Page 1
USER’S MANUAL
Issue date : 1/27/2009
INSTRUCTIONS
FOR OPERATION AND MAINTENANCE
OF
RECIPROCATING PUMPS FOR LIQUEFIED GASES FOR HIGH PRESSURES
Type:
SDPD 30/32-K
Comm. No.:
ECC48536-01/02/03
Order No.:
1010 Dated 10 NOV 08
Customer:
ABSOLUTE ZERO
AURORA – IL 60505
USA
The purpose of these instructions is to facilitate the operation of your pump and to avoid errors.
Reading these instructions carefully before installation and start-up means safe-guarding your
interests and will be repaid by satisfactory service and performance of the machine and low
cost of repair.
We recommend you to keep on stock all spare parts mentioned in these instructions and would
be grateful if, when placing orders for spares, you would use our designation and indicate the
number of your pump. You will find the machine number on the name plate of each pump.
Orders can be placed at :
Sales and service departments
Cryostar-USA
5897 Colony Drive
Bethlehem, PA 18017
Manufacturer
Cryostar-USA
13117 Meyer Road
Whittier, CA 90605
Telephone:
fax:
Telephone:
fax:
(484) 281-3401
(484) 281-3402
(562) 903-1290
(562) 903-4511
Page 2
USER’S MANUAL
Issue date : 1/27/2009
GLOBAL LOCATIONS
CRYOSTAR – FRANCE S.A.
GLOBAL HEADQUARTERS
Zone Industrielle
B.P. 48
Hesingue
F-68221 HEGENHEIM CEDEX
Tel: +33(3) 89 70 27 27
Fax: +33(3) 80 67 59 54
CRYOSTAR SINGAPORE
CRYOSTAR UK
203 Henderson Road
Blk B# 10-09
Henderson Industrial Park
SGP - SINGAPORE 159546
Tel: +65 276 7441
Fax: +65 276 7442
Station Road, Industrial Estate
Unit 4+5
GB - WOMBWELL, Barnsley
S73 OHA, S. Yorkshire
Tel: +44 1226 759 921
Fax: +44 1226 756 729
USER RESPONSIBILITY
This equipment will perform in accordance with the instructions and information contained in this manual, and its
referenced documents, when such equipment is installed, operated and maintained in compliance with such
instructions. The equipment must be checked periodically. Defective equipment shall not be used. Parts that are
brocken, missing, plainly worn, distorted or contaminated shall be replaced immediately. Should such repair or
replacement become necessary, CRYOSTAR recommends that a request for service will be made. We
recommend you to keep on stock all spare parts mentioned in these instructions. At the end of the manual we
indicate how to put in an ordre for spares.
The equipment, or any of its parts, shall not be altered without the prior written approval of CRYOSTAR. The user
and /or purchaser of this equipment shall have the sole responsibility for any malfunction which results from
improper use, faulty maintenance, damage, the use of spare parts that are not from CRYOSTAR, improper repair
or alteration by any party other than the manufacturer.
Attention
It is essential to read the directions for use prior to unpacking and installation.
Moreover, the machine must be used and maintained by qualified personnel.
Note
This document is the property of Cryostar. It is not permitted to copy it, or to relate its contents to other persons,
or to misuse it in any other way.
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USER’S MANUAL
Issue date : 1/27/2009
TABLE OF CONTENTS
1.
1.1.
1.2.
1.3.
1.4.
2.
2.1.
3.
3.1.
3.2.
TECHNICAL DATA
6
Pump Data
Operating data
Acoustic pressure
Test
6
6
6
6
GENERAL
Description of the Design
SAFETY
Warning
Isolation and energy dissipation
3.2.1.
3.2.2.
3.2.3.
3.3.
3.4.
4.
4.1.
4.2.
4.3.
4.4.
5.
5.1.
5.2.
Safety form for oxygen pump
Customer safety instructions - Summary
STORAGE OF THE EQUIPMENT PRIOR TO INSTALLATION
Cryostar Delivery Inspection
Degreasing and Lubricating Grease/Oil for Oxygen Duty
Inspection by Customers on Arrival
Storage of the Pump
INSTALLATION
Handling
Erection
5.2.1.
5.3.
5.4.
5.5.
Isolation and dissipation of gas process energy
Isolation and dissipation of purging gas energy
Isolation and dissipation of electrical energy
Protection Hood
Installation Scheme
Storage Tank
Piping
5.5.1.
5.5.2.
5.5.3.
5.5.4.
5.5.5.
Option : Control Panel
Suction Line
Design of the Suction Line
Gas Vent Lines
N2-Purging
6
6
8
8
10
10
10
10
11
13
15
15
15
15
15
16
16
16
16
17
17
18
18
18
19
20
21
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USER’S MANUAL
Issue date : 1/27/2009
5.5.6.
5.6.
6.
LUBRICATION
6.1.
6.2.
7.
Crank Drive
Grease characteristics
START-UP
7.1.
7.2.
7.3.
7.4.
8.
Pre-Start-up Inspection
Direction of rotation
Start-up of the Pump
Shutdown of the Pump
TROUBLE SHOOTING
8.1.
9.
Discharge Line
Valves and Fittings
Malfunction of the Pump
MAINTENANCE INSTRUCTIONS
9.1.
General
9.1.1.
9.2.
9.3.
9.4.
9.5.
9.6.
9.7.
9.8.
9.9.
9.10.
Assembly / Disassembly : Table of tightening torques and forces
Vacuum chamber
Removal of the Cold End from the Crank Drive
Fitting of the Cold End at the Crank Drive
Dismantling of the Cold End
Assembly of the Cold End (see drawing 'Cold End')
Assembly of the Cold End (continuation)
Dismantling of the Crank Drive
Assembly of the Crank Drive
Belt/Pulley Assembly (reference)
9.10.1. Bushing and Sprocket Assembly / Removal
9.10.2. Checking alignment and Belt tensioning
9.11.
9.12.
Crosshead Assembly
Crank Drive Regrease and Maintenance
9.12.1. Pump / Crank Drive
21
23
24
24
25
26
26
27
27
28
30
30
31
31
32
33
34
34
35
35
36
36
37
38
38
39
42
43
43
10. CRYOSTAR’S MAINTENANCE AND SPARE PARTS SERVICE
44
10.1.
44
Order Instructions
11. ANNEX
45
11.1.
11.2.
45
47
NPSH
Appendix to spare parts lists
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USER’S MANUAL
Issue date : 1/27/2009
LIST OF DRAWINGS AND OTHER ENCLOSURES
DRAWING TITLE
DRAWING
NUMBER
Handling drawing
Performance diagram
Cold End
Pump assembly
Valve assembly
Suction adapter
Crank drive assembly
Crank drive casing
Crosshead assembly
Skid assembly matrix
Electrical Schematic
Installation drawing
Special tools
Checklist
Spares kit Cold End
Spares kit Crank Drive
708111523
700062202
760150540
760154426
760020197
760139933
770023849
760024426
760021920
760154076-06
760154070-02
702150550
709042082
706100945
SPARE PART
LIST NUMBER
E – 760150540
E – 760154426
E – 760020197
E – 760139933
E – 770023849
E – 760024426
E – 760021920
E – 760154076-06
E-770024217-SE
E-770023849-WP
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USER’S MANUAL
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1.
TECHNICAL DATA
1.1.
Pump Data
Serial number
Type
Piston Diameter
Stroke
Speed
Year / Month built
1.2.
Operating data
Medium
Flow rate
Discharge Pressure
Power consumption
1.3.
LOX/LIN/LAR
7.5 l/min (2.0 gpm)
240 bar (3500 psig)
11.0 kW (15 hp)
Acoustic pressure
Average value
1.4.
ECC48536-01
SDPD30/32 ‘Independence’
32 mm
30 mm
390 rpm
2008-12
≈ 85 dB A
Test
Medium
Test speed
Nitrogen
Note : Working data have been measured at the test stand.
The test allows pressure to be checked under cryogenic working conditions.
2.
GENERAL
2.1.
Description of the Design
The pump is a single-action mono cylinder reciprocating pump.
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The pump is delivered, mounted as a compact unit coupled with an electrical
motor on a base frame, but may be equipped with different kinds of drives.
The piston is coupled to a crosshead driven by a connecting rod which is in turn
driven by an eccentric.
Maintenance is facilitated by different parts such as the cold end or the crank
drive being easily dismantled.
The direction of rotation of the motor does not matter. The machine may be
operated in both directions.
These instructions contain a description of the pump, as well as complete
descriptions of installation, operation and maintenance of the pump.
The function of the reciprocating pump unit is to increase pressure in cylinder
filling stations systems i.e. with tank, vaporizer, trim heater.
Option
To adapt the pumping unit to the required flow rate and pressure, a frequency
converter may be installed.
Depending on the scope of supply, the reciprocating pump unit is delivered with a pulsation
dampener, suction line, discharge line, suction filter, safety valves, shut-off valves, vent valves,
flexible gas return line, pressure gauges, differential pressure switch ...
If the scope of supply comprises a trim heater, please also refer to the trim heater instructions.
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3.
SAFETY
3.1.
Warning
Safety norms applied on site must be scrupulously respected. The
enforcement of a safety area will limit access to authorized personnel only.
Any operation on equipment in use is prohibited
Any operation on equipment in use is prohibited
Any normal operation must be made according to the recommendations in
the instructions
Any repairs must be made according to the recommendations in the
instructions
FATAL OR MOST SERIOUS INJURIES MAY OCCUR IF SERVICE
PERSONNEL DO NOT FOLLOW THE SAFETY REGULATIONS
High voltage is applied in the operation of this equipment.
The use of liquid gases or gases under high pressure has high risk factors if
service personnel do not follow safety regulations.
Fatal or most serious injuries, fire, explosions or suffocation may occur
depending on the liquid gas used in the system. Please, refer to the motor
instructions
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Explosion hazard in the presence of oxygen
Cleaning and degreasing for use with oxygen
All components and equipment must be cleaned and degreased and must be
safe for use with oxygen.
After cleaning and degreasing, the components and equipment should be sealed
and protected against contamination. The sealing and protection should not be
removed until immediately before installation. Consult Cryostar.
Explosion hazard in the presence of oxygen !
Carefully remove all degreasing fluid, which may also be extremely
hazardous in the presence of oxygen!
For obvious technical reasons linked to ice formation, it is not possible to
completely isolate all pump components.
Burning hazard !
During cool-down and working periods, it is strictly forbidden to touch the
machine
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Our products must be handled with a handling system. Please, refer to the
Installation scheme
3.2.
Isolation and energy dissipation
(Maintenance)
Our products must be installed in a unit which ensures all functions of
cutting, separation, locking, pressure purging and checking
All energy external to our product originating from the customer (electricity,
purging gas, compressed air, N2-purging, etc...) must be isolated and dissipated
by means of isolating switches (hand operated valves with padlocks, locking
electric switches..). Gas line valves must be chosen carefully so as to permit a
VOLUNTARY locking or unlocking of the user with valve isolation.
3.2.1. Isolation and dissipation of gas process energy
Components and instruments which permit the isolation and the dissipation of the
gas process energy depend on the users internal procedures of isolation and
energy dissipation and the parameters of their networks. Thus, it is not possible
for CRYOSTAR to plan the installation of this type of equipment on the supplied
machine.
3.2.2. Isolation and dissipation of purging gas energy
The user must ensure that all purging pipes have been isolated before any
operation on the product.
3.2.3. Isolation and dissipation of electrical energy
Before each operation on parts or equipment normally under voltage, the
personnel must isolate them when the equipment is at a standstill.
- Cut off and separate the equipment from the supply source by switching off.
- Lock the switch in a separation position with a padlock or any equivalent locking
device. The locking switch must be in an open position.
- Before operation, check that there is no more accumulated residual voltage
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(Note : All orange colored electrical circuit of the electrical equipment supplied by
CRYOSTAR remain permanently under voltage).
All electrical operation should be carried out by trained and authorized
personnel. The electrical connections must be connected by trained and
empowered personnel who must respect the local regulations and
protection rules in force.
3.3.
Safety form for oxygen pump
Physical properties:
Formula :
O2
Atomic number
Z=8
Molecular weight :
31.9988 g.mole-1
Molecular dimensions :
4,2-2,8Å
First ionization potential :
12.059 eV
Gas density S.T.P. :
1,4289 kg.m-3
Oxygen is a gas colorless, odorless and tasteless.
Working recommendations
Oil and grease stained clothing must not be worn.
Greasy rags should not be left lying about and the floor must be free of oil stains.
Work with flame should be avoided in the enclosure of the pump.
No smoking near the pump.
Recommendations in case of accident (fires, burns)
In case of clothing fires, it is essential to act with maximum speed.
Water is still the best extinguisher in several cases. Hence quick action with a shower,
bath or extinguisher is necessary. It appears that hasty wrapping in a blanket is of
doubtful effectiveness.
First aid for burn victims (low temperatures of liquid oxygen)
Burns of this type are generally local.
Burnt parts of the body should be warmed gradually and then treated as conventional
burns.
While awaiting the doctor, carry out the following first aid measures :
If large blisters have been formed on the skin or if the eyes are suffering from burns,
immerse the burnt area in water or apply cold compresses, and convey the victim to a
doctor.
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If the injury is less serious (spattering on the skin, small blisters), immerse the burned
area in cold water until the pain stops, coat the area with Vaseline and keep it wet for
24 hours by means of a cold 30 g/l boric acid solution.
Do not pierce the blisters.
Do not touch or undress the victim
Do not speak to the victim face to face
If possible, wrap burnt parts of the body in sterilized compresses
Always summon a doctor immediately.
Cover the victim with a sterilized blanket.
Leak detection and analysis :
Before employing a pump intended for use with pressurized oxygen, test the assembly
with a leak detector according to the regulations.
The atmosphere surrounding an installation containing oxygen must be monitored for
oxygen concentration.
Any rise in the latter considerably increase the risk of accident. Portable oxygen
analyzers may be employed.
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3.4.
Customer safety instructions - Summary
WARNING
All operations must be carried out by
appropriately trained personnel
AVERTISSEMENT
Toutes les interventions doivent être
effectuées par un personnel habilité
ACHTUNG
Alle Arbeiten müssen von
entsprechend geschultem Personal
ausgeführt werden
Gases and liquid under high pressure
Gaz et liquides sous haute pression
Flüssigkeiten und Gase unter hohem
Druck
LIFTING
Vertical lifting : prevent uncontrolled
rotation
LEVAGE
Levage vertical : Empêcher toute
rotation non contrôlée
HEBEN
Senkrechtes Heben : unkontrolliertes
Drehen vermeiden
PRE-INSTALLATION CHECKS
CONTRÔLES AVANT
INSTALLATION
Toute pompe doit être contrôlée dès
réception
UEBERPRUEFUNGEN VOR DER
INSTALLATION
Jede Pumpe sollte unverzüglich nach
Ankunft untersucht werden
Check nameplate details
Vérifier les informations sur la plaque
signalétique
Typenschilddetails prüfen
Check stored equipment every 6
months
Vérifier le matériel entreposé tous les
6 mois
Gelagertes Material alle 6 Monate
kontrollieren
No loose fasteners
Pas de fixations desserrées
Keine losen Befestigungen
MECHANICAL INSTALLATION
Refer to instructions
INSTALLATION MECANIQUE
Se reporter au manuel d’instructions
MECHANISCHE INSTALLATION
Siehe Betriebsanleitung
ELECTRICAL INSTALLATION
All operations must be carried out by
appropriately trained personnel
INSTALLATION ELECTRIQUE
Toutes les interventions doivent être
effectuées par un personnel habilité
ELEKTRISCHE INSTALLATION
Alle Arbeiten müssen von
entsprechend geschultem Personal
ausgeführt werden
Earthed
Mise à la terre
geerdet
Check rotation, uncoupled
Vérifier la rotation à vide
Maschine in Leerlauf prüfen
Connections are tight ?
Les connexions sont-elles serrées ?
Sind die Anschlüsse fest angezogen ?
Covers must be fitted
Les capots de protection des boîtes à
borne doivent être en place
Abdeckungen der Klemmenkasten
müssen angebracht sein
Fused and isolated correctly
Protégé par coupe circuit et isolé
correctement
Korrekt abgesichert und isoliert
Every control box with a heating band
must be ‘’on ‘
Toute armoire électrique équipée
d’une résistance chauffante doit rester
sous tension
Jeder Elektro-Schrank mit Heizband
muss unter Spannung sein
Respect tightness of the control box
Respecter l’étanchéité de l’armoire
Beim Anschlussen des Elektro-
Every pump should be checked
immediately upon delivery
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while cabling
électrique lors du câblage
Schrank Dichtheit beachten
Shut front protection covers after use
Veiller à fermer les capots de
protection en façade après utilisation
CONNEXIONS
Vérifier le schéma de câblage
Nach dem Gebrauch vordere
Abdeckungen zumachen
ANSCHLUESSE
Anschlüsse nach Anschlussplan
überprüfen
Check driven equipment is free
Vérifier que la machine entraînée soit
libre
Prüfen, ob angetriebene Maschine frei
beweglich ist
Correct terminal arrangement
Vérifier le repérage des bornes
Auf einwandfreien elektrischen
Anschluss achten
PROBLEMS
Refer to instructions manual
PROBLEMES
Se reporter au manuel d’instructions
PROBLEME
Siehe Betriebsanleitungen
Pressure drop
Perte de charge
Druckverlust
Heat inleak
Pénétration de chaleur
Wärmeeinfall
Gas formation
Poche de gaz
Gasbildung
Additional forces
Contraintes mécaniques
supplémentaires
Zusätzliche Krafteinwirkung
Pump or seal failure
MAINTENANCE
Isolate
Risques de détérioration de la pompe
et des joints
ENTRETIEN
isoler
Schadensgefahr für die Pumpe und
Dichtungen
WARTUNG
trennen
Refer to supplier for details of
greasing etc...
Pour les détails de lubrification etc..
consulter le fournisseur
Schmierung usw. siehe
Herstellungsangaben
SPARES
Refer to supplier
PIECES DE RECHANGE
Consulter le fournisseur
ERSATZTEILE
An Hersteller wenden
Quote equipment number, stock
number, designation
Indiquer le numéro de la machine, le
numéro de plan de la pièce, la
désignation
Maschinennummer,
Zeichnungsnummer, Benennung
angeben
HAZARDOUS AREAS
All operations must be carried out by
appropriately trained personnel
ZONES DANGEREUSES
Toutes les interventions doivent être
effectuées par un personnel habilité
GEFAHRENBEREICHE
Alle Arbeiten müssen von
entsprechend geschultem Personal
ausgeführt werden
Refer to:
construction standard EN 294
Se reporter à:
norme de construction EN 294
Bitte nachschlagen in :
Baunorme EN 294
STORAGE
Storage in a dry environment
the right way round
STOCKAGE
Stockage en lieu sec
à l’endroit
LAGERUNG
Lagerung in trockenem Raum
Richtig stellen
CONNECTIONS
Check connection diagram
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4.
STORAGE OF THE EQUIPMENT PRIOR TO INSTALLATION
4.1.
Cryostar Delivery Inspection
Every pump undergoes a trial operation with liquid nitrogen before leaving our
works, hence only perfectly functioning machines are delivered from our factory.
4.2.
Degreasing and Lubricating Grease/Oil for Oxygen Duty
Pumps labeled 'degreased for running with oxygen' may be run with oxygen
without further treatment. They are delivered with a grease/oil suitable for oxygen
service. Pumps delivered, by customer request, with mineral grease, are labeled
'not for oxygen'.
4.3.
Inspection by Customers on Arrival
Every pump should be checked immediately upon delivery, and any damages
incurred during transportation should be reported immediately to the transporters
or to Cryostar. Refer to Sales Conditions, Incoterms, Issue 1990.
4.4.
Storage of the Pump
If the pump is not for immediate use, it must be stored in a dry environment,
protected from oil, dust and water.
Important: The polyethylene wrapping around the pump, and the protective covers on the
pipe connections should only be removed immediately before installation.
CAUTION: Check stored equipment and spare parts at regular intervals e.g. every six
months at minimum. Any moisture, dust, rust etc. must be removed before use.
Note, parts for oxygen service, which are stored or installed for more then six
months prior to use must be dismantled and checked carefully prior to start-up.
The time period given above is our recommendation only and must be adapted
to the users own safety regulations. Fatal or most serious injuries may occur if
service personnel do not follow the safety regulations.
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5.
INSTALLATION
5.1.
Handling
Every machine that weights more than 55 kg must only be handled with a
Handling System. Refer to drawing 702 111523.
5.2.
Erection
Place skid on a flat surface that has been prepared according to the dimensional
layout drawing and capable of supporting the indicated load.
Secure the skid to the surface with the required amount and size of bolts as
indicated in the foundation drawing. The skid to be preferably grouted to limit
vibration. The stability of the whole installation must be ensured.
5.2.1. Protection Hood
At the installation, make sure that the hood can be opened above the pump.
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H
H + 200
A-SDPD
5.3.
Installation Scheme
The enclosed installation schematic drawing and operating instructions on the
following pages apply in normal operating circumstances only. Therefore, they
are relatively general and only the most important points for all different service
applications are mentioned. The installation schematic drawing shows only
indispensable equipment and piping for the operation of a pump for liquefied
gases and should be completed accordingly for different applications.
5.4.
Storage Tank
Most suitable is a pressurized storage tank which maintains the required NPSH
of the pump (Please, refer to the Annex). The machine must be installed as close
as possible from the tank.
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The tank discharge connection should be in the bottom of the tank and short. A
siphon or plunging pipe is unsuitable as gas, which is formed in the line, is
collected and cannot leave the pipe.
The diameter of the tank discharge connection should be adjusted to the flow. It
should not be too small (minimum diameter same as the pump suction
connection) to keep the pressure drop small.
5.5.
Piping
Piping must be carefully designed so as not to transmit any stresses or forces to
the pump during operation or during stand still. Thermal contractions and
elongation must also be taken into consideration. Flexible pipe parts and if
necessary an expansion joint should be installed to avoid any transmission of
vibrations to the pump or excessive stresses on the pump flanges.
5.5.1. Option : Control Panel
If a control panel is loose supplied, the length of the piping connection to the
pump must be lower than 2 meters and the number of bends reduced as a
minimum.
5.5.2. Suction Line
The suction line connects the tank discharge and the pump suction connection
and should be as direct and as short as possible.
CLASSICAL INSTALLATION K
The suction pipe between the tank outlet and the pump has a 10° constant
downward slope whereas the gas return pipe between the pump and the top of
the tank has a 10° constant upward slope to allow the forthcoming gas to return
to the tank by one of the pipes. The gas return pipe is linked to the gaseous
phase of the tank in order to optimize the installation. Please, refer to connection
principle.
THERMOSIPHON INSTALLATION T
The suction pipe between the tank outlet and the pump has a 5° constant upward
slope. The return gas pipe between the pump and the bottom of the tank has a
10° constant upward slope. This ‘loop’ installation allows the forthcoming gas to
return to the tank only by the return pipe. It allows a flash gas venting. It is
imperative to be respectful of the angles and slopes recommended for the pipes
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so as to obtain a good circulation of the liquid. Please, refer to connection
principle.
The pipe diameter should be selected and designed for flow with an average
velocity of approx. 1 m/sec. Smaller velocities reduce the pressure drop, but
disadvantageously increase heat inleak accordingly. This reduces the available
NPSH (see §. NPSH) and increases the gas vaporization loss during the cool
down period.
• A velocity below 0.5 m/s increases the heat inleak.
• A velocity above 1.5 m/s draws too much pressure losses.
Good insulation is therefore essential. But it should not hinder the movements of
flexible pipe parts (flexible hose).
In view of gas vaporization losses the shut-off valves and the filter should not
be too large, as larger sizes mean increased heat inleak and a longer cool down
period.
All the pumps must be protected against foreign particles by a filter in the suction
line. Particles, which enter the pump are a potential fire or explosion hazard.
The filter should have approx. 150 micron mesh and the useful surface should
be two times the suction pipe area at minimum.
Manifolds without a constant liquid flow should be shut-off as close as possible
to the branch in order to minimize the liquid gas vaporization.
All piping sections which could be shut-off must be equipped with safety valves
to avoid excessive pressure increase due to the vaporization of liquid gas.
Caution : One liquid feeding line per pump is recommended. Several pumps on
the same piping can be disturbed by preferential flows, turbulence, insufficient
liquid supply or severe heat inleaks.
5.5.3. Design of the Suction Line
Installation of the Suction Line
• The pipe must be as short and direct as possible
• Well insulated and applying no force to the pump
• Same diameter as the pump suction connection (also fittings and valves)
• Fitting and valves limited to a minimum
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Required Fittings and Valves
• Shut-off valve
• Safety valve
• Flexible pipe section
• Filter for oxygen service
• Non-return valve on the pump discharge
Recommendations
• Shut-off valve in every branch
• Pressure gauge
• Gradual pipe diameter changes
• Oblique branch connections
• Filter even for non oxygen service
• Insulation
Caution
All pipes that can be shut or isolated must be equipped with safety systems so
as to avoid any overpressure due to liquid pressurization.
Possible Installation Errors
Abrupt pipe or valve diameter changes
Narrow bends, T-branches
Long pipe without insulation
Branch shut-off valve not close enough
Branch pipe insulation
High point in the line
Flexible bend
Lack of filter or safety valve
Bad anchorage of pump
Problem
Pressure drop
Pressure drop
Pressure drop and heat leak
Gas formation, gas will be sucked into the
pump or the suction line will become clogged
Gas accumulation, gas bubbles will be sucked
into the pump or the suction line will become
clogged
Additional force
Pump or seal failure possible
Pump failure possible
Note: Pressure drop, heat leak = lowers the available NPSH
5.5.4. Gas Vent Lines
The vent pipe should have at least the same diameter as the vent connection of
the pump. The pipe should have no siphons between the pump and the gas side
of the tank and should be properly supported so as not to transmit any forces to
the pump.
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5.5.5. N2-Purging
Connections for a nitrogen gas purge are provided on the crank drive. If the pump
is flooded and doesn't convey for more than 15 minutes an N2 purge is
necessary. This prevents damage to the low pressure gaskets due to the
formation of ice crystals. The gas consumption must be approximately 1 Nm3/h
and the pressure of the gas purge must be between 0.05 and 0.1 barg. The outlet
connections of the N2 purge must be fully opened during the operation of the
pump.
Important : When the pump is stopped, a N2 purge is always necessary to
prevent any humidity entering the crank drive.
5.5.6. Discharge Line
The discharge pipe should have the same diameter as the discharge connection
of the pump, or somewhat larger for pipes of more than 3m in length. A pulsation
damper should be connected to the discharge pipe, as close as possible to the
discharge connection of the pump. In the case of multiple cylinder pumps, the
discharge connections should be combined in a collector close to the cylinders
and then enter the pulsation damper. The pulsation damper should be connected
to the collector. A vent valve to facilitate starting, a shut-off valve, a non-return
valve, a safety valve, a manometer and a pressure switch can be installed in the
discharge line. A safety valve must be installed between the pump and any
device such a valve or a non-return valve, which could be clogged or un-open for
any reason.
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CLASSICAL INSTALLATION
CONNECTION PRINCIPLE for A-SDPD / A-GDPD
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Issue date : 1/27/2009
THERMOSIPHON INSTALLATION
CONNECTION PRINCIPLE for A-SDPD / A-GDPD
5.6.
Valves and Fittings
All valves, fittings, filters, manometers, etc.. must be adapted to a company’s own
internal safety regulations and must also correspond to health-safety legislation.
For any damages caused by unsuitable assembly of the piping system,
CRYOSTAR cannot be held responsible.
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6.
LUBRICATION
6.1.
Crank Drive
To lubricate the crank drive the following greases should be used:
for oxygen service
Bearings Krytox 283 AC
*for argon, nitrogen or
Bearings Lithium Grease (SKF 65-2) or
Krytox 283 AC
hydrocarbon service
*To avoid any confusion CRYOSTAR always pre-lubricate with Krytox 283 AC.
When assembling the cold end and the crank drive the same grease must be
used for all connections.
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6.2.
Grease characteristics
CHARACTERISTICS
KRYTOX 283 AC
UNIT AVERAGE
VALUE
cSt
270
Viscosity of base oil at 38°C
Vapor Pressure of Base oil
at 38°C
at 260°C
Volatility of Base oil Weight loss after
61/2 hours at 204°C
Penetration after 60 strokes 10 to
25°C
Mechanical Stability after
2 hours roll
100000 strokes
Evaporation, Weight loss in 22 hours
at 204°C
at 260°C
Oxidation Stability, after 600 hours at
99°C
Liquid Oxygen Impact
Density at 25°C
Oil separation, Weight loss in 30 hours
at 99°C
at 204°C
Water resistant
Weight loss at 80°C
Wear prevention characteristics 4ball test (during 1 hour, 1200 tr/min)
cap diameter
Load (Kg)
0
10
20
30
40
Torr
Torr
8x10-8
2x10-8
%
mm
1
MIN
MA
X.
TEST METHOD
ASTM D 445
Knudsen
ASTM D972 Mod.
%
%
bar
1
6
0
g/cm3
yes
1.97
%
%
3
13
%
-
265
295
ASTM D217
290
300
330
320
ASTM D1831
ASTM D 217
FTMS 791B,
350.1
ASTM D942
ASTM D2512
FTMS 791B,
321.2
mm
Temp. °C
204
204
204
121
0
0.3
0.5
0.7
0.9
Used oil or grease
Used oil or grease may contain hazardous constituents. Handle with care. Skin
contact should be avoided. Reprocessing and elimination should be made
according to regulations in force.
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7.
START-UP
7.1.
Pre-Start-up Inspection
Check all pipes, fittings, fixing bolts and electrical connections are ready for startup :
1. Check connections of your pump
2. Check motor connection according to voltage
3. Check if the flexible lines are dry
4. Check that there is no siphon in the suction pipes
5. Check that the gas return line has a constant upwards inclination to the tank
6. If there is a pressure switch, check the triggering pressure (setting if
necessary)
7. If there is a control box, check or adjust the safety parameters (setting if
necessary)
8. Check the tightening of high pressure connections
9. If necessary, check temperature probes and heaters connections
CAUTION
BEFORE OPERATING THE PUMP, SUCTION LINE,
DISCHARGE LINE AND PUMP SHOULD BE PURGED WITH
DRY GAS SO AS TO PREVENT HUMIDITY OR ICE FROM
BUILDING-UP IN THE PUMP DURING THE COOL DOWN
PERIOD
Check that the high-pressure system and if necessary, the trim heater and the
vaporizer are also ready for start-up.
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7.2.
Direction of rotation
The machine may rotate in either direction. The direction of rotation may be
changed periodically (after about 500 hours), to ensure a longer lifetime for the
pump.
7.3.
Start-up of the Pump
(Refer to Drawing 'Reciprocating pump unit’)
Protective clothes, spectacles etc... according to « On-Site » regulations
Do not touch the equipment while in use
Note : If the pump has a crank drive purging system, it can be run without
stopping.
Classical installation, K POSITION :
To cool the pump, slowly open the suction valve, the gas return valve and the
discharge valve. The fluid will flow into the pump through the suction line, and a
mixture of gas and liquid will flow back to the tank through the gas return line.
During pump cool down the pressure in the storage tank will build up. After a
cooling time of about 15 minutes*, the pump can be started, valves still fully open.
Thermosyphon installation, T POSITION :
To cool down the pump, slowly open the suction valve and the valve on the gas
return line situated between the pump and the storage tank. The fluid will flow
into the pump through the suction line. A flow will be produced by thermosyphon
effects and the reheated liquid will return into the liquid phase of the storage tank.
After a cooling down time of about 5 minutes*, the pump can be started. Valves
are still fully open.
* Period: for information only. Refer to ‘electrical start-up’.
Note : For high pressure (Psuction > 7 barg), the suction must be progressively opened in
order to prevent the liquid from coming up roughly into the tightness systems.
------------------
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Important : If the system has an automatic or a manual vent valve, it should be
opened during 10 to 20 seconds at pump start-up.
----------------After priming and start up of the pump, the following should be observed:
a) The pressure pipe to the vaporizer begins to show frost
b) A slight pulsing noise becomes audible, which indicates that the valves are
functioning
c) The manometer in the pressure pipe shows an increasing pressure
If the pump does not prime, it must be stopped and cooled down further. If it still
does not prime, or if the priming is lost when pumping, the tank pressure (NPSH)
must be increased.
Check that frost doesn’t reach driving parts. In that case, purge with hot nitrogen.
After correct start-up the gas return valve can be partially closed, so that only gas
collected in the suction chamber is vented and there is no unnecessary
vaporization in the gas return line.
Warning
As the pump is a reciprocating pump, pressures of more than 1500 bars may
build up if the pressure pipe is closed thus: there must always be a safety valve
in the pressure line.
If the pump makes strange noises or shows excessive pressure in the
pressure line, it must be stopped and the cause investigated.
7.4.
Shutdown of the Pump
For shutdown this sequence should be followed:
Installation K
1.Press upon the button "Pump off"
2.Close the tank suction valve
3.Completely open the tank gas return line valve
4.If the installation is equipped with a high pressure discharge valve, close it
5.Open the high pressure vent valve
6.After the pump has been defrosted, close the vent valve
Installation T
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1.Press upon the button "Pump off"
2.Close the suction valve
3.If the installation is equipped with a high pressure discharge valve, close the
valve
4.Completely open the tank gas return line valve
DANGER
Venting the pump discharge line is imperative
If the discharge line has not been vented, the liquid remaining after use of the
pump transforms into gas, what may cause a high pressure and damage the
discharge valve and the piston rings
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8.
TROUBLE SHOOTING
8.1.
Malfunction of the Pump
Problem
Pump does not prime,
or the priming is lost
Probable Cause
Insufficient cool-down of
the pump or insufficient
suction pressure
(insufficient NPSH)
Gas vent pipe shut-off
Trouble Shooting
Continue the cool-down or
increase suction pressure,
tank pressure
Contamination in the
pump
Purge interior components with
clean, dry gas or dismantle and
clean thoroughly
Increase speed to normal
value (where this is possible)
check belts
Revise cold end
clean filter, check valves or
replace
Works too slowly
Leakage form the lowpressure packing
Excessive noise or too
high a temperature at the
crank drive
Vibrations
Worn-out parts
clogged filter, stuck
suction valve or
discharge valve
Gas in the liquid
Worn-out packing, piston
ring or O-ring
Overloaded
Worn-out or damaged
parts (Bearings)
Insufficient suction
pressure, cavitation
Pump not secured
Open gas vent valve to tank
check pipes
Replace packing, piston ring,
O-ring or change cold end
Decrease discharge pressure
stop the pump, repair or
replace
Increase suction pressure
Re-tighten the pump on the
skid
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9.
MAINTENANCE INSTRUCTIONS
9.1.
General
Although the pump design incorporates both simplicity and reliability, it is not
recommended or practical to attempt to completely overhaul it due to the close
tolerances and precision finishes of the interior components.
Estimates and proposals for spare parts and revisions will be supplied upon
request.
In normal use, the following maintenance instructions are sufficient.
WARNING
Before use, ensure that the pump is not under voltage and that it is not cold. If
necessary, the installation must be isolated and the energy must be dissipated
according to safety procedures.
WARNING
Before use, ensure that no impurity enters into the pump or the pipes.
WARNING
To avoid jamming, we recommend to grease the assembled parts of similar
nature with oxygen compatible grease
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9.1.1. Assembly / Disassembly : Table of tightening torques and forces
After manual tightening, the end tightening must be made with a torque wrench,
at 75% of the limit of elasticity or at the drawing value.
Torques and forces for Bolts of type H, in stainless steel, class A1, A2, A4
Bolts class of resistance: 70
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Torque (Nm)
Max
5.9
14.5
30
50
79
121
174
244
182
234
328
445
Standard
5
12
25
42
66
101
145
203
152
195
273
371
Force (Nm)
Max.
6.85
12.6
20
29.1
40
55
69
88.6
61.5
70.9
90
109.4
Standard
6
11
17
24
33
46
58
74
51
59
75
91
Bolts class of resistance : 80
M6
M8
M10
M12
M14
M16
M18
M20
Torque (Nm)
Max
8
19.3
39.4
67
106
161
232
325
Standard
7
16
33
56
88
134
193
271
Force (Nm)
Max.
9.13
16.7
26.6
38.8
53.3
73.3
92
118.1
Standard
8
14
22
32
44
61
77
98
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Torques (Nm) for hexagon socket flat or small head cap screws in stainless steel,
class A2, A4
Screw
type
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
Din 6912
Chc
70
Max
5
12
24
40
66
110
Standard
4
10
20
33
55
92
170
142
Din 7991
Fhc
70
Max.
5
7
21
30
66
Standard
4
6
18
25
0
55
Din 7991
FHc
70
Max
5
8
20
33
50
55
Standard
4
7
17
28
42
46
120
100
75
63
235
196
200
167
Torques (Nm) for hexagon socket flat or small head cap screws in stainless steel
Screw
type
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
9.2.
Din 6912
Chc
8.8
Class of
resistance
Max
9
20
40
65
110
180
Din 7984
Fhc
8.8
Class of
resistance
Standard Max
8
8
17
12
33
35
54
50
92
150
110
280
233
Standard
7
10
29
42
0
92
Din 7991
FHc
10.9
Class of
resistance
Max
9
15
40
65
100
110
Standard
8
13
33
54
83
92
200
167
150
125
390
325
400
333
Vacuum chamber
The entire cold end is enclosed in a vacuum insulated chamber which permits the
pump to remain cold with minimal heat inleak. Vacuum must be 10-3 torr.
Not applicable for PPC pumps.
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9.3.
Removal of the Cold End from the Crank Drive
(See drawings 'Cold End' reference -A hereafter and 'Crank Drive' reference -B
hereafter)
- Remove suction, gas vent and discharge pipes
- Dismantle the 2 covers from the connecting lantern of the crank drive (13-B)
- Loosen the securing nut (26-A) which secures the connection cold end/crank
drive
- Loosen the grub screw (27-A) for piston securing
- Unscrew the piston with a special tool and hold the coupling adapter of the
crosshead (9-B)
- Unscrew the complete cold end assembly
Be sure to unscrew the piston together with the cylinder in order to have the
complete cold end as a unit.
9.4.
Fitting of the Cold End at the Crank Drive
(See drawings. 'Cold End' reference -A hereafter and 'Crank Drive' reference -B
hereafter)
Attention: Spare cold ends supplied by Cryostar are degreased for operation with
oxygen. Take special care that during assembly no impurities are introduced into
the cold end or the pipe connections.
- Lubricate both threads (on cylinder and piston) for ease of assembly (for
oxygen service: special grease)
- Rotate the crank shaft by hand so that the crosshead is in its extreme upper
dead point position
- Screw the cylinder into the crank drive. Screw and then tighten the piston (1-A)
firmly into the crosshead (9-B) using special tool. For correct tightening, hold
connecting piece to prevent rotation.
- Tighten the safety screw (27-A) to lock the piston
The pump piston must sit against the crosshead shoulder and be locked
- Screw the cylinder into the drive housing until the piston bottoms against the
suction valve. Now unscrew the cylinder between 1/2 thread and 1 thread and a
half until the discharge connection is in its upper position
- For checking, carefully turn the crank drive shaft once by hand to ensure that
the piston does not touch. If it touches, unscrew the cylinder one thread more
- Fasten the safety nut (26-A) of the cold end
- Screw the two covers (13-B) on the connecting lantern
- Connect suction, gas vent and discharge pipes
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9.5.
Dismantling of the Cold End
(see drawing 'Cold End')
Important: During overhaul of the cold end, care should be taken to keep all
parts free of moisture, lubricants and foreign matter.
Note: Do not remove or disturb the vacuum fitting in cylinder assembly.
a) Removal of packing and piston
- Remove lock nut 26
- Remove packing nut 4 and remove circlip 2, scraper 3 and if necessary guide
ring
- Turn the cold end upside down on a block of wood or soft material to remove
parts 5,6,7,8,9,10 and 11
- Pull piston 1. Upon removal of piston, remove rider ring 25 and piston rings
24 and springs
- Remove six screws 19 with special tool (see drwg. 709 042082)
- Remove suction valve 18 assy and gasket 20
- Remove fitting 12, washer 16 and discharge poppet 17
Note: The replacement of sleeve 23 and the lapping of the valve head and
poppet should be done at Cryostar to ensure proper tolerances are held and lap
finish per Cryostar blue print is achieved.
b) Dismantling of the suction valve
(see drawing "Suction Valve assy.")
- Remove lock wire 4, unscrew nut 3 and valve stop 2, remove spring 1, valve
stem 5 and, if necessary, DU sleeve 6.
9.6.
Assembly of the Cold End (see drawing 'Cold End')
For the assembly of the Cold End, proceed as described under par. 9.4.
a) General
- All parts must be degreased for oxygen service. The assembly should be
carried out in a clean , dry place.
- Humidity in the pump prevents it from functioning.
- Do not drop or disturb the vacuum fitting.
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b) Preassembly
- Set scraper 3 and retaining ring 2 into packing nut 4
- Install rider ring 25 and piston rings 24 on piston 1
- The splits of the three piston rings should be located about 120°C from each
other.
c) Suction valve assembly (see drawing 'Suction Valve Assy.')
- Check all sealing surfaces of the surfaces of the valve head and remachine
them, if necessary.
- Install valve stem 5 and spring 1, screw on valve stop 2 and nut 3. Valve stroke
should be 2.5 mm. Then secure with lock wire 4.
- Check tightness of the valve with trichlorethylene or similar liquid.
9.7.
Assembly of the Cold End (continuation)
d) Main assembly
- Install gasket 20 and suction valve assembly 18
- Install six screws 19 and tighten to 2.5 daN.m torque
- Place piston 1 into special tool 4 (drwg. No. 709 042082) until all rings are
compressed Then push piston with tool into sleeve 23 until all rings are
compressed.
- Remove the tool
- Turn the cold end with the suction valve side down
- Install as indicated on drwg. "Cold End" following parts:
Latern ring 11, four belleville springs 10, four supporting rings 9 with four hat
seal rings 8, spacer 7, three supporting rings 9 with four hat seal rings 8, O-ring
6 and supporting ring 5 and hat seal ring 8
- Screw packing nut 4 into cylinder and tighten to 2.5 daN.m torque
- Install in cylinder: washer 16 and screw in fitting 12 with poppet 17
9.8.
Dismantling of the Crank Drive
(see drawing 'Crank Drive')
- Remove the pulley or the coupling and key 14 with pin 15.
- Remove the screws 32, spring washers 33 and covers 20 and 31.
- Remove screws 4, spring washers 5 and cover 1.
- Remove the four screws 2 and spring washers 3.
- Take out complete shaft with bearing housings, crosshead and connecting rod.
Then disassemble into parts:
At the roller bearing:
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- Remove screw 24 with spring washer 25 and washer 23
- Remove the complete bearing
- Remove the nilo-rings 40 and circlips 28
At the barrel-shaped bearing:
- Remove the circlip 19
- Remove the complete bearing
- Remove the circlips 17 and 28
- Remove the support 18 and the bearing 29
At the needle bearings:
- Remove complete connecting rod off the shaft, press-out crosshead pin 36 and
remove the bearings 27 and 34.
- Break up the sleeve 730002333 with the three set grub screw 26 and press it
out of the housing. The sleeve must be replaced only if there are strong running
traces (seizures) on it.
- Remove carefully all gaskets by the bearings, so that they may be used again, if
necessary.
- Clean bearings and running surfaces. Check, and if still usable, lubricate.
Damaged parts must be remachined or replaced.
9.9.
Assembly of the Crank Drive
(see drawing 'Crank Drive Assembly')
- Assembly of the crank drive must be carried out in a clean, dry room
- To assemble the crank drive carry out in reverse order the procedure described
in paragraph 'Dismantling of the crank drive'. Check whether the crank drive is
right or left execution and work accordingly.
Important Notes:
- To mount connection rod bearings the connecting rod must be heated to
approximately 80°C
- To mount the crosshead pin, dunk it into liquid nitrogen and heat the crosshead
between 50°C and 60°C
- To mount the shaft bearings (or eccentric for some crank drive executions) the
bearings (or eccentric) must be heated to 70°C approximately.
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9.10. Belt/Pulley Assembly (reference)
Before you remove the protection hood, isolate the machine. To change the
belt, follow the safety procedure. After belt change, assemble the protection
hood and switch on the machine again.
9.10.1.Bushing and Sprocket Assembly / Removal
9.10.1.1.To assemble Q-D Style Taper Bushings
Clean shaft, bush, screws and pulley taper bore.
The taper bushing is fitted on the shaft after enlarging the slit with a
screwdriver.
Lubricate the conical bore of the pulley and slide it on the bush. The drilled
holes for screws must correspond to the tapped holes.
Lubricate the thread and the head underface of both screws, place and
tighten them one after the other progressively until the blocking-up, without
exceeding the torque indicated in the table.
9.10.1.2.Removal Q-D Style Taper Bushings
Remove both setscrews, screw them into the tapped holes of the pulley,
provided for disassembling, and tighten them progressively until the
release of the pulley.
9.10.1.3.To assemble Split Taper Bushings
Clean and degrease the bore and taper surfaces of the bush and the taper
bore of the pulley.
Insert the bush in the pulley hub and line up the holes (half thread holes
must line up with half straight holes).
Lightly oil the grub screws and screw them in, do not tighten yet.
Clean and degrease the shaft. Fit pulley with taper bush on shaft and
locate in desired position.
The key must be correctly positioned and there should be a tap clearance
between it and the keyway.
Using a hexagon socket wrench gradually tighten the screws in
accordance with the torque as listed in the chart of screw tightening
torques.
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When the drive has been operating under load for a short period (1/2 hour)
check and ensure that the screws remain at the appropriate tightening
torque.
In order to eliminate the ingress of dirt, fill all empty holes with grease.
9.10.1.4.Removal Split Taper Bushings
Slacken all screws, remove and lubricate them. Insert them into the jacking
off holes in bush.
Tighten screws uniformly and alternately until the bush is loose in the
pulley and the pulley/bush assembly is removable from the shaft.
Remove pulley/bush assembly from the shaft.
9.10.1.5.To assemble sprocket
Inspect the bore of the sprocket, the tapered barrel and bore of the
bushing and the shaft. Any paint, burrs, rough places and dirt must be
removed.
Assemble bushing into sprocket. Loosely insert the capscrews into the
assembly.
With key in keyseat of the shaft, slide sprocket to its desired position with
capscrew heads to the outside. (A few small sprockets may have to be
installed with capscrew head to the inside). If it is hard to slide the bushing
onto the shaft, wedge a screwdriver blade into the saw cut to overcome
the tightness.
Line up the assembly per the alignment instructions that follow and tighten
capscrews evenly and progressively to the recommended torque on the
instruction sheet that comes with each bushing. There should be a 1/8 to
1/4 of an inch gap between the sprocket hub and the bushing flange. If
gap is closed, the shaft is seriously undersize.
9.10.2.Checking alignment and Belt tensioning
Good alignment of pulleys is important to avoid belt flank wear.
Position a rule against the flank of the motor pulley, allow clearance of 1 mm on
each side of the pump pulley (this clearance corresponds to the width difference
of both pulleys).
Sprocket alignment and parallelism of the shafts is very important. Place a
straight edge against the outside edges of the sprockets and move sprockets
until the straightedge touches the two outside and two inside edges of the
sprockets. The straightedge should cross the sprockets as near the shafts as
possible.
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New belts (after checking alignment)
New V-Belts are properly tightened if the force required for their tensioning
corresponds to the required deflection of the table here under.
A new drive should be tensioned to the higher value to allow for the normal drop
in tension during the running-in period.
After the drive has been running for 50 working hours, the tension should be
checked and re-adjusted to the higher value, if necessary.
Synchronous type belts do not require as much tension as other belt drives that
depend on friction to transmit the load. Belts should be installed with a snug fit,
neither to taut nor too loose.
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Poly-V Belt Tensioning
Small
Belt Section Sheave P.D. POUNDS FORCE PER
RIB
Range
Min .
Max.
3.0" - 3.6"
1 5/8
2 7/16
3.8 - 4.8
2 1/16
3 1/8
L
5.0 - 7.0
2 1/2
3 13/16
7.2 - 9.2
2 3/4
4 1 /8
9.4 - 12.0
2 7/8
4 1/4
12.0 -14.0
3
4 1/2
Gripbelt V-Belt Tensioning
Sheave Diameter-Inches
Cross Section
3V, 3VX
Smallest Sheave
RPM
Diameter Range
Range
2.2-2.4
1000-2500
2501-4000
2.65-3.65
5V, 5VX
4.4 - 6.7
7.1 - 10.9
11.8 - 16.0
8V
12.5 - 17.0
18.0 - 22.4
1000-2500
2501-4000
1000-2500
2501-4000
500 -1749
1750 -3000
3001 -4000
500 -1740
1741 -3000
500 -1740
1741 -3000
200 -850
851 -1000
200 -850
851 -1500
Deflection Force-LBS
Belt Deflection Force
Gripnotch Belts
Super Gripbelts
and Notched
and Unnotched
Gripbands
Gripbands
Used
New
Used
New
Belt
Belt
Belt
Belt
3.3
4.9
2.9
4.3
3.6
3.0
4.9
4.4
5.1
4.4
7.3
6.6
12.7
11.2
15.5
14.6
33.0
26.8
39.6
35.3
18.9
16.7
23.4
21.8
49.3
39.9
59.2
52.7
Synchronous Belts
Pitch
8 mm
Width
20 mm
30 mm
50 mm
85 mm
Force – LBS
4
6
11
19
4.2
3.8
5.3
7.9
10.2
8.8
5.6
14.8
13.7
17.1
16.8
6.2
5.6
7.9
7.3
15.2
13.2
8.5
22.1
20.1
25.5
25.0
Page 42
USER’S MANUAL
Issue date : 1/27/2009
80% of lengthening of a trapezoidal belt occurs during the 15 first working hours.
1. Measure the center distance of the axes. Apply a belt tension indicator to midcenter distance and measure the bending force. There must be 1/64 inch
deflection per 1 inch of span.
2. A measured force below the lower value indicates under-tensioning. Increase
belt tensioning if the force is lower than the minimal values indicated in the table
and reduce the belt tensioning if the force is higher.
Belt Span
F
1/64 “Per inch of belt span
(deflection)
9.11. Crosshead Assembly
(see drawing 'Crosshead')
Caution: Crosshead has must be handled with care to avoid any damages to the
hard surface overlay
a) General
- The dismantling of this part is required only when a noticeable axial play is seen
at the coupling adapter 7
b) Dismantling
- Loosen coupling nut 6 and unscrew carefully
- Dismantle all parts, except washer 3 which is shrink fitted
- Clean all parts, check for wear and if required replace them
c) Assembly
- Slide coupling nut 6 into coupling adapter 7
- Slide Belleville springs 5 over it as shown on drawing
Page 43
USER’S MANUAL
Issue date : 1/27/2009
- Insert split ring 4 and coupling nut 6 over it
- Screw assembled coupling nut into crosshead and tighten with 8 daN.m torque
- Check, that coupling adapter 7 has no axial play
9.12. Crank Drive Regrease and Maintenance
The crank drive is pre-lubricated at our works and is ready for operation. Relubrication with a recommended lubricant is necessary after every 1500 hours of
service.
9.12.1.Pump / Crank Drive
WORKS TO BE DONE
Clean the bearings, lubricate
Check the packing nut, tighten again after
start-up
Check the suction filter, Clean the filter
Dismantle the cold end
Change the sleeves
If necessary, change the piston rings
Remove the crank drive cover
Check: - the crosshead
- the DU-sleeves
- the bearings
Change the guiding sleeves and the
Belleville washers in the cold end
Maintenance at Cryostar
Complete maintenance of the cold end
and of the crank drive
Change the crosshead and DU sleeves
Vacuum in the cylinder
Check the suction valves and discharge
valves (Lapping)
Change the discharge valve
Change the crank drive bearings
Change the direction or rotation
Check and tighten belts again
Tighten the coupling
Cold end / Crank drive
Check safety valve
MAINTENANCE PERIOD
(WORKING HOURS)
1 year
storage
x
50
500
1000
1500
2000
2500 3000
x
x
x
x
x
x
x
x
every
year
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Page 44
USER’S MANUAL
Issue date : 1/27/2009
10.
CRYOSTAR’S MAINTENANCE AND SPARE PARTS SERVICE
10.1. Order Instructions
Lists of spare parts are enclosed with these instructions. On each sectional
drawing, the spare parts are marked with item numbers corresponding with those
on the spare parts list; on the spare parts list, stock part number and designation
are added to each item.
It is advisable to always keep in stock the spare parts recommended in these
lists; you may save unwelcome waiting time.
When ordering the spare parts, please indicate the following:
1. Cryostar Comm. No.
2. Equipment number
3. Stock number of the required part
4. Designation of the required part
When extensive overhaul works or complete revisions are necessary, we
recommend returning the machine to our works, or that the help of our service
engineer is requested.
Page 45
USER’S MANUAL
Issue date : 1/27/2009
11.
ANNEX
11.1. NPSH
NPSH = ”Net positive Suction Head” = difference between the static
pressure (Ps) and the actual vapor pressure (Pt) of the vapor-free liquid in
the suction nozzle of the pump.
To allow a cryogenic pump to start and operate correctly, a specific NPSH must
be available.
The NPSH in the suction nozzle of the pump has to prevent local vaporization of
the liquid and can also be described as relative undercooling ( DT). The actual
vapor pressure (Pt) is determined only by the temperature (Ts) in the suction
nozzle of the pump, expressed in meters of liquid head.
The required NPSH (=NPSHr) must be available during starting as well as during
operation of the pump.
The available NPSH (NPSHa) in the suction nozzle of the pump can be attained
or improved by:
- Increasing the static liquid head
- Relative undercooling of the liquid
- Pressure built-up in the tank over the actual vapor pressure
- Better insulation of the piping
Page 46
USER’S MANUAL
Issue date : 1/27/2009
- Reduction of pressure loss in the piping
The necessary NPSH must be guaranteed during start-up as well as under
service conditions of the pump.
The necessary NPSH in the suction nozzle may be reached or improved by:
- Increasing the static liquid head (higher position of the tank)
- Undercooling of the liquid
- Pressure increase in the tank
- Better piping insulation in the given installation
- Reduction of piping pressure
Page 47
USER’S MANUAL
Issue date : 1/27/2009
11.2. Appendix to spare parts lists
P U
A B
Ref. No.
™
Explanation
Position on drawing. Pos. 800 and above : Part lists supplied with the machine
™
Quantity of parts per unit
™
Parts subject to normal wear to be kept on stock, to be replaced at each
disassembly
Commissioning spares
™
Recommended spare parts for 2 years operation
XXXXXXX Stock number
X
IMPORTANT :
The prices are subject to change without previous
notice. The prices are net, in U.S. currency, for supply
ex works, including packing, excluding any customs
duties or taxes.
Every part should be replaced by a CRYOSTAR genuine part.
CRYOSTAR accepts no responsibility if these rules are not respected.
Environmental Performance for Industry!
F80 SERIES
SAFETY RELIEF VALVE
•
•
•
•
TYPE F84 (PLASTIC-SEATED)
TYPE F85 (ELASTOMER-SEATED)
-4, -6, -8 Orifices (WITH INTEGRAL BONNET)
-4, -6, -8, -F, -G, -H, -J Orifices (WITH BOLTED BONNET)
INSTALLATION,
OPERATION, & MAINTENANCE MANUAL
Revision:
Date of Issue:
D
April 1, 2003
Approved by:
Design Engineer
Service Manager
Engineering / Quality Mgr.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
Page 2 of 17
TABLE OF CONTENTS
Topic
Page
1.0
General ...................................................................................................3
2.0
2.1
2.2
2.3
2.4
Description, Operation, Service Envelope, Installation, & Startup
Description / Operation ...........................................................................4
Service Envelope ....................................................................................5
Installation...............................................................................................5
Startup ....................................................................................................6
3.0
3.1
3.2
3.3
3.4
Valve Maintenance
Disassembly – ‘B’ Body (Integral Bonnet) Valves ...................................7
Reassembly – ‘B’ Body (Integral Bonnet) Valves....................................7
Disassembly – ‘C’, ‘D’, ‘E’ Body (Bolted Bonnet) Valves.........................8
Reassembly – ‘C’, ‘D’, ‘E’ Body (Bolted Bonnet) Valves .........................8
4.0
4.1
4.2
4.3
4.4
4.5
Valve Testing and Adjustment
Test Equipment.......................................................................................9
Setting / Adjustment Tolerances .............................................................9
Set Pressure and Blowdown Adjustments ..............................................10
Seat Tightness ........................................................................................10
Lift Lever Operation ................................................................................10
5.0
Accessories................................................................ .............................11
6.0
Troubleshooting Guide .......................................... ................................12
Illustrations
F84 - 4 / -6 / -8 (Plastic-Seated) Valve with “B” Body (Integral Bonnet).............14
F84 Series (Plastic-Seated) Valve with Bolted Bonnet ......................................15
F85 - 4 / -6 / -8 (Plastic-Seated) Valve with “B” Body (Integral Bonnet).............16
F85 Series (Elastomer-Seated) Valve with Bolted Bonnet.................................17
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
1.0
F80 Series Safety Relief Valve
Rev. D
Page 3 of 17
GENERAL
1)
This manual is intended to provide users with direction and guidance for the maintenance of
FLOW SAFE F80 Series safety relief valves. This manual indicates the proper method of valve
disassembly, soft goods replacement, and valve reassembly. FLOW SAFE provides this manual
as a guideline and reference only. It is not intended to serve as a training manual or
manufacturing guide. FLOW SAFE assumes no responsibility for personal or property damage
that may occur in conjunction with this manual.
2)
FLOW SAFE recommends that all valves be placed on a regular maintenance schedule that
includes the routine replacement of softgoods. FLOW SAFE recommends softgoods
replacement every three years but cautions that each customer make their own determination
and set their own schedule based upon use and environment. FLOW SAFE believes that when
maintenance and reassembly is performed as outlined in this manual there is no safety hazard.
Cycling the valve at least once a year is considered to be good practice to verify operation.
3)
When a new valve leaves FLOW SAFE, it has been manufactured and tested by trained and
experienced personnel. When you remove a valve from your system and perform the
maintenance tasks that are outlined herein you will need proper training.
Do not attempt to accomplish these tasks without adequate training and understanding of the
valve operation.
4)
Any and all stated or implied warranties that are in effect during the purchase of a new FLOW
SAFE valve are null and void once the valve has been disassembled by someone other than
approved FLOW SAFE personnel.
All repair and resetting of "UV"-stamped safety relief valves should be performed either by FLOW
SAFE, Inc., or by a National Board-certified valve repair shop holding a "VR" (Valve Repair)
stamp.
5)
It is highly recommended that all instructions herein be read in full prior to any assembly,
disassembly, or operation of this equipment.
6)
The noted manufacturer’s standard lubricants should be used only if compatible with process fluid
and application.
7)
Specific design details described in this document are subject to change without notice.
8)
Should the need arise for general assistance, contact the FLOW SAFE Sales department at (716)
662-2585 or (800) 828-1036. For more detailed technical assistance, contact the FLOW SAFE
Engineering department at (716) 667-3640.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
2.0
DESCRIPTION, OPERATION, SERVICE ENVELOPE,
INSTALLATION, and STARTUP
2.1
DESCRIPTION / OPERATION
Rev. D
Page 4 of 17
The FLOW SAFE F80 Series safety relief valve is a direct-acting spring-loaded relief valve, suitable for
gas service. The Type F84 is plastic-seated and the F85 is elastomer-seated.
Orifice sizes are available in -4, -6, -8, -F, -G, -H, and -J with set pressures from 15 to 9612 psig
(depending on the orifice size).
Blowdown, up to approx. 20%, is readily controlled by adjusting the blowdown ring. FLOW SAFE valves
are typically shipped with 7% blowdown, allowing the valve to reseat bubbletight to approximately 93% of
the set point.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
2.2
F80 Series Safety Relief Valve
Rev. D
Page 5 of 17
SERVICE ENVELOPE
Body
Size
Maximum
Set
Pressure
(psig)
Medium
(B)
Large
(C, D, E)
X-Large
(C, D, E)
SEAT
MATERIAL
F84
Vespel
PEEK
Teflon
Kel-F
ORIFICE SIZE
Material
Brass
CS
SS
NACE
Brass
CS
SS
NACE
Brass
CS
SS
NACE
-4
-6
-8
-F
-G
-H
-J
3500
4921
4921
4921
5000
9612
9612
9612
---------
2900
2900
2900
2900
4500
5774
5774
5774
---------
1125
1125
1125
1125
2600
4292
4292
4292
---------
--------500
839
839
839
--5000
5000
5000
--------500
668
668
668
--3705
3705
3705
--------382
382
382
382
450
2750
2750
2750
--------298
298
298
298
450
2700
2700
2700
Temperature ( oF)
MAX.
MIN. *
500
-423
525
0
400
-423
400
-423
F85
Buna-N
Viton
EPR
Kalrez
Polyurethane
275
400
325
500
225
-30
-30
-65
0
-60
* Confirm service / application with factory.
2.3
INSTALLATION
Prior to installation, check that the set pressure on the nameplate is as required, and meets the system
requirements.
The F80 Series safety relief valve should be installed in the upright position per the figure on the next
page, as close as possible to the pressure source, to minimize pressure losses between the system and
the valve. This should be in accordance with accepted piping practices, as set forth in the API RP 520,
Part II, which recommends that inlet piping pressure losses should not exceed 3% of the set pressure
when the valve is flowing.
The valve discharge pipe should be sufficiently large so that backpressure does not exceed 10% of the
set pressure when relieving. Higher backpressures may cause the valve to chatter (rapid cycle), or affect
capacity.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
Page 6 of 17
The F80 Series valves are not balanced against superimposed backpressure,
so that the set pressure will change one-for-one with the backpressure.
This means that for each 1 psi of backpressure, the set pressure will increase
by 1 psi. Refer to Section 4.3 for setting instructions. Check the valve
manufacturer’s nameplate(s) to determine if the valve was already
set with a correction for backpressure.
Make sure that the inlet piping/flanges have an opening equal
to or greater than the valve's inlet diameter. Make sure that there
are no obstructions like gaskets, fittings, etc., in the flow path
to restrict the flow or cause chatter.
If a block valve is used below the relief valve, it should be opened before
pressurizing the system. This block valve should be locked open during
normal system operation.
Use only the wrench flats on the valve inlet bushing, taking care not to
make any wrench marks, for tightening and installation. Do not wrench
on cast body or bonnet.
2.4
STARTUP
Foreign particles or dirt can damage the valve and make it inoperative. Prior to installation, clean out the
piping thoroughly. If the valve is not installed immediately, inlet and outlet connections should be
protected and covered.
Pressure can be applied to the valve as system pressure increases, or by opening the block valve (if
there is one) after the system has attained operating pressure. Verify the valve seat is leak-tight, in
accordance with Section 4.4.
The valve is now ready for service. Inspection and maintenance should be performed on a regular basis,
typically once a year, depending on the service conditions.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
3.0
VALVE MAINTENANCE
3.1
DISASSEMBLY – 'B' BODY (INTEGRAL BONNET) VALVES
Page 7 of 17
(See Illustrations on pages 14 and 16)
CAUTION:
1)
Remove the valve from service, or adequately and safely block the incoming pressure before
disassembling the valve and performing maintenance.
NOTE:
2)
3)
4)
5)
6)
7)
8)
9)
10)
3.2
It is extremely dangerous to attempt to disassemble any valve while it remains in
service with incoming line pressure.
If bushing remains connected to the system piping, then the valve's internal
components (spring, washer, spindle) will fall out of the body as it is removed.
Cut and remove the lockwire.
For valves with lift lever, first remove the lock nut and lift lever. Slowly unscrew the bushing,
holding the shaft. Unscrew the lift lever housing.
Remove the pressure adjusting (PA) screw cap. Measure the height of the PA screw above the
body and record value. For lift levers, record distance from jam nut to top of threaded lifting rod.
Remove jam nut and lift nut.
Loosen the PA screw lock nut. Loosen PA screw until spring load is removed.
Record the gap between the bottom of the blowdown (BD) ring and bushing shoulder. Then
loosen the BD lock nut and lock screw.
Unscrew and remove the bushing, using the wrench flats.
Remove the spindle assembly. Remove retainer screw (if applicable), retainer, and seat.
Remove the spring washer(s), spring, and lifting rod assembly (if applicable).
Replace the softgoods per the instructions in Section 3.2.
• Replacement parts may be found in the appropriate FLOW SAFE softgoods kit, as listed
in Section 5.0 of this manual.
REASSEMBLY – 'B' BODY (INTEGRAL BONNET) VALVES
1)
Reassembly of these valves is basically the reverse of the disassembly.
NOTE: Care must be taken in the handling of all items, particularly softgoods and nozzle
surfaces.
2)
3)
4)
Inspect condition of nozzle seating surface and spindle guide surface inside body. Buff out or
polish any scratches that may interfere with a good seal, or replace part if necessary.
Apply Neverseez or DuPont Krytox (for oxygen service) to all straight threads.
Complete the seat assembly as follows:
a)
F84: Insert the plastic seat, seat retainer, and retainer screw into the spindle. Install the
seat dry. Apply Loctite or Vibra-tite to retainer screw threads. As screw is tightened,
ensure that it meets firm resistance against the locking Heli-Coil in spindle.
b)
F85: Insert the O-ring seat into the spindle. To ease seat installation, apply a light coat
of Dow Corning 33 or 55 (or Molykote) or Krytox (oxygen service). If fitted with a push-in
retainer, the retainer must fit tight as it is pushed in against the seat (tapered end inward).
If fitted with a set screw, install the screw in the top of the spindle. Newer models will
incorporate a retainer screw; apply Loctite or Vibra-tite to threads and tighten firmly.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
5)
6)
7)
8)
9)
10)
11)
12)
13)
3.3
F80 Series Safety Relief Valve
Rev. D
Page 8 of 17
Assemble the spring washer(s), spring, and lift lever (if applicable) into the body.
Insert the spindle assembly into the body, making sure that it travels freely on the guide surface.
Screw the blowdown ring onto the bushing, to the same gap as previously recorded.
Position the bushing seal on the appropriate shoulder of the bushing.
Screw the bushing / seal / BD ring assembly into the body and tighten using the wrench flats.
Screw the PA screw, lock nut, and seal into the top of the body, with top of screw at previously
recorded value.
For lift levers, assemble the PA screw, lock nut, and seal around lifting rod. Then reassemble the
lift nut and jam nut to the previously recorded position. Assemble the lift lever housing and then
the bushing, seals, shaft, lift lever, and lock nut.
Screw the BD ring lock screw, lock nut, and seal into the back of the body.
The valve is now completely assembled and ready to be tested. See Section 4.0.
DISASSEMBLY – ‘C’, ‘D’, ‘E’ BODY (BOLTED BONNET) VALVES
(See Illustrations on pages 15 and 17)
CAUTION:
1)
Remove the valve from service, or adequately and safely block the incoming pressure before
disassembling the valve and performing maintenance.
NOTE:
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
3.4
It is extremely dangerous to attempt to disassemble any valve while it remains in
service with incoming line pressure.
If bushing remains connected to the system piping, then the valve's spindle will
fall out of the body as it is removed.
Cut and remove the lockwire.
For valves with lift lever, first remove the lock nut and lift lever. Slowly unscrew the bushing,
holding the shaft. Unscrew the lift lever housing.
Remove the pressure adjusting (PA) screw cap. Measure the height of the PA screw above the
body and record value. For lift levers, record distance from jam nut to top of threaded lifting rod.
Remove jam nut and lift nut.
Loosen the PA screw lock nut. Loosen the PA screw until the spring load is removed.
Unscrew and remove the four bolts, nuts, and lockwashers between the body and bonnet.
Remove the washer(s), spring, and lifting rod subassembly (if applicable).
Record the gap between the bottom of the blowdown (BD) ring and the bushing shoulder. Then
loosen the BD lock nut and lock screw.
Unscrew and remove the bushing, using the wrench flats.
Remove the spindle assembly. Remove retainer screw (if applicable), retainer, and seat.
Replace the softgoods per the instructions in Section 3.4.
• Replacement parts may be found in the appropriate FLOW SAFE softgoods kit, as listed
in Section 5.0 of this manual.
REASSEMBLY – ‘C’, ‘D’, ‘E’ BODY (BOLTED BONNET) VALVES
1)
Reassembly of these valves is basically the reverse of the disassembly.
NOTE: Care must be taken in the handling of all items, particularly softgoods.
2)
3)
Inspect condition of nozzle seating surface and spindle guide surface inside body. Buff out or
polish any scratches that may interfere with a good seal, or replace part if necessary.
Apply Neverseez or DuPont Krytox (for oxygen service) to all straight threads.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
4.0
F80 Series Safety Relief Valve
Rev. D
Page 9 of 17
Complete the seat assembly as follows:
a)
F84: Insert the plastic seat, seat retainer, and retainer screw into the spindle. Install the
seat dry. Apply Loctite or Vibra-tite to retainer screw threads. As screw is tightened,
ensure that it meets firm resistance against the locking Heli-Coil in spindle.
b)
F85: Insert the O-ring seat into the spindle. To ease seat installation, apply a light coat
of Dow Corning 33 or 55 (or Molykote) or Krytox (oxygen service). If fitted with a push-in
retainer, the retainer must fit tight as it is pushed in against the seat (tapered end inward).
If fitted with a set screw, install the screw in the top of the spindle. Newer models will
incorporate a retainer screw; apply Loctite or Vibra-tite to threads and tighten firmly.
Insert the spindle assembly into the body, making sure that it travels freely on the guide surface.
Screw the BD ring onto the bushing, to the same gap as previously recorded.
Position the bushing seal on the appropriate shoulder of the bushing.
Screw the bushing / seal / blowdown ring assembly into the body and tighten using wrench flats.
Assemble the spring washer(s), spring, and lifting rod subassembly (if applicable) into the bonnet.
Assemble the bonnet, bolts, nuts, and lockwashers to the body. Torque to following value:
25-30 ft-lbs
-3/8-in bolts marked “B8” on ‘C’-body
25-30 ft-lbs
-1/2-in bolts marked “B8” on ‘D’ or ‘E’ body
65-70 ft-lbs
-1/2-in bolts marked “B8” on ‘D’ or ‘E’ body
Screw the PA screw, lock nut, and seal into the top of the body, with top of screw at previously
recorded value.
For lift levers, assemble PA screw, lock nut, and seal around lifting rod. Then reassemble the lift
nut and jam nut to previously recorded position. Assemble the lift lever housing and then the
bushing, seals, shaft, lift lever, and lock nut.
Screw the BD lock screw, lock nut, and seal into the back of the body.
The valve is now completely assembled and ready to be tested. See Section 4.0.
VALVE TESTING AND ADJUSTMENT
The following tests and adjustments are necessary for gas service valves: set pressure, reseat pressure
(blowdown), and seat tightness.
4.1
TEST EQUIPMENT
Where practical, a sufficiently large accumulator or pressure vessel should be used to read and set
blowdown. At a minimum a four (4) ft3 vessel is recommended for the -4 orifice to 4000 psig, -6 orifice to
1500 psig, and -8 to 600 psig. The supply pipe should have an ID equal to or greater than the valve's,
and should be no more than 10" long.
4.2
SETTING / ADJUSTMENT TOLERANCES
Set Pressure:
Set Pressure
> 70 psig
< 70 psig
Tolerance
+ 3% of specified set pressure
+ 2 psi
Seat Tightness: There should be ZERO leakage with inlet pressure at or below:
•
•
0.90 x set pressure, if set pressure > 50 psig
5 psi below set pressure, if set pressure < 50 psig
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
4.3
F80 Series Safety Relief Valve
1) If the set pressure is changed more than + 5% from the nameplate set pressure, then the
spring, spring washer, PA screw, body, and bonnet may need to be changed. Consult
the factory or an authorized FLOW SAFE assembler for the correct parts.
2) If the valve must be set to compensate for constant superimposed backpressure, the set
pressure to be used on a test stand (with zero backpressure) is obtained by subtracting
the amount of backpressure from the desired in-service set pressure.
Example:
1)
2)
3)
4)
Desired set point (in service):
Superimposed backpressure:
Adjusted set pressure (without backpressure):
100 psig
10 psig
90 psig
Remove the PA screw cap (if installed), loosen the PA screw lock nut, and screw the PA screw in
(clockwise) most of the way.
Increase the inlet pressure to the desired level, and then unscrew (counterclockwise) the PA
screw until the valve pops. Tighten down the lock nut and retest. Readjust as required.
To adjust blowdown:
a)
Be sure the blowdown lock screw and lock nut are loosened.
b)
Raise or lower the blowdown ring using a screwdriver through the valve outlet. Raising
the ring shortens blowdown; lowering the ring lengthens blowdown.
c)
Re-tighten lock screw and lock nut after adjustments have been made. Tighten lock
screw firmly into blowdown ring knurls enough to prevent ring from turning.
Install and tighten down the PA screw cap. Test valve at least one more time to verify pop
pressure and blowdown.
SEAT TIGHTNESS
1)
2)
4.5
Page 10 of 17
SET PRESSURE and BLOWDOWN ADJUSTMENTS
NOTES:
4.4
Rev. D
After any repairs and set pressure adjustments, seat tightness should meet the criteria stated in
Section 4.2.
If the valve leaks after repair refer to the troubleshooting guide on Pages 12 & 13. Check for:
• Even seating between the spindle and bushing. With the F84’s, you should be able to
see a full circular line contact on the bushing surface. Make sure that the seat is installed
all the way in the spindle and that the retainer is tight.
• Foreign particles trapped between the seat and bushing. If found, they may have
damaged the seat, requiring that it be replaced.
• Scratches in the seating area of the bushing. On the F84, this is the top beveled surface,
near the ID. On the F85, this is the top crown on the bushing.
LIFT LEVER OPERATION
CAUTION:
Do not operate a lift lever unless valve inlet pressure is at least 75% of nameplate set
pressure. Prepare the system as necessary to handle a discharge from the valve.
NOTE:
The lift lever enables verification that the valve spindle and seat can open freely, but does
not allow set pressure to be verified.
1)
With inlet pressure as stated in the above CAUTION, rotate the lift lever handle clockwise or
counterclockwise until it meets resistance.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
5.0
F80 Series Safety Relief Valve
Rev. D
Page 11 of 17
2)
Continue rotating the handle slowly until there is indication of flow through the valve. The F80
spindle should pop open following initial simmer and then quickly reclose, assuming inlet
pressure is below reseat pressure (normally 90-93% of set pressure). If the valve is opened
above its reseat pressure, the valve should stay open long enough to blow down to that pressure.
3)
Return the lift lever handle to the down position. If flow through valve could not be achieved, or if
the valve does not close, have the valve disassembled and serviced by a qualified organization.
ACCESSORIES
1)
Softgoods Kits
Kit Part Number
F84 w/lift
F85
lever
Orifice / Body
F84
-4/B
-6/B
-8/B
-4/C
-6/C
-8/C
-F/D
-G/D
-H/E
-J/E
F84B-4-XT
F84B-6-XT
F84B-8-XT
F84C-4-XT
F84C-6-XT
F84C-8-XT
F84D-F-XT
F84D-G-XT
F84E-H-XT
F84E-J-XT
F84B-4L-XT
F84B-6L-XT
F84B-8L-XT
F84C-4L-XT
F84C-6L-XT
F84C-8L-XT
F84D-FL-XT
F84D-GL-XT
F84E-HL-XT
F84E-JL-XT
X = Seat Material
Code
F84M
T
Teflon
K
PCTFE / Kel-F
W
Vespel
P
PEEK
F
Ekonol-filled Teflon
B
--V
--U
--E
--Z
--C
--N
---
F85M
----------Buna-N
Viton
Polyurethane
EPR / EPDM
Kalrez
Chemraz
Lo-temp nitrile
F85B-4-DXT
F85B-6-DXT
F85B-8-DXT
F85C-4-DXT
F85C-6-DXT
F85C-8-DXT
F85D-F-DXT
F85D-G-DXT
F85E-H-DXT
F85E-J-DXT
F85 w/lift
lever
F85B-4L-DXT
F85B-6L-DXT
F85B-8L-DXT
F85C-4L-DXT
F85C-6L-DXT
F85C-8L-DXT
F85D-FL-DXT
F85D-GL-DXT
F85E-HL-DXT
F85E-JL-DXT
D = Seat Hardness (F85)
Code
5
7
9
0
Soft: < 50 psig
Medium: 51-999 psig
Hard: > 1000 psig
“Universal”: 1 each
of above seats
Most common seat materials listed; contact Flow Safe for availability of other materials.
Seat hardness vs. set pressure listings for F85 are approximate only.
“T” in kit part number indicates seals are Teflon.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
Page 12 of 17
SOFTGOODS KIT CONTENTS (See pages 14 through 17)
Qty.
Description
1*
Seat
1
Bushing Seal
1
PA Screw Seal
1
Blowdown Lock Screw Seal
1
Bonnet / Body Seal (‘C’, ‘D’, ‘E’ Bodies only)
* Additional seats provided with “universal” kit.
2)
Lift Lever Kits
Orifice
- 4, - 6, - 8 (‘B’ Body)
- 4, - 6, - 8 (‘C’ Body)
- F, - G (‘D’ Body)
- H, - J (‘E’ Body)
6.0
Part Number
01-4200-03
01-4232-03
01-4201-03
01-4202-03
TROUBLESHOOTING GUIDE:
Symptom
Possible Cause
Inadequate bushing torque.
The valve leaks around
the bushing.
The valve leaks through
the outlet.
The valve does not
close.
The valve opens below
the designated set point.
Sealing surface on body or
bushing is damaged.
Bushing seal is damaged or
contaminated.
Seat or nozzle seating surface is
damaged or contaminated.
Uneven torque on body-to-bonnet
bolts
The spindle is stuck.
The spring preload is low due to
misadjustment, vibration, or other.
The seat leaks due to possible
damage, allowing early simmer
and pop.
Remedy
Tighten until the bushing bottoms firmly
on the body.
Inspect and polish sealing surfaces.
Remove bushing seal. If damaged,
replace with new seal. If contaminated,
clean and replace.
Disassemble the valve, remove the
spindle, and examine the seat and
seating surface under magnification. If
damaged, replace with new seat; if
contaminated, clean and reinstall.
Torque bolts evenly (see P. 9 for
values)
Disassemble and check for binding.
Deburr or replace parts.
Adjust pressure adjusting screw in
(clockwise). Ensure PA screw lock nut
and cap are tight.
Disassemble and inspect seat; replace
if damaged.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
6.0
F80 Series Safety Relief Valve
Rev. D
Page 13 of 17
TROUBLESHOOTING GUIDE (cont'd):
Symptom
The valve opens above
the designated set point.
Possible Cause
The spring preload is high.
The spindle is stuck or sticking.
Backpressure exists.
Spindle is stuck closed.
The valve does not
open.
Nozzle stuck to seat.
The set pressure has not been
reached.
Isolation valve is closed.
There is superimposed
backpressure.
The valve chatters or
rapid-cycles
The valve is oversized for the
application.
The inlet is choked.
Too much built-up backpressure
due to excessive flow, or outlet
piping undersized or too long.
Remedy
Adjust PA screw out (counterclockwise).
Disassemble and check for binding.
Deburr or replace parts. Check for a
permanent nozzle impression in the Oring seat (F85). Replace or contact
factory.
See below under “The valve does not
open.”
Disassemble the valve and examine the
sliding surfaces. If damaged, replace.
If contaminated, clean.
Disassemble and check seat for
permanent impression. Replace O-ring
seat (F85) with harder material.
Increase inlet pressure. Confirm
pressure gage is calibrated.
Open isolation (block) valve.
Increase pressure until valve pops, or
adjust (lower) set pressure (1:1) to
compensate for backpressure [See
Section 4.3].
Install smaller valve.
Open the inlet to be equal to or greater
than the valve orifice.
At a backpressure equal to
approximately 40% of set pressure,
chatter / rapid-cycling may start.
Reduce backpressure by reducing flow
rate or reworking outlet piping (increase
size; shorten; reduce number of turns).
It is recommended that outlet piping
size be equal to or greater than the
valve outlet size.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
F84 -4 / -6 / -8 (Plastic-Seated) Valve
with “B” Body (Integral Bonnet)
ASSEMBLY ILLUSTRATION
See Page 15 for
typical lift lever assembly.
Page 14 of 17
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
F84 SERIES (Plastic-Seated) Valve
with Bolted Bonnet
ASSEMBLY ILLUSTRATION
F84 -4 / -6 / -8, “C” Body
F84 -F / -G, “D” Body
F84 -H / -J, “E” Body
Page 15 of 17
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
F85 -4 / -6 / -8 (Elastomer-Seated) Valve
with “B” Body (Integral Bonnet)
ASSEMBLY ILLUSTRATION
See Page 15 for
typical lift lever assembly.
Page 16 of 17
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
TITLE:
F80 Series Safety Relief Valve
Rev. D
Page 17 of 17
F85 SERIES (Elastomer-Seated) Valve
with Bolted Bonnet
ASSEMBLY ILLUSTRATION
F85 -4 / -6 / -8, “C” Body
F85 -F / -G, “D” Body
F85 -H / -J, “E” Body
See Page 15 for
typical lift lever assembly.