OPERATION MANUAL 2 WAY

VALVE FOR BURNING GAS FCC

1676/1200/1200 Exemplary:
PETROBRAZI
Page: 2 from 19

OPERATION MANUAL 2 WAY VALVE

BURNING GAS FCC 1676/1200/1200

Author: CRACKING / PETROBRAZI

File I.D.:
Total
pages:

The present manual is a translation of the manuals given to us by the suppliers of the equipment
ZIMMERMANN & JANSEN and BAFCO

Date Function Name and surname Signature

Approve
d
Verified

Elaborated
 O P E R A T I O N
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G A S FCC
1676/1200/1200

NOTE !

This operation manual must be read and studied

carefully before the unpacking and installation of
the valve.
The valve must be used, maintained and repaired
only by persons familiarized with the operation
manual.
It is not allowed to modify the valve without the
written approval of the company
ZIMMERMANN & JANSEN GMBH.

General

1 Technical data

General data, field of appliance and purpose of use.

General description of the valve
Characteristics of the valve
General view of the structural components
Project and operation conditions
Materials
General data regarding the actuator element (actuator)

2 General safety instructions

Safety measures
Routine measures
Safety 2.1.9
1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 systems2.1.10 2.1.11 2.1.12 2.1.13
Justifying safety measures
Staff training
Valve manipulation
Safety measures during operation
Dangers due to electricity
Dangers due to hydraulic energy
Dangers due to pneumatic energy
Dangerous Gas and vapors leaks
Maintenance and repairs, faults due to explosions
modification of the valve
Cleaning and evacuation of the valve

3 Purpose of use, starting, manner of operation, faults

3.1 Purpose of use

 3.2 Start
3.2.1 Model of valve operation
3.2.2 Faults and removal of faults effects
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4 Maintenance

Maintenance instructions
General instructions
Lubrication schema
Visual inspection
4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1
Repair4.3 4.3.1 4.3.2
works
Replacement of the sealing box gasket
Spare parts
Setting into function the spare parts
Spare parts for a period of 4-5 years of operation

5 Operation manual of the actuator

5.1 Actuator description

5.2 Description of the Hydraulic System

6 Service Address

7 SCHEME
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1 Technical data
1.1 General data, field of application and purpose of use

NOTE ! The 2 ways valve According to drawing no. 906811 serves exclusively to the stop and
change of process medium mentioned into paragraph 1.3.
It is not allowed to use in any other purpose.
The producer is not responsible for the damages provoked by inappropriate use; in this
case, the user shall be held responsible for all the risks.

Applications Burnt gas

Type of valve 2 way valve (body in welded construction)
Size 1676/12®/12W mm
Quantity 1
Frontal surface 1880 mm
Exit connections Oblique for welding to meet the thickness of the
wall on the lines
Project Hot wall
Entrance Interior diameter1676 x 24 mm
Exit Interior diameter1200 x 9,5 mm
Lining with refractory material At the interior
Steam valve (valve spindle) Horizontal
Course 1700 mm
Total length of the valve Aprox. 9000 mm
Total net weight of the valve Aprox. 17500 kg
Total no of steam purging plugs 3
Size and class of purging plugs DN 1", 300# RF
Serial no 10719
Manufacture year 1999
Ensemble drawing no 906811

1.1 General description of the valve

The description of the 2 way valve (referring to drawing nr. 906011)

Valve designing – line type, according to drawing 906011 is done so that the entrance is on
the top and the exit below (2 ways), with the possibility of closing the valve to the CO Boiler
or chimney. The disk is located over the ring set and it is maintained in position by guiding
rods placed laterally. The disk shall insure the complete closure of each of the 2 exit ways.
The design insures the protection of the bonnet, axel and actuator in case the disk, either the
rod become rigid (are blocked). The entrance, exit and the surface before the disk have a
lining of refractory material.
The seat rings and the guiding rods are fixed to the body in welded spots.
All the internal parts of the sealing system may be taken off by opening the bonnet. The
valve body has a peeping hole 19" covered with a blind flange. The sealing gaskets are
replaced after min. 4 uses.
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The internal parts allow the thermal differentiated dilatation.
The designed disk is plan, with refractory insulation erosion proof in the upper part. The disk,
seat rings and guiding rods are plated with STELLITE # 1. The layer of STELLITE is of 0,25
mm. the distance between the disk, guiding rods and seat rings prevent the blocking during
the temperature variations, as well as the disk vibration.
The spindle is forged from one piece and it is covered with COLMONOY#6, as it is exposed
at average flows to the chimney when CO-Boiler is in the closed position.
The limits of the actuation device (actuator) insure the correct movement as well as the auto-
control signals to the control chamber. These regulations are verified by the supplier and no
further modifications are allowed. The valve is actuated by a hydraulic actuation device with
an battery for emergency cases and it can also be manually actuated for these emergency
cases.

Characteristics of the valve

The valve disk is guided between the lateral guiding rods. The gasket between the body and
the bonnet allows multiple uses.
The sliding valve has a bolted bonnet and a protection cap.
Connection of 1" between the valve bolt and packing gland to allow the sealing gas injection
or the plastic gasket.
Valve with coupling 1" for steam bleeding according to ASA 300 R.F.

Quantity
Size of the bleeding sockets

Exit body 3 1"(300 lbs.)

Sealing box 2 1"(800 lbs.)

1.1.2 General view of the structural components

The offer includes the following structural components

Two way valve (DIVERTER)

Drawing no. Subject
406811 General view

1.2 Project and operation conditions

Medium/process fluid Burnt gas, steam, catalyst dust

Project pressure of the body 1,76 bar
Project pressure of the disk 0,10 bar
Project temperature in the interior 788 °C
Project pressure difference (for the
actuation element) 0,1 bar
Maximum pressure of operation 0,07/0,04 bar
Maximum operation temperature 702 °C
Exterior solicitation unaccepted
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Corrosion 3mm
Bleeding azoth, overheated steam (dry)
the bleeding pressure must be controlled and
maintained at approx.0, 5 bar above the actual
operation pressure of the valve

NOTE ! The excessive bleeding may damage the interior of the valve by erosion.

1.3 Materials

Body, bonnet, disk, protection cover A 240-Or. 304 H

The body and support surface of the disk, STELLITE # 1
guiding parts of the disk
Guiding rods A 240 -GR. 304 H +STELLIIE # 1
Spindle A 182-F 304 H+ COLMONOY # 6
Guide bush Nitronic C 60
Packing gland ring Grey cast iron
Ring gasket Graphite/ J.Crane
Etoier Carbon-Steel

The carbon content is of minimum 0,04 % and maximum 0,08 %.

1.5 General data about the actuation element (actuator)

Actuator electric Manufactured by BAFCO

Type Model 764+790
Explosion proof Class 1, group D, div. (NEC)
Motor power source Tri-phase, 380 V. 50 Hz
Voltage control 24 VDC
Valve track 1700 mm
Time duration between two tracks Approx. 60 s (adjustable)

For supplementary information and details about the characteristics of the actuator see paragraph
“Manual operation of the actuator BAFCO ", in this manual.

NOTE! The actuator was set into the manufacture plant Z & J, so that a supplementary or
subsequent regulation of the functioning open or closed is not necessary.

2 SAFETY INSTRUCTIONS

2.1 Protection measures

2.1.1 Routine measures

The beneficiary of the installation must insure the personal protection

equipment. All the existent safety installations must be checked regularly.
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2.1.2 Safety Systems

Before each start of the valve, all the safety devices must be connected correctly and must
function normally.
The safety devices may be dismounted only:
-after the stop;
- after the insurance for operation during this time.
The exterior safety devices are produced and maintained by those who use the valve.

2.1.3 Justifying safety measures

The operation manual must be kept at the operation site.

Besides the universal operation manual there must also be observed the local standards and
instructions for prevention of accidents and environment protection.
All the safety and danger indications must be kept next to the valve, written carefully.

2.1.4 Training of the staff

The operation of the valve is done only by trained and informed staff.
The authorization of the staff must be clearly delimited for installation, preparation as well as
maintenance.
The staff in training must operate the valve only under the supervision of the qualified staff.

2.1.5 Check of the valve

Shall be done only by qualifies staff.

2.1.6 Safety measures during normal operation

The valve must be operated only when the safety devices are operated accordingly. At least
once per month the valve must be checked to identify the malfunctions or good operation of
the safety devices.

2.1.7 Dangers due to electricity

The works to the electric energy source must be realized by qualified electricians.
The electric equipment shall be checked periodically. The un-insulated cables shall be replaced
immediately. The gearbox, if any, shall be kept permanently closed. Only authorized staff shall
have access to it, with keys and tools.
In case of necessary works to the parts in function, a second person must also be present to
operate the main switch, if needed.
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2.1.8 Dangers due to hydraulic energy

The works to the hydraulic equipment must be executed only by qualified staff, with
knowledge in the field and experience in hydraulic equipment. The lines under pressure and
the parts of the system which must be opened shall be depressurized before the start of repair
works.
The hydraulic tubes shall be replaced at adequate intervals. This is also performed when the
cause of a malfunction cannot be identified.

2.1.9 The dangers due to pneumatic energy

The works to the pneumatic equipment must be realized only by qualified personal with
special knowledge and experience into pneumatic installations. The lines under pressure and
parts of the system which must be opened shall be depressurized before the start of works for
repairs. The pneumatic tubes shall be replaced periodically. This is also performed when the
cause of a malfunction cannot be identified.

2.1.10 dangerous Gas and vapors leaks

In case of opening the lines there may be leaks of gas and/or dangerous vapors. Special
measures of prevention must be taken for dangerous mediums.

2.1.11 Maintenance, repairs, damages

The regulation, maintenance and inspection must be done regularly in settled periods. Before
the start of these works the staff must be trained about it.
All the parts before and after the valve, as well as the compressed air and hydraulic fluid must
be protected from unintentional operation.
Big components must be fixed and insured accordingly when lifting the devices for
replacement.
The unsealed connection by bolts must be verified by wrenches.
After finishing the maintenance works, there shall be checked all safety devices for function.

2.1.12 Modification of the valve

No modification or addition shall be performed to the valve without the written approval of
the manufacturer. The same conditions apply also for welding works. No reconstruction
works will be performed without the written approval of the manufacturer
ZIMMERMANN& J A N S E N GMBH.
The parts that do not function properly shall be replaced immediately.
Only original spare parts shall be used. In case of purchased parts, no guarantee of correct
project or according functioning of these parts shall be granted.
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2.1.13 Cleaning of the valve and evacuation

All the materials must be manipulated accordingly. The same

conditions for residual materials apply, especially for:
Works with lubrication systems and devices;
Cleaning with solvents.

Multiplication rights

The right for multiplying this operation manual is reserved to the company ZIMMERMANN
& JANSEN GMBH.
This manual is designated solely to the users of the valve and
their staff. It includes instructions and indications which must
not be:
-copied;
-distributed;
-communicated.
The non-observance of these conditions may have legal consequences.

3. PURPOSE OF USING, STARTING, OPERATION MODULE,

FAULTS
3.1 Scope of Use

NOTE ! two way valve (Diverter) serves to the stop/change of the process fluid mentioned under
paragraph „ Project and operation conditions "
Any other use is not in accordance to the specification. The
manufacturer is not to be held responsible for the damages
caused by abnormal use. In this case the user is held responsible
for the respective damages.

NOTE ! There must be guaranteed the fact that this valve is operated only
by authorized persons. Any maneuver reducing the safety in
functioning of the valve and connecting pipes must be avoided.
The valve must be actuated only in accordance conditions.
During the operations of closing, and opening nobody should
remain into the actuator.
There must be worn the protection equipment if necessary. During operation there
shall be paid care to the danger represented by mobile parts in movement.
When works are performed to the installation there must be
observed the Work Protection rules.
When working at the valve there must be taken special care that the maintenance staff
is not exposed to the environment danger (pollution), temperature or pressure.
According measures must be taken.

3.2 Setting into function

 NOTE ! Before setting into function, make sure that it is impossible any
actuation by mistake (unwanted).
Before start the following maneuvers must be performed:

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1.Care must be taken that all the moving parts of the valve
can change their position without blocking. All foreign
materials which may prevent the movement must be
removed.
2.The interior of the valve must be cleaned from dirt and dust.
3.The plane facets and the irregular ones must be checked for
flaws that may affect the use of the valve.
All the parts which do not belong to the valve are to be removed: non-isolated wire,
tools that may cause faulty functioning both for the valve and adjacent lines.
4.Verify that the lubrication points are filled with the proper vaseline.
5.Insure a smooth functioning of the valve.
6.Check if the functioning of the valve is according to the normal functioning.
7.Check if the packing gland’s gasket is long lasting and functional.

NOTE! After the initial start, all screwed connections into the flange must be tightened.

3.2.1 Operation manner of the valve

The actuation of the valve is done by electric and hydraulic devices.

In normal functioning conditions the position of the valve is any of the final positions of the
course.
a)Normal functioning
During normal functioning, the valve is actuated by an electric/hydraulic device
(actuator).
b)Functioning conditions in case of fault
In fault conditions, that is during the loss of supply current, the valve can be actuated by:
- hydraulic accumulator;
- maneuver wheel.
(see also the functioning manual of the actuator).
If the fault results from the faulty functioning of the actuation device, the reason of the
malfunction must be found.

3.2.2 Detection of technical malfunctions and removal of flaws

NOTE! During the repair operation, the valve must be brought to the closed position.
The valve must not be pressurized, it must be cleaned by the environment agents and
cooled to the ambient temperature.
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Fault The flap does not move up to the final position.

Causes Mechanical blockings.
Measures The interior surface of the valve body is cleaned from impurities and foreign materials; if
considered needed, it is lubricated again.
Measures It is checked if any foreign body is into the movement track of the valve.
Measures It is checked the valve and if necessary it is lubricated again.
Causes The final position is not reached.
Measures The actuator is checked and if it is necessary it is regulated again (see also the
operation manual of the actuator).
Measures Check the supply of energy.
Check the energy supply failure.
Measures Check that the components are on position and correct functioning.
Fault There appear leakages when closing (in closed position).
Causes The disk does not move in final position.
Measures It is checked that the actuator closes up to the final position.
Causes Leaks at the packing gland.
Measures It is tightened and lubricated again at the packing gland and the gaskets can be
replaced.

4. Maintenance
4.1 Maintenance instructions

NOTE! Any intervention or repair to the valve involving hazardous materials shall be done with the
appropriate breathing equipment (gas mask). Fire is not to be lit next to the valve.

4.1.1 General Instructions

When working at the valve, care must be taken for the staff not to be exposed to any danger. If
the valve is taken out from the installation for repairs, the lifting equipment must insure the lift
of the valve.
4.1.2. Lubrication chart
NOTE! Pay attention because the valve cannot be lubricated during functioning.

TABLE 1

Lubrication point Spindle

Lubricant Molykote Spray Rapid
Lubrication interval Weekly
 TABLE 2
Lubrication point Packing gland
Lubricant Molykote-spray type Rapid
Lubrication interval Monthly

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4.1.3 Visual inspection

The following checks must be performed:

Testing place What is verified Frequency

Thickness of connection to flanges Weekly
Flanges screws and gasket
Sealing box Sealing thickness into the Weekly
Sealing box
Protection layer of the Strikes or rust Annual
valve

Spindle Scratches Weekly

Smooth Function (without
interruptions Weekly
Flaws to cables
Weekly
BAFCO actuation It is checked according to the
device manual
electric/hydraulic BAFCO

4.1.3. Repair

N O T E ! B e f o r e r e p a i r , there must be taken care that the exploitation staff as well as the
equipment of the valve are not exposed to danger.

We must be aware of the following dangers:

- high pressure in the system;
- high temperature (referring to the working field of the valve);
- chemical composition of the medium.
It is recommended that the first repair of the valve is made by ZIMMERMANN&JANSEN. It
prevents the inappropriate repairs and the possibility of destroying the valve. Meanwhile, it serves as
training for the maintenance staff. Usually the user must repair only those parts mentioned into the
spare parts list. Other repairs must be done by the staff of ZIMMERMANN & JANSEN or their
supervision.
 4.2.1 The replacement of the gasket from the sealing box

Attention! Before replacing the gasket, make sure that the line is depressurized and it is not hot
so that it does not represent any danger caused by the working medium. Make sure that the valve is
not actuated during the replacement of the gasket.

Concerning the drawing no.. 906811:

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1. Loosen pos. 35, push the flange of the packing se impinge pos. 16 and 15 over the spindle.
2.Remove the gasket from the sealing box, that is pos. 22 and 23 with the extraction
device.
3.Extract the ring from the sealing box.
4.Remove the gasket pos. 21, 22 with the extraction device.
Insert a new set of gaskets. Introduce the gasket for the quality specified by Z & J (see the list with
spare parts). When the sealing screws are introduced, care shall be taken that the sealing packages are
mounted different. The sealing cords must be pressed individually into the respective space with the
help of the packing gland’s flange pos. 16 and 15.
5.Mount in the reverse order.
After the introduction and total pressing of the gasket, the packing gland is sealed again pos. 16
and 15 with pos. 35. After tightening, (for the screwing couple) the packing gland must be
checked. The movement capacity of the spindle must not be affected.
4.3 Spare parts
To guarantee a correct functioning and avoid malfunctions, it is recommended to keep on stock
the spare parts proposed by Z & J with sufficient quantity.
Proposed spare parts:
- spare parts for exploitation:
- spare parts for 4-5 years of exploitation.

4.3.1

Spare parts for functioning

Two way valve ( DIVERTER)

Material Quantity Observation
Drawing no.
necessary
Nr.crt Description Cod

Ring gasket 906811 J.Crane

21 (base) 908101 1600 N 2
Ring gasket 906811 J.Crane,
22
908103 235 6
Ring gasket 906811 J.Crane
23
908102 1625 G 4
Sealing 906811
24 gasket orifice
901596 Graphite 1
25 Gasket for 906811 1.4301/graphite
239147 1
Gasket for 906811
908099 1
- Hydraulic filter 906818 BAFCO 6
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4.3.2

Spare parts for 4-5 years of exploitation

Two way valve (DIVERTER)

N e c e s s a r y
Nr. Description Drawing nr. Material q u a n t i t y p e r Observation
Cod
6 Steam valve 906811
(valve A 182-F 304 1
906817

O p e r a t i o n m a n u a l f o r t h e a c t u a t o r

5.1 Description of the actuator

The actuator is the first motor of the hydraulic system. It includes a cylinder, two (2) cylinder heads (C 1 and
C2), piston axel, a piston and an auto control position.
The clapets of the cylinder Cl (above) and C2 (below) have the interface between the hydraulic power
installation and the actuator. The spindle of the piston is attached to the piston and is spread to the inferior
head of the cylinder (C2). The piston separates the superior and the inferior head (Cl, respectively C2).
When opening command is given, the pressure is increased to the opening of C2 through the servo valve.
This difference of pressure obliges the actuator to extend the piston rod thus opening the valve. If the
pressure is increased to the opening Cl and decreased to the opening of C2, the actuator shall close in a
similar manner.
"Standoff' represents the axle of the actuator/couple spindle of the valve and the decoupling mechanical
mechanism. The blocking collar is the connection point for the actuator axle, the valve spindle and
mechanical mechanism. When the thread of the valve spindle is calibrated into the blocking collar, the
rotating frame of the linear movement of the actuator is responsible for the linear movement of the valve.
The movement is represented by the top of the actuation screw (advance) rotating the actuation mechanism
when the manual actuation is rotated and the mechanism of the blocking collar transforms the rotation
movement of the actuation screw into a linear movement. The top of the nut sectioned into the blocking
collar engages or disengages the actuation screw when the rotation lever is rotated.
The auto control position is LVDT (linear variable differential transformation), structured into the actuator
cylinder center. LVDT has the central metallic part into the interior of a tubular tri-phase transformer. The
position of the central part in connection to the winding produces a specific exit signal. The signal is
transformed into the valve position.

Operation into the manual hydraulic system

PASUL 1- Se inchide MV-5 si se deschide MV-6.

PASUL 2 - Se roteste MCV (controlul manual al ventilului) pentru "a deschide" sau "a
inchide" ventilul.Se revine in pozitia "auto" pentru a opri.
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S E A CONTROLULUI AUTOMATIC DIN OPERAREA MANUALA HIDRAULICA

PASUL 1- Se potriveste semnalul de comanda cu pozitia ventilului.

PASUL 2- Se deschide MV-5 si se inchide MV-6.

OPERAREA IN SISTEMUL DE ACTIONARE MANUAL

PASUL 1- Se inchide MV-5 si se deschide MV-6.

PASUL 2- Se roteste pirghia de blocare in pozitia de deblocare.
PASUL 3- Se roteste sistemul de actionare manual in Limp ce se trage maneta in pozitia
"Engaged".
PASUL 4- Se roteste pirghia de blocare in pozitia "Blocat".
PASUL 5- Se roteste MSV in pozitia "MECH".

R E Z ~ A CONTROLULUI AUTOMAT DIN OPERAREA MANUALA

PASUL 1- Se potriveste semnalul de comanda cu pozitia ventilului.

PASUL 2- Se inverseaza procedura de mai sus.

INLOCUIREA PROCEDIRII PENTRU LVDT

1) Se utilizeaza cored procedura de a angrena sistemul de actionare manual (referitor la instructiumle

actuatorului).
2) Se inchide presiunea hidraulica sipresiunea de purjare din sistem si acumulatori.
3) Se scoate capacul LVDT din partea din spate a aduatorului.
4) Se desurubeaza cablul de conexiune de la LVDT.
5) Se desurubeaza traductorul de autocontrol (LVDT).
6) Se inlocuieste tradudorul de autocontrol (LVDT) cu unul nou, avand grija sa se centrze gaurile la
sfarsit cu partea centrala din actuator.
Verificarea LVDT se face in mod cored astfel:
A.Se reconedeza cablul de la LVDT.
B.Se conedeaza un voltmetru (DC) la TB1 si TB2. LVDT trebuie citit intre-2VDC si -5VDC.
C.Se introduce si se retrage LVDT din actuator si se urmareste dace voltajul se modifica..
D.Se deconedeaza cablul de la LVDT.
E.Se insurubeaza (se roteste) LVDT in actuator pina card ielul 0 se aseaza.
7)Se reconedeaza cablul.
8)Se face o citire a pozitiei ventilului din scala actuatorului. Se utilizeaza pozitia de zero de autocontrol
pentu a potrivi scale cu pozitia aparatului de masura al ventilului.
9)Se represurizeaza sistemul si se dezangreneaza sistemul de actionare manual.
10)Se repune capacul LVDT din partea din spate a catuatorului.

5.2 DESCRIEREA SISTEMULUI HIDRAULIC

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Uleiul hidraulic este asigurat de un singer rezervor de 28/80 Gallon. Rezervorul este construit Cu talere,
filtru, intrerupator de vacuum/venril al variatiei de presiune, indicator de nivel, comutator de temperatura
ridicata, scala de temperatura si robinet de evacuare.
Pompele au un piston axial cu care se corecteaza presiunea si debitul maxim.Fiecare pompa are un un ventil
de control localizat in fluxul din aval, un filtru manifold, pentru a preveni intoarcerea debitului de ulei.

ASPIRATIA COMBINATA, PRESIUNEA MANIFOLD

Aspiratia combinata., presiune manifold conecteaza rezervorul cu pompa interioara si exterioara cu servo-
control manifold. Ca functii suplimentare sunt presiunea de variatie si a r u m ul6ului.
Aspiratia combinata, presiunea manifold are urmatoarele componente:
A)Ventil interior (MV-lA, MV-IB)
B)Ventil interior de control (CV)
Previne revenirea debitului prin pompa.
C)Ventilul de variatie (RV)
Asigura variatia sistemului de variatie, de aproximativ 200 psi peste presiunea de operare.
D)Filtrele de inalta presiune (FIL)
Filtreaza uleiul la 10 micron.
E)Ventile izolatoare cu filtru (MV-2A, MV-2B, MV-3A, MV-3B).
Izoleaza manifold-ul de debitul din aval (pentru intretinere).
In conditii normale de operare , in mod uzual, doua ventile izolatoare cu filtru (MV-2A, MV-2B sau
MV-3A, MV-3B) sunt inchise, permitind unui filtru sa fie utilizat la time.
F)Acumulatorul principal de legatura
Acumulatorul conectat in acest punt este utilizat pentru a agora ulei daca siste-
mul necesita necesita mai mutt decat poate asigura pompa.
G)Ventilele blocului de masura
I z o l a calibre manifold (pentru intretinere).
H)Calibre (masura) (PI-1A)
0-300 psi, indica sistemul presiuni.
I)Comutatorul de legatura at presiuni
Comutatorul de indepartare a presiuni (PSL-1A sau PSL-1B) este utilizat pentru a semnaliza
sistemul de inalta presiune care porneste din instalatia din spatele pompei.

SISTEMUL DE CONTROL

Uleiul intra in manifold control prin ventilul de inchidere (MV-5). In afara de MV-5, control ma
ifold tontine: (3) operare pilot a ventilului de control (POCV), un ventil de control manual
(MCV),(2)ventilele de temperatura (TR) , rezerva/caz de urgenta a acumulatorului indicator de
presiune si comutatorul alarmei de joasa presiune (PI- 4, PSL- 4), ventilul servo-control (SEV) si
sistemul de masura al presiuni (PI-3).
Doua dintre POCV sunt localizate aval de ventilul servo-control (SEV) pe Cl si C2 si unul dintre
POCV este localizat inainte debitul de intrare in ventilul servo. Cand liniile de control ale sistemului
de presiune POCV sent deschise si aici este o cadere de presiune, presiunea scale la aprox. 100 psi.
 MANUAL DE OPERARE
PETROBRAZI VENTIL CU DOUA CAI
PENTRU Exemplar: Page: 18 din 19

GAZE DE ARDERE FCC

1676/1200/1200

Servo este un ventil cu patru cai

hidraulic/electronic care masoara uleiul
pentru a controla miscarea actuatorului. In
acest ventil, debitul de ulei este
proportional cu eroarea semnalului
(electric). Directia debitului de ulei este
controlata prin senuial (+) sau (-) a1 acestui
semnal.
MCV permite operarea locala hidraulica a
actuatorului cand comutatorul "local
remote" este in pozitia "local", MV-5 este
inchis si MV-6 este deschis. Schimbarea
manuala a MCV directioneaza uleiul la Cl
sau C2 din actuator, care actioneaza pozitia
AND/OR a ventilului.
MSV pure in legatura Cl si C2 pentru
intoarcere. Aceasta pernute debitului de ulei
sa patrunda in interiorul actuatorului si sa
paraseasca actuatorul, in timp ce se
utilizeaza sistemul de actioanre mecanic
manual. Urmati instructiunile actuatorului
pentru a pune in functiune si a decupla
sistemul de actionare manual. Ventilul
blocului de masura izoleaza manometrul
pentru intrtinerea directs, Ventilul purjei
elibereaza presiunea reziduala inainte de
inceperea intretinerii.
Ventilul TR previne cresterea excesiva a
presiunii din actuator cand POCV sum
mchise si actuatorul este supus unui schimb
termic.
Manometrul PI-3 inregistreaza presiunea
disponibila pentru a schimba pozitia
ventilului automat. NOTA: Presiunea
trebuie sa fie pana la 200 psi pentru PI-1.
A

L
A

c
e

t
 i

cand PSV-2 este inchis,

acumulatorul de rezerva/urgenta
aduna fluidul hidraulic in
sistemul de presiune; ventilele
de control suet utilizate pentru a
asigura fluidului o curgere
corecta;
cand PSV-2 este deschis, fluidul
este furnizat manifoldului de
control, permitand actionarea
suplimentara a actuatorului;
PSL-4 alarmeaza cand
acumulatorul de rezerva/urgenta
este pe lime dupa PSV-2 si este
deschis.
Acumulatorul de rezerva/urgenta este
utilizat dupa ce acumulatorul principal este
gol si pompele sunt defecte. Sistemul total
de control este disponibil pana ce (I)
actioneaza asupra acumulatorului ramas,
cand functionarea acumulatorului de
rezerva este incapabila sa impiedice
fitnctionarea acumulatorului de urgenta.

A) VERIFICAREA
PRESIUNII
DE PRE-
INCARCAR
EA
ACUMULAT
ORULUI (0
DATA PE
AN)

ACUMULATOR NORMAL

1) Ventilul trebuie sa fie in operare manuals (vezi placuta de avertizare a actua

2) Instalatia de putere hidraulica trebuie sa fie inchisa.
3) Se deschide MV-6 si se lasa aprox. 5 min. acumulatorul principal sa se purj
4) Se deschide solenoidal acumulatorului rezerva si se lase aprox. 5
purjeze prin MV-6.
5) Se inlocuieste dispozitiwl de protectie al ventilului pe gaze si capatul galbe
gaze.
6) Maneta "T" de pe charging kit trebuie adusa inapoi (in sens rovers acelor de
opreste, inainte de atasarea acumulatorului la ventilul pe gaze.
7) Se inchide purja ventilului de pe charging kit.
8) Se ataseaza bucsa (piulita) reductiei a charging kit la acumulatorul ventilului
 MANUAL DE OPERARE Exemplary:
VENTIL CU DOUA CAI PENTRU
PETROBRAZI Page: 19 din
GAZE DE ARDERE FCC
19
1676/1200/1200

9) Se refine charging kit a bucsei capului de injectie (reductiei) cu cheia fixa

de piulite (1), in time ce se desurubeaza piulita hexagonala de pe partea
inferioara a acumulatorului ventilului pe gaze Cu cea de-a doua cheie fixa.
Aceasat va deschide supapa de aerisire (supapa fixa cu tija) din
interiorul acumulatorului pentru a indica domeniul azotului.
Nota: Patru (4) rotiri ale piulitei hexagonale vor deschide complet ventilul pe
gaze.
10)Se verifica valoarea p re si u i pe scala cu ajutorul inscriptiei de pe
partea inferioara a fiecarui
acumulator. Presiunea trebuie reglata.
11)Daca presiunea este mai mare, se purjeaza presiunea prin ventilul de
purjare de pe scala charging
gage.
12)Daca presiunea este mai mica, se reincarm cu azot uscat.kit la cutia
de alimentare cu azot
13)Se ataseaza furtunul reductiei (capului de ectie) a charging
care are o ptresiune corespunzatoare. Ne vom asigura ca furtunul nu are
bucle sau nu este
rasucit.
14)Se sparge deschiderea cutiei cu azot a ventilului si se umple incet
acumulatorul. Se opreste
atunci card scala grata domeniul dorit. aturii gazuhxi sa
15)Se lass timp de 10-15 in acest domeniu. Acest lucre va permite
temper
stabilizeze. Daca domeniul dorit este prey mare, se va inchide ventilul de
alimentare cu not,
apoi se deschide incet ventilul de p a r e .
16)Cu o cheie fixa se strange bine piulita hexagonala pentru a inchide
supapa de aerisire din interior (supapa cu tija fixa - 5-8FT.LBS).
17)Se schimba pre-domeniul de pe cutia ventilului pe gaze.
18)Se inlocuieste capul de gaze si se strange b e (10-15 IN. LBS.) si se
instaleaza protectia
ventilului pe gaze.
19)Se inchide MV-6 card procedura este completa, se deschide pompa,
se respecta procedurile
pentru trecerea actuatorului de la operarea normala la operarea automata.

B) INLOCUIREA ELEMENTELOR FILTRULUI

Se deschide MV-2B si MV-3B. Se inchide MV-2A, MV-3A si se deschide ventilul de
purjare din baza bazinului filtrului. Se desunubeaza bazinul filtrului din baza
corpului pompei si se inlocuieste, avand grija sa nu se deterioreze etansarea 0-
ring. Se scoate filtrul pentru a se inlocui; se rebuteaza elementele vechi. Se
 unge O-ringul pe noul element si se sprijina pe niplu. Se fixeaza bazinul filtrului
pans ce se fixeaza pe suport. Nu se va inchide filtrul ventilului de purja, si se va
deschide MV-2A, MV-3A. Se inchide MV-2B si MV-3B.

C) INLOCUIREA MANOMETRELOR
Se izoleaza manometrul prin inchiderea ventilului placutei de calibrare. Se
deschide ventilul purjei pentru a elibera presiunea reziduala. Se inlocuieste
manometrul. Fiecare manometru este fixat printr-un 0-ring care trebuie verificat
inaintea instalarii si inlocuit daca este necesar. Se instaleaza noul manometru.
Se inlocuieste ventilul de purjare, se deschide trunchiul ventilului. Noua
componenta este
in functiune.
Atentie: Comutatorul de presiune interactioneaza cu sitemul de control automat.
Sistemul logic trebuie
sa fie verificat inainte de a proba aceasta procedura.
 D U A L DE OPERARE
VENTIL CU DOUA CAI PENTRU
GAZE DE ARDERE FCC Exemplar: Page: 20 din 19
PETROBRAZI
1676/1200/1200

D)IZOLAREA POMPEI
Pompa trebuie sa fie inchisa pe partea care trebuie
sa fie izolata, inchizand MV-1 cand instaland o
noua pompa carcass tubului de drenaj trebuie sa
fie umpluta cu lichid hidraulic inainte de
instalare.
Atentie: Inainte de pornirea pompei se deschide
complet MV-1, altfel se poate produce defeetarea
mi
E)IZOLAREA SERVOVENTILUI-UI

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