8 h=4.8 -seat gasket(spring energized PTFE seal)

4024.4353 -seat 3825.6811 -graphit pakingO-ring 12.37x2.62 -trunnion gasket

A3.2 On stream maintenance

Stem seal replacement can be made on stream (Refer to Assembly drawing fig.1)




Page 15 of

The RSD-BB has2 stem seals, one primary seal(poz.38 Graphit paking ) backed up by secondindependent seal (poz19.shaft gasket)1. Turn valve to fully open position.2. Remove the action.3. Remove Extension.(44)4. Remove GLAND [17], and clean gland surfaces.5.Clean and grease GLAND BEARING(poz18)6. Check and replace if necessary GRAPHIT PAKING(poz38).7. Check and grease if necessary Stem(poz.21)

To rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it oall seals.Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions.Reassemble in reverse order ;make sure that is correct alignment of actuation components after re-assembly.

A3.3 OFF STREAM MAINTENANCE


DISASSEMBLY PROCEDURE(Refer to Assembly Drawing)1. If the valve is in line, isolate the valve from the line pressure.

2. Release the pressure from the inlet and outlet ports.3. Place the valve in the open position. 4. Remove the valve from the line. 5. Remove the action.6.Remove the Extension 6.To disassemble the gland [17], carefully remove theGLAND SEALS[40.38)SPACER [11] , SEGMENTS[10] ,STEMsealing(9,19.20)Axial bearig(8)], then carefully remove STEM [21] 7. Position the valve so that it rests on one port/flange face.8. Remove theSTUD and NUTS [6,7] from the CLOSURE FLANGED [5], lift up the upper end9 .Remove from the body and place on a clean solid surface.10. Hang the BALL [37] with a strap through the bore, so that the weight of the ball is supported by the strap. Do not lthe whole valve. Remove the Trunnion [35]11. Lift the BALL [37] carefully out from the BODY [12] and place it on a clean solid surface.12. From the end CLOSURES FLANGED[5], disassemble SEAT SUBANSAMBLY [25], SEALS [26] , and SPRINGS[24].


LUBRICATIONLubricate all moving surfaces


Documents

IOM RSD-BB