Professional Documents
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FOR
LIQUID CO2 DOSING SYSTEM
21-MAY-12
LH
LBS
AS BUILT
AB
4-Jan-12
LH
LBS
AS BUILT
REV
DATE
PREPARED
REVIEWED
APROVED
DESCRIPTION
LOCAL CONSULTANT
CONTRACTOR
STATUS
FILE NAME
AS BUILT
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HYDROCHEM (S) PTE LTD.
RESERVE THE RIGHT OF
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TITLE
DOC NO.
C200903-MP-W1-003-P
REV
AB
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
KKS!CODE!
1!
2!
3!
4!
5!
B0GDU01BB001!
B0GDU02BB001!
B0GDU14AC001!
B0GDU32AC002!
B0GDU37AM001!
DESCRIPTION!
Liquid!CO2!Bulk!Storage!Tank!
Liquid!CO2!Bulk!Storage!Tank!!
Ambient!Heat!Vaporiser!1
Ambient!Heat!Vaporiser!2!
Static!Mixer!
P&ID!Dwg!No.!
C200903"PR"W1"133"C
C200903"PR"W1"133"C!
C200903"PR"W1"133"C
C200903"PR"W1"133"C!
C200903"PR"W1"133"C!
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
TABLE OF CONTENT
Actuator
Ball Valve
Control Valve Operating Instruction
Differential Pressure Meter
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
SECTION A
EQUIPMENT MECHANICAL MANUAL
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
SECTION A
Part I General Engineering Data
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A1-1
Application
Microprocessor-controlled transmitter for measuring and
indicating the differential pressure or measured variables
derived from it Suitable for gases or liquids Measuring
ranges from 0...100 to 0...3600 mbar PN 50
Scope of application
Liquid level measurements in pressure vessels, in particular,
for cryogenic, liquefied gases
Differential pressure measurements between the flow pipe
and return flow pipe
Pressure drop measurements in valves and filters
Flow rate measurement according to the differential pressure method
Liquid level measurement
When used in combination with an appropriate power supply
unit (e.g. SAMSON Type 5024-1) for the electric power supply
or the Media MTM 32 hardware for remote data transmission,
the tank content (function of hydrostatic pressure, tank geometry
data and liquid density of the stored gas) is converted into a 4 to
20 mA signal, which is proportional to the tank content and displayed on a LCD in the selected unit of measure. Additionally,
limit values can be monitored and indicated.
Remote transmission of all relevant Media 6 data is possible using the Media MTM 32 hardware and the Media MTM 98 software. The tank data can be transmitted via a phone line or GSM
to a remote PC, where they are analyzed.
Flow rate measurement
When used in combination with an orifice plate assembly
(Type 90 Orifice Flange), the Media 6 devices can be used for
continuous flow measurement or counting the flow rate1) of
gases, vapors and liquids (differential pressure method).
Special features
Suitable for liquids, gases, and vapors
Microprocessor-controlled transmitter with RS-232 interface for configuration and programming on site
Two adjustable software limit switches
Gas selection by switch
Programming via memory pen
Digital display (LCD) for temperatures down to 40 C
with 100 % bar graph as well as alarm and warning
markers
Zero point and span adjustment activated via key without
influencing each other
Two-wire connection for 4 to 20 mA signal
1)
Fig. 1 Media 6
1)
Versions
Media 6 with LCD Transmitter with digital display Two-wire
connection Output signal 4 to 20 mA, supply voltage 12 to
36 V DC, consisting of:
LCD 90 mm with 100 % bar graph and blinking alarm and
warning markers Two software limit switches or one software
limit switch acc. to NAMUR and a pulse output 1) dp cell made
of CW617N (brass) or stainless steel Free of oil and grease for
oxygen Measuring ranges from 100 to 3600 mbar ECO
measuring diaphragm Zero point and span adjustment activated via key Process connections G 3/8 A RS-232 interface
Media 6 optionally available with:
Version as above, but for hazardous areas Input circuit
with type of protection
II 2 G EEx ia IIC T6
Directly connectable valve block with test connection to
check the tank pressure and with connection for pressure
switch
T 9500 EN
Data Sheet
T 9527 EN
9
Connector A
7
40
60
IA = 4 to 20 mA
80
20
m3
UB = 12 to 36 V
8
Connector B
100
Alarm 1
5
Alarm 2
3
MP
Pulse output 1)
RS-232
10
4
FRAM
dp cell
2
1.1
1.4
1.3
1.5
1.2
1.2
Valve block
with
pressure gauge
p2 _
p1 +
Four types of gas as well as the span and write protection function can be set at the DIL switch (6). In combination with three
keys (5), several operating functions (zero point and span adjustment, max. alarm limit switch and test function settings, etc.)
as well as the operating status (load/save operating values) can
be adjusted.
Typical application
Storage tank
60
40
20
0
80
3
100
H
h
1
1.1
1.2
1.3
1.4
1.5
2
3
4
5
6
dp cell
Measuring diaphragm
Range spring
Lever
Flexible disk
Diaphragm axis
Displacement sensor
Microprocessor
Data memory (FRAM)
Keys for operating functions
4-pin DIL switch
for selecting gas type, span protection and write
protection
7 Indicating unit with LCD
8 Limit switch/pulse output 1)
9 D/A converter
10 RS-232 interface
H
h
Measuring range
Measured height (z tank content)
T 9527 EN
0 to 100
0 to 160
0 to 250
0 to 400
0 to 600
0 to
1000 1)
0 to
1600 1)
0 to
2500 1)
0 to
3600 1)
From
to
b 250
r 125
b 400
r 100
b 600
r 150
b 1000
r 250
b 1600
r 320
Class 1.6 %
From
to
b 100
r 60
160
r60
< 125
r 50
< 100
r 80
< 150
r 120
< 250
r 200
Class 2.5 %
From
to
< 60
r 35 2)
< 60
r 32
Nominal pressure
b 2500 to b 3600 to
r 500
r 720
Indicator
LCD 90 mm
Performance
Output and reading linear or square root extraction depending on operating mode
Conforming error
< 1.0 % to < 2.5 % (including hysteresis) depending on measuring span selected
Sensitivity
Limit switches
Switching accuracy
Range of inversion, approx.
< 0.6 %
Degree of protection
Weight
Version
IP 65
Approx. 3.0 kg without valve block Approx. 5.0 kg with valve block
5006- _0 ...
Two-wire circuit
5006- _1 ...
Output 4 to 20 mA
UB - 12 V
RB =
0.020 A
Perm. load RB in 7
12 to 36 V DC
40 to +70 C
T6; 20 to +60 C
T5; 20 to +70 C
40 to +80 C
1) A class accuracy of 0.6 % can be expected in these measuring ranges with measuring spans b 100 % to r 50 % of the nominal range.
2) The accuracy of class 2.5 % can be exceeded when this measuring span is not reached.
3) e.g. KFA6-SR2-Ex2.W as per EN 60947-5-6
4) MCN = Maximum Capacity Nominal; SCN = Save Capacity Nominal
5) Pulse output only with Media 6 Z
Notes
All pressure specifications stated in bar (gauge) All errors and deviations are specified in % of the adjusted measuring span!
The Media 6 Differential Pressure Meter is not approved for measuring flammable gases or liquids in hazardous areas of Zone 0!
(Refer to EB 9527-3 EN for more details).
Table 2 Materials
Media 6 Differential Pressure Meter
dp cell
Measuring diaphragm and seals
Range springs
Diaphragm plates and function parts
CrNi steel
Lever
Housing of indicating unit
Polycarbonate
T 9527 EN
Electrical connection
In combination with a power supply unit (e.g. SAMSON
Type 5024) or the Media MTM 32 hardware, the tank content
can be transmitted and displayed over a 4 to 20 mA signal proportional to the tank content. In addition, the limits values can
be monitored and signalized.
Tank farm
Control room
Control room
Data
transmission
Power supply
unit
e.g. Type 5024
Gas supplier
RS - 232
#
20
MTM 32
60
40
80
m3
100
Power
supply
230 V AC
Switching amplifier
acc. to EN 60947-5-6
Terminal assignment
The Media 6 Differential Pressure Meter is designed for a two-wire
circuit. Both the 4 to 20 mA measuring signal and the required supply
voltage UB = 12 to 36 V DC for the two-wire transmitter are
transmitted by the same pair of wires.
The Media 6 is connected over a DIN 43650 connector, type 1,
4-pole.
Connector A
1+
1
3
~
2
Two-wire connection
Connector B
1+
2
1
4
3+
4
Alarm contact
2 min. contacts
(gas tapping)
2 max. contacts
(tank filling)
A1
A2
A1
A2
A1
A2
Value
below limit value
High resistance
Low resistance
High resistance
High resistance
Low resistance
Low resistance
Limit value
exceeded
Low resistance
High resistance
Low resistance
Low resistance
High resistance
High resistance
Both limit switches A1/A2 can be configured separately as minimum or maximum alarms.
Contact with low resistance
Switching signal ON Function: Contact closed or output effectively conducting, power consumption r 3 mA
Contact with high resistance
Switching signal OFF Function: Contact open or output effectively non-conducting, power consumption b 1 mA
T 9527 EN
20 V
Ii
60 mA
Pi
250 mW
Ci
5.3 F
Li
Mounting
On mounting the Media 6, the following points must be observed:
Attach it to a pipe, wall or mounting plate free of vibration.
Use mounting part with clamp for pipe mounting to attach it
to a vertical or horizontal pipe.
Use mounting part without clamp for wall mounting.
See bottom diagram in Fig. 6 for control panel mounting.
We recommend installing a shut-off valve in each measuring
line as well as an equalizing valve. SAMSON provides for this
purpose a valve block designed as a compact unit (see
T 9555 EN) for direct connection to the Media 6 device.
8 H
Maximum values only apply to the network connection to a certified intrinsically safe circuit.
Dimensions in mm
Mounting versions
Pipe mounting With mounting device and clamp for attachment to
a vertical or horizontal 2 pipe.
141.5
80
37
194
180.5
148
20
0
80
m3
100
25.5
43
80
145.8
114.5
158.5
117
245.5
32.5
60
40
121
M8
72
Control panel
58
Pressure sensor
31
60
30
54
158
17
30
T 9527 EN
__
Type 5006
__
__
__
__
__
__
__
Device
Media 6
Media 6 Z
Explosion protection
Without
Material
Brass
Stainless steel
Measuring range
100 mbar
03
160 mbar*)
04
250 mbar
05
400 mbar*)
06
600 mbar*)
07
1000 mbar
08
1600 mbar*)
09
2500 mbar*)
10
3600 mbar*)
11
Diaphragm
ECO diaphragm (40 to +80 C)
00
10
50
000
Special version
Data logging
Data need to be made available about the tank characteristics
and the stored gas for the factory settings of the LCD reading
and the 4 to 20 mA signal to ensure that they are proportional
to the tank content and flow rate.
Ordering text
Differential pressure meter Media 6
Version Type 5006 _ _ _ _ _ _ _ _
Special version
You can enter these data in the Specification Sheet for Media 6
parameterization.
A SAMSON Questionnaire for Flow Rate Measurement according to the Differential Pressure Method FB 9550 EN is available
to record the relevant data for flow rate measurement.
Accessories Refer to T 9555 EN for accessories and details
T 9527 EN
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A1-2
ON
REQUEST
STANDARD
MATERIAL
ITEM
PART
BODY
(on request)
SPRING
AISI 316
Face A
To be installed
in any position
Face B
Downwards
flow
Horizontal flow
15
20
25
32
40
50
65
80
100
mm
43
48
58
68
75
94
113
129
159
mm
54
64
71
81
93
110
130
149
181
mm
45
54
63
72
82
95
115
131
160
mm
23
28
36
50
58
71
86
105
130
mm
14
19
25
31
38
48
62
77
95
mm
17
20
22
28
32
40
46
50
60
Weight
Kg
0,11
0,18
0,26
0,4
0,55
1,0
1,5
3,2
Upwards flow
CAT CH-EN-07
50 bar
40 bar
30 bar
20 bar
10 bar
0
100C
200C
300C
400C
DN
15
20
25
32
40
50
65
80
100
With spring
mbar
25
25
25
27
28
30
30
25
21
With spring
mbar
23
23
23
25
23
24
24
19
15
With spring
mbar
21
21
21
22
18
18
18
13
Without spring
Note: GB015 and GB019 are not designed to be installed without spring.
100
10
0,1
DN
15
DN
20
DN
25
32 40 N50
D
DN DN
10
100
m3/h
0
65 N80 10
DN D DN
d
1000
CAT CH-EN-07
For different liquid , gas or steam head losses are determined by equivalent water rate of flow, as follows:
Qe - equivalent water flow (mc/h o l/s)
Q - fluid flow (mc/h o l/s)
d - fluid specific gravity (Kg/mc)
5
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A1-3
Catalogue 4921/GB
4921/GB
INDEX
General Information ..........page 2
G 1/4 Series .....................page 4
G 1/2 Serie .......................page 6
Accessories ......................page 8
TECHNICAL DATA
Function :
Manual override :
Design :
Pilot operated spool valve with combined pneumatic and spring return
Mounting :
Mounting position :
Indifferent.
Material specifications :
Media :
Fluid temperature :
Ambient temperature :
-10 C to +50 C.
Electrical part :
Solenoid duty :
100% ED
Voltage :
Voltage tolerance :
10% of nominal
Applications
"
3- or 4-way directional valves for the control of single or double acting pneumatic actuators
"
The interface design corresponds to the NAMUR standard and the VDI/VDE 3845 recommendations of the
actuator industry and permits a compact design of the actuator/valve unit.
NAMUR Interfaces
T
1/4
1/2
D1
mm
32
45
D2
mm
24
40
D3
mm
8
10
D4 min.
Mm
12
16
M
mm
M5
M6
Page 2/8
Parker Lucifer SA
CH-1227 Carouge-Genve
4921/GB
Coils
Voltage
12VDC
24VDC
48VDC
24/50AC
110/50AC
230/50AC
Description
22mm standard coil
22mm standard coil
22mm standard coil
22mm standard coil
22mm standard coil
22mm standard coil
Order No.
496131 C1
496131 C2
496131 C4
496131 A2
496131 A5
496131 F4
How to order
Valve reference No. * - Coil reference Voltage code = order code
* includes mounting kit for coil assembly + 2x NAMUR O-rings + 2 mounting screws and positioning dowel
Example: 341 N 03 +
496131C2
order code
341N03-496131C2
Spare Parts
"
Spare Housing
"
Page 3/8
Parker Lucifer SA
CH-1227 Carouge-Genve
4921/GB
Seat
disc
Reference N
Min. = 0 C
Dim. ref.
Max. admissible
fluid temperature
[C]
[Watt]
Admissible
differential
pressure [bar]
Weight
[g]
QN
Power
consumption
Orifice
Port
size
max
G
mm
3/2
1/4
5/2
1/4
5/2
1/4
5/3
1/4
3/2
1/4
5/2
1/4
5/2
1/4
5/3
1/4
L/min
min
DC#
AC$
Air &
Neutral gases
Valve
Coil
DC
AC
496131
300
496131
300
496131
430
496131
430
210
210
240
210
1.5
10
10
50
NBR
331N03
1.5
10
10
50
NBR
341N03
1.5
10
10
50
NBR
347N03
1.5
10
10
50
NBR
342N03
2.5
10
10
50
NBR
531N03
1250
2.5
10
10
50
NBR
541N03
1250
1.5
10
10
50
NBR
547N03
1.5
10
10
50
NBR
Page 4/8
542N03
Parker Lucifer SA
CH-1227 Carouge-Genve
4921/GB
Dimension ref. 1
Dimension ref. 2
Dimension ref. 5
Dimension ref. 6
Parker Lucifer SA
CH-1227 Carouge-Genve
4921/GB
Seat
disc
Reference N
Min. = 0 C
Dim. ref.
Max. admissible
fluid temperature
[C]
[Watt]
Admissible
differential
pressure [bar]
Weight
[g]
QN
Power
consumption
Orifice
Port
size
max
G
mm
3/2
1/2
12
5/2
1/2
12
3/2
1/2
12
5/2
1/2
12
L/min
min
DC#
AC$
Air &
Neutral gases
Valve
Coil
DC
AC
496131
720
496131
700
10
620
11
600
12
1.5
10
10
50
NBR
331N04
1.5
10
10
50
NBR
341N04
2.5
10
10
50
NBR
531N04
2.5
10
10
50
NBR
Page 6/8
541N04
Parker Lucifer SA
CH-1227 Carouge-Genve
4921/GB
Dimension ref. 10
Dimension ref. 9
Dimension ref. 11
Dimension ref. 12
Page 7/8
Parker Lucifer SA
CH-1227 Carouge-Genve
Parker Lucifer SA
Fluid Control Division Europe
16, Ch. du Faubourg de Cruseilles
CH-1227 Carouge-Geneva - Switzerland
Tel. +41 22 3077 111 Fax +41 22 3077 110
www.parker.com/lucifer
Catalogue
4921/GB
November 2005
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A1-4
DM 505, 505Z
DM 505 for liquids and gases up to 130 C, DM 505Z for steam up to 200 C
for low flow rates
Technical Data
Connection
G 1/2
DN 15 - 25
Nominal Pressure Inlet PN 250
Outlet PN 1 - 25
Inlet Pressure
up to 250 bar
DM 505: 0.005 - 20 bar in 8 ranges
Outlet Pressure
DM 505Z: 0.005 - 12 bar in 7 ranges
Kvs-Value
0.15 - 0.9 m3/h
Sense Line
DM 505: setting range 0.005 - 1.1 bar
DM 505Z: all setting ranges
acc. to VDI/VDE-guideline 2174
Tightness
(leakage rate K 0.05% of Kvs-value)
Description
Medium-controlled pressure reducers are simple control valves offering accurate control while being easy to install and maintain. They
control the pressure downstream of the valve without requiring pneumatic or electrical control elements.
The DM 505 pressure reducing valve is a diaphragm-controlled springloaded proportional control valve for small volumes.
This pressure reducer is manufactured from deep-drawn stainless
steel featuring excellent corrosion resistance. The tubular inlet spigot
of the valve body accommodates the seat aperture. The soft-sealing
valve cone is guided in the seat assembly and connected with the control diaphragm by means of a stirrup which surrounds the seat assembly.
The valve type 505 Z, recommended for temperatures up to 200 C, is
identical in its design apart from the metallic cone seal and water-cooled thermal protection between body and diaphragm.
The spring module comprising bonnet, spring, adjusting screw, diaphragm and internal components, is connected to the valve body only
by means of a clamp ring and two bolts. Changing the diaphragm or
the complete spring assembly for a different control pressure range is
extremely simple and does not call for special tools. The same applies
to servicing and maintenance. Changing the control pressure setting
does not affect the height of the valve (non increasing adjusting
screw).
The outlet pressure to be controlled is balanced across the diaphragm
by the force of the valve spring (set pressure). As the outlet pressure
rises above the pressure set using the adjusting screw, the valve cone
moves towards the seat and the volume of medium is reduced. As the
outlet pressure drops the valve control orifice increases; when the
pipeline is depressurised the valve is open. Rotating the adjusjting
screw clockwise increases the outlet pressure.
DM 505 Z requires a pilot line (to be installed on-site); for outlet pressures K 1.1 bar DM 505 also requires a pilot line.
STANDARD EQUIPMENT
OPTIONS
Pressure gauge connection
For toxic or hazardous media: sealed bonnet complete with
leakage line connection (incl. sealed adjusting screw). Must be
installed with a leakage line capable of draining leaking medium
safely and without pressure
Various diaphragm and seal materials suitable for your medium
Special versions on request
Operating instructions, Know How and Safety instructions must be observed.
spring module
adjusting screw
(non increasing)
Kvs-values [m3/h]
for all body sizes, please select
0.15
0.4
0.9
1-5
4-12 10-20
0.2-1.1
0.8-2.5
1-5
4-12
0.9
750
0.9
210
0.9
100
0.9
50
0.9
20
DM 505, 505Z
DM 505 for liquids and gases up to 130 C, DM 505Z for steam up to 200 C
for low flow rates
Materials
Type
Temperature
Body
Spring Cap
Internals
Set Screw
Spring
DM 505
80 C
130 C
DM 505Z
200 C
CrNiMo-steel
CrNiMo-steel
CrNiMo-steel
Valve Seal
EU
CrNi-steel
CrNi-steel
FPM optional
EPDM or PTFE
FPM oder EPDM
PTFE (option)
Diaphragm
CR
Protection Foil PTFE (option)
DM 505
A1
A
manometer
connection
G 1/4 (option)
CrNi-steel
CrNiMo-steel
EPDM
PTFE (option)
Dimensions [mm]
all ranges
0.005
0.02
0.025
0.12
0.1
0.5
0.2
1.1
0.8
2.5
1
4
10
5
12
20
size
A/A1
B
C
C
D
C
C
D
C
C
D
C
C
D
C
C
D
DM
G 1/2
505 + 505Z 100
505 + 505Z
505
505Z
505 + 505Z
505
505Z
505 + 505Z
505
505Z
505 + 505Z
505
505Z
505 + 505Z
505
505Z
505 + 505Z
53
257
387
360
257
387
264
257
387
200
196
326
138
190
320
114
53
257
387
360
257
387
264
257
387
200
196
326
138
190
320
114
53
267
297
360
267
297
264
257
387
200
196
326
138
190
320
114
Weights [kg]
pressure range
[bar]
0.005 - 0.025
0.002 - 0.12
0.1
0.5
0.2
1.1
0.8
2.5
1
4
10
5
12
20
DM
505
505Z
505
505Z
505
505Z
505
505Z
505
505Z
G 1/2
6
6.5
5.5
6
4.5
5
2
2.5
7.5
8
7
7.5
6
6.5
3.5
4
7.5
8
7
7.5
6
6.5
3.5
4
8
8.5
7.5
8
6.5
7
4
4.5
1.5
3.5
3.5
3.5
D
leakage line connection
G 1/8 (option)
DM 505Z
dimensions see DM 505
manometer connection
G 1/4 (option)
Recommended Installation
Bypass for maintenance
1
2
3
4
Strainer
Shutoff Valves
Pressure Reducer
Safety Valve
5 Pressure Gauge
6 Sense Line G 1/4 (DM 505Z)
7 Leakage Line G 1/8 (option)
pressure range
[bar]
TYPE 505
Sheet no.
DM 505/5.1.032.1.1
OPERA TION
The outlet pressure to be controlled exerts a force on the diaphragm which balances the load exerted by the spring in the normal operating state. As the outlet pressure increases above the pressure set via the setting screw, the valve closes; the valve opens when the outlet pressure falls below the set pressure. The valve is open when the pipeline is depressurised.
INSTA L L A TION
Before installing the valve the pipeline should be flushed through thoroughly. If coarse particles of dirt and foreign bodies cannot be avoided during operation, a strainer should be fitted. Remove any packaging material including
plastic plugs and install the valve into the pipeline ensuring that the arrow on the valve points in the direction of flow and the valve is free
of stress. The spring cover can, unless specified otherwise, be at the top or the bottom.
Type 505Z should always be installed with the spring cover at the bottom; type 505 should be installed with its spring cover at the bottom
only for liquids and outlet pressures up to 1.1 bar. The installation site should always be in a horizontal section of the pipeline that is not
subject to turbulence. Manifolds, stop valves or other restrictions immediately upstream or downstream from the valve should be avoided.
Pilot lines* should be connected at a distance of at least 10 times nominal bore downstream from the pressure reducer. The diameter
should match the valve connection diameter. In the case of steam installations operating at pressures below 0.1 bar the pilot line should
be fitted with an expansion vessel.
*applies only to pressure settings up to 1.1 bar and valve type 505Z
SA FETY DEVICES
Pressure reducers are not stop valves which provide a leak-proof shutoff function. According to VDI/VDE Guideline 2174 a leakage rate of
0.05% of the constant volume flow value is permitted. For this reason the German accident
prevention regulations VBG17 specify the installation of a safety device which prevents the maximum permitted system pressure being
exceeded. Unless otherwise specified, the pressure reducer itself should be protected in such a way that 1.5 times the maximum set pressure is not exceeded; e.g. with a set pressure of 5 bar the relief pressure of the safety valve should not exceed 7.5 bar. The relief pressure
must, however, not exceed the rated pressure of the valve body.
In addition the user must ensure that in the case of a diaphragm rupture any escaping fluid does not create a hazard. If necessary, a drain
line should be connected to the diaphragm housing breather orifice.
COMMISSIONING
The pressure reducer has been tested for correct operation and leakage before despatch from the works. The valve is supplied with the
spring relaxed. In the case of steam applications the control chamber should be filled with water via the pilot line connection before the
valve is commissioned. During commissioning the valve inlet should be opened slowly ensuring that the fluid drains from the outlet side.
Pressure surges must be avoided. Finally the outlet pressure should be set using the setting screw. The spring should not be compressed
beyond the specified maximum pressure to avoid restricting the diaphragm movement or jamming the valve in open position. The outlet
pressure may be increased temporarily by applying a light axial pressure to the setting screw.
MA INTENA NCE
Depending on the properties of the medium and the operating conditions of the system, the valve should be serviced and checked for correct functioning once a year or at shorter intervals.
The following procedure should be adopted in case of maintenance or repair: depressurise valve, relax spring, remove spring cover.
Check control mechanism for freedom of movement. In case of jamming remove any high spots using fine emery cloth. Leakage or diaphragm damage is indicated by fluid escaping from the spring cover breather orifice. If a leak cannot be remedied by slightly tightening the
clamp ring or spring cover bolts, the diaphragm should be checked. To do this the spring should be relaxed, the spring cover removed and
the spindle nut tightened. Then all components should be reassembled and the valve checked for leaks. If the leak persists the diaphragm
should be renewed as follows: unscrew spindle nut on diaphragm, withdraw diaphragm disc and remove diaphragm together with its Oring (if fitted). Once the new diaphragm has been fitted complete with O-ring, the spindle nut and clamp ring bolts should be fully tightened
whereas the spring cover screws should be torqued only gently to avoid crushing the diaphragm.
A strongly increasing outlet pressure at low flow rates indicates a defective cone seal. To remove the valve cone remove the spring cover
as described above, remove the diaphragm from the spindle and unscrew the spindle approximately 10 mm from its guide. Then lift the
spindle complete with its guide and cone (towards the bottom of the valve body) and withdraw completely past the seat towards the outlet.. Renew the valve cone. When screwing the spindle back into its guide please make sure that the valve cone moves freely in its seat.
IMPORTA NT: L u b r i c at e O-r i n g s , s l i d i n g s u r f ac es an d t h r ead s w i t h g r eas e.
Us e Par k er " Su p er -L u b e" t o l u b r i c at e EPDM O-r i n g s (Pl eas e n o t e: t h i s l u b r i c an t c o n t ai n s s i l i c o n e). Us e o n l y r ec o m m en d ed l u b r i c an t s f o r i n t er n al l u b r i c at i o n .
REPL A CEMENT PA RTS
When ordering spare parts please provide the serial or catalogue number of the
product as well as the item number on the drawing and an accurate description of the part.
1 Strainer*
2 Shut-off valve
3 Pr es s u r e Red u c er *
4 Safety valve*
5 Pressure gauge*
6 Control line G 1/4
7 Damping pot
*
Mankenberg reserves the right, without notice, to alter or improve the designs or specifications of the products described herein.
31.03.2003
Mankenberg GmbH Spenglerstr. 99 D-23556 Lbeck Tel. +49 - 451 - 8 79 75 0 Fax. +49 - 451 - 8 79 75 99 www.mankenberg.de e-mail: gm@mankenberg.de
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A1-5
Edition 02-2006
PN 40, 16
-28,9 C to 205 C
Face to Face:
Flanges:
DIN 3202 - F1
DIN 2545
Dimensions
Dimensions [mm]
Head flange
DN
HxQ
PN
ISO
5211
SW
ca.
weight
[kg]
15
130
95
65
14x4
42
M5
40
F 04
11
2,10
20
150
105
75
14x4
42
M5
40
F 04
11
2,90
25
160
115
85
14x4
42
M5
40
F 04
11
3,70
32
180
140
100
18x4
50
M6
40
F 05
14
5,50
40
200
150
110
18x4
50
M6
40
F 05
14
6,80
50
230
165
125
18x4
70
M8
40
F 07
17
9,60
65
290
185
145
18x4
70
M8
16
F 07
17
16,20
80
310
200
160
18x8
102
M 10
16
F 10
17
24,00
100
350
220
180
18x8
102
M 10
16
F 10
22
33,90
Page 1 of 2
Edition 02-2006
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part
Body
Stem
Thrust washer
Ball seat
Ball
Ball seat
Joint gasket
End cap
Stud
Nut
Gland packing
Gland ring
Disc washer
Adjust nut
Stop washer
Handle
Locking handle
Handle cover
Handle nut
Stop pin
Stop nut
Material
1.4408/1.0619
1.4401
PTFE
PTFE
1.4408
PTFE
PTFE
1.4408/1.0619
ASTM A193 Gr B8
ASTM A194 Gr 8
PTFE
AISI 304
AISI 301
ASTM A194 Gr 8
AISI 304
AISI 304
AISI 304
PVC
ASTM A194 Gr 8
ASTM A 193 Gr B8
ASTM A194 G 8
Page 2 of 2
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
SECTION A
Part II Technical Data
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
NIL
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
SECTION A
Part III Drawings
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-1
Dieses Dokument ist unser geistiges Eigentum. Es darf ohne unsere ausdrckliche Genehmigung
weder kopiert, vervielfltigt oder verwertet, noch an Dritte weitergegeben werden. Zuwiderhandlung
ist strafbar und wird strafrechtlich verfolgt.
Copyright reserved!
Solid Solutions AG
1000
1000
1400
1020
1600
600
600
1600
700
2200
700
1200
3000
2770
12000
4750
3500
3000
5400
2500
2750
4500
500
1300
7
Please note:
Pipework between dosing system and static
mixer has to be installed directly on site,
as the position of static mixer is not yet defined
SWITZERLAND
(HEAD OFFICE)
Industriestr. 2
CH-8590 Romanshorn
Tel. +41 71 466 80 80
Fax +41 71 466 80 66
info@ascoco2.com
Filename:
Drawingnumber:
Material:
Articlenumber:
Status:
Hydrochem Salalah
Relased
Machine/System:
Customer:
11
10
11
2010-SW033
plan and elevation
10
Kel
Drawn by:
Size:
Plotdatum: 23.11.2010
Index:
1:100 A2
Format:
25.10.2010
Date:
16.10.2010
Date:
KI
Checked by:
12
CAD-System: SolidWorks
2100
10000
16400
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-2
P&ID Drawing
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-3
Dieses Dokument ist unser geistiges Eigentum. Es darf ohne unsere ausdrckliche Genehmigung
weder kopiert, vervielfltigt oder verwertet, noch an Dritte weitergegeben werden. Zuwiderhandlung
ist strafbar und wird strafrechtlich verfolgt.
Copyright reserved!
Asco Carbon Dioxide
5
6
SWITZERLAND
(HEAD OFFICE)
Industriestr. 2
CH-8590 Romanshorn
Tel. +41 71 466 80 80
Fax +41 71 466 80 66
info@ascoco2.com
Filename:
Drawingnumber:
Material:
Articlenumber:
Hydrochem Salalah
Relased
2010-SW034
interfacing details
Machine/System:
Customer:
Status:
liquid-connection: system1-system2
change over: flange connection DIN2635 DN15 PN40
gas-connection: system1-system2
change over: flange connection DIN2635 DN15 PN40
liquid-connection: tank-pipework
tank: brazed connection for 33.7mm pipe
gas-connection tank-pipework
tank: 1"BSP female
25.10.2010
Date:
16.10.2010
Date:
Format:
Index:
1:100 A3
Size:
16.11.2010
Plotdatum: 23.11.2010
Kel
KI
Checked by:
Kel
Drawn by:
CAD-System: SolidWorks
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-4
Foundation Drawing
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-5
Electrical Drawing
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FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-6
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-7
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-8
Dieses Dokument ist unser geistiges Eigentum. Es darf ohne unsere ausdrckliche Genehmigung
weder kopiert, vervielfltigt oder verwertet, noch an Dritte weitergegeben werden. Zuwiderhandlung
ist strafbar und wird strafrechtlich verfolgt.
Copyright reserved!
Asco Carbon Dioxide
27
33
29
40
22
28
23
26
17
120235
912119
Drawn by:
Remark
1
4
1
1
1
1
1
1
2
33
29
28
27
26
24
23
22
17
Filename:
Drawingnumber:
Material:
Hydrochem Salalah
Relased
Size:
Plotdatum: 26.10.2010
Index:
A3
Format:
25.10.10
Date:
21.09.2010
Date:
KI
Checked by:
Kel
2010-SW032
1:20
dosing system & frame 30-300kg
Machine/System:
Customer:
Status:
Description
Articlenumber:
120250
Articlenumber
908514
908540
908565
914270
145020
145050
120255
910200-S
145044
SWITZERLAND
(HEAD OFFICE)
Industriestr. 2
CH-8590 Romanshorn
Tel. +41 71 466 80 80
Fax +41 71 466 80 66
info@ascoco2.com
14
5
POSQTY
NR.
2
1
40
35
24
35
14
CAD-System: SolidWorks
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-9
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
A3-10
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
SECTION A
Part IV Spare Parts
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
NIL
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
SECTION B
EQUIPMENT OPERATING & MAINTENANCE MANUAL
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
B1
Actuator
IMAT 4thGU-E
ISSUE: 12/09
GB
GB
IMAT 4thGU-E
CONTENTS
1) GENERAL
.........................................................................................
pag.
2) WARNING
.........................................................................................
pag.
pag.
............................
pag.
5) INSTALLATION INSTRUCTIONS
.............................................................
pag.
6) MAINTENANCE INSTRUCTIONS
............................................................
pag.
...................................................................
pag.
11
.....................................................................
pag.
11
.......................................
7) STORAGE INSTRUCTIONS
8) LIFTING AND HANDLING
GB
IMAT 4thGU-E
1) GENERAL
This instruction manual contains important information
regarding the installation, operation, maintenance and
storage for AIR TORQUE rack and pinion pneumatic actuators.
Please read these instructions carefully and keep them
for future reference. It is important that the use and
maintenance of the actuator is made only by properly
trained personnel.
m 2) WARNING
GB
IMAT 4thGU-E
Air supplied to Port 2 forces the pistons toward the actuator end caps,
compressing the springs.
A counter-clockwise rotation is achieved. Exhaust air exits from Port 4.
The loss of air pressure (air or electric failure) at Port 2 allows the springs
to force the pistons inward.
A clockwise rotation is achieved.
Exhaust air exits from Port 2.
Air supplied to port 2 forces the pistons towards the actuator end caps.
A counter-clockwise rotation is achieved.
Exhaust air exits from Port 4.
GB
IMAT 4thGU-E
Fig. C
Fig. A
Fig. B
M..
M5
M6
M8
M10
M12
M14
M16
M20
M24
M30
Nm
5 6
10 11
23 25
48 52
82 86
132 138
200 210
390 410
675 705
1340 1400
6) MAINTENANCE INSTRUCTION
With the information given below, AIR TORQUE provides
the end user with all the required information necessary
for maintenance. Under normal conditions, the actuator
requires only periodic observation to ensure proper operation.
Maintenance (disassembly, maintenance and rebuilding)
of AIR TORQUE actuators is allowed only to AIR TORQUE
personnel or properly instructed personnel. In case of
controversy the product guarantee will expire!
Spare kits for maintenace are available to replace all
seals and bearings (soft parts indicated into the table),
that may be necessary between 300.000 and 1.000.000
cycles depending on operating and environmental
conditions and actuator size.
GB
IMAT 4thGU-E
60.1
d mm
Model
Ex1 mm
Ex2 mm
AT045U
13
AT051U
10
14
AT101U
10
10
16
AT201U
13
10
22
AT251U
13
10
25
AT301U
17
13
26
AT351U
19
13
36
AT401U
19
17
38
AT451U
22
17
45
AT501U
22
19
48
AT551U
24
19
52
AT601U
30
22
58
AT651U
30
24
68
AT701U
36
22
80
AT751U
46
24
85
AT801U
46
24
90
GB
IMAT 4thGU-E
PA R T N
UNIT Q.TY
PART DESCRIPTION
NOTE
01
NA for AT045U
02
NA for AT045U
03
NA for AT045U
WASHER
04
NA for AT045U
05*
06*
07*
08*
09*
NA for AT801U
PLUG
09.1*
10
11*
NA for AT045U
12
NA for AT045U
PISTON GUIDE
13
8/12/16
(A)
14*
15*
16*
17
min.5/max.12
17.1
17.2
max. 4 for AT051U
17.3
SPRING (Cartridge)
18
19
19.0
GRADUATED RING
19.1
POSITION INDICATOR
19.5
TOP ADAPTOR
19.6
20*
21*
30
END CAP
39
40
PISTON
41
42
43
50
BODY
60
DRIVE SHAFT
60.1
65
AT101U)
GB
IMAT 4thGU-E
6.2) DISASSEMBLY
When disassembly of actuator is required for maintenance,
firstly remove the actuator from the valve. Before
performing any disassembly operations it is important
to verify that the actuator is not pressurised.
Always use caution and double check that the ports 2 and
4 are vented and are free from any accessory and/or
device. When the actuator is a spring return unit, make
sure that the actuator is in the failed position and with
pistons completely inwards before disassembling.
A) Removal of position indicator and graduated ring
(Part N 19,19.0,19.1), figure 01:
Fig. 01
Fig. 03
Fig. 04
B) Removal of stop cap screws (Part N 02), figure 02:
Fig. 02
Fig. 05
GB
IMAT 4thGU-E
Remove top (06) and bottom (07) pinion bearings and top
(20) and bottom (21) pinion o-rings.
Discard bearings (06) and (07), internal and external thrust
washer (08) and o-rings (20) and (21) if replacing the soft
components.
Fig. 07A
Fig. 08
Fig. 06
Fit external thrust bearing (08), thrust washer (10) and then
external spring clip (18) using snap ring pliers or screwdriver
for spiral rings.
Fig. 09
Fig. 10
Fig. 07
GB
IMAT 4thGU-E
AT051U configuration:
Side B
Fig. 11
Side A
Spring
AT051U
AT051U
AT051U
AT051U
Set
Internal
External
Internal
External
C)
S1
1(green)
------------
------------
2 (black)
S2
------------
2 (black)
------------
2 (black)
S3
------------
2 (black)
------------
3 (red)
S4
------------
3 (red)
------------
3 (red)
S5
------------
3 (red)
1 (green)
2 (black)
S6
1 (green)
2 (black)
1 (green)
2 (black)
S7
1 (green)
2 (black)
1 (green)
3 (red)
S8
1 (green)
3 (red)
1 (green)
3 (red)
Fig. 13
Fit end cap o-ring seal (14) into the groove on both end caps.
Fig. 14
Fig. 12
Side B
Side A
AT045U
AT045U
Spring type
Spring type
S1-1
1 (green)
1 (green)
S1-2
1 (green)
2 (red)
S2-2
2 (red)
2 (red)
S2-3
2 (red)
3 (black)
S3-3
3 (black)
3 (black)
Spring Set
10
Fit end caps onto the body (50), verifying that the o-ring
remains in the groove.
Only for actuators with 50% or 100% stroke adjustment,
ensure that the adjustment screws 221G/222G are
completely screwed into the end-cap.
Insert the cap screws (13) and tighten each only partially.
Complete tightening by making 1-2 turns for each screw
in the sequence shown in figure 14 until tightening is
completed. See the table for screw tightening torque.
GB
IMAT 4thGU-E
Fig. 15
Fig. 16
Fig. 18
Fig. 19
7) STORAGE INSTRUCTIONS
If the actuator is not for immediate use, the following
precaution must be taken for storage:
Store the actuator in a clean and dry environment and at
temperature between 20C (-4F) and +40C (+104F).
It is recommended that the actuator be stored in its
original box.
Do not remove the plastic plugs on air supply ports.
8) LIFTING and HANDLING
It is recommended to lift the actuators with proper, adequate
and permitted systems in relation to the actuator weight and
by following the ruling laws in terms of safety and health
protection. The weight of the actuators is indicated on the Air
Torque catalogue and on the related technical data-sheets.
During the lifting and the handling of the actuators, it is
recommended to avoid clashes and/or accidental falls in
order to avoid irreparable damages to the actuators and to
compromise the functionality.
Contact Air Torque for any information and technical
data-sheets.
Fig. 17
11
This manual is property of AIR TORQUE S.p.a. - Costa di Mezzate - Italy and all rights of use and reproduction are reserved - Subject change without notice
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FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
B2
Ball Valve
Zentrale - Wels:
Telefon
: +43(0)72 42 / 66811-0
Fax
: +43(0)72 42 / 66811-26
E-mail
: office@gebetsroither.at
Filiale - Gumpoldskirchen:
Telefon
: +43(0)22 52 / 607100
Fax
: +43(0)22 52 / 607100-10
E-mail
: filiale@gebetsroither.at
Version 21.5.2001
page 1 of 5
body / caps
insert parts
Xc
stainless steel
part
1 body
2 extension
3 pressure disk
4 ball
5 seat-sealing
6 body-sealing
7 flanged end piece
8 screw bolt
9 washer
10 hex nut
11 gland nut
12 adjusting nut
13 lever
14 Sperrlasche
15 lever prodection
16 locking ring
17 hex nut
Version 21.5.2001
material code
ASTM A351 CF8M
SS 316
PTFE
ASTM A351 CF8M
PTFE
PTFE
ASTM A351 CF8M
SS 304
SS 304
SS 304
PTFE
SS 304
SS 304
SS 304
Kunststoff
SS 304
SS 304
page 2 of 5
colour of the
ball-valves
pickling treated
Operation instruction
GEROI ball valves are delivered in "open position". The ball-valves may only be stored in closed
storage rooms, in non-aggressive atmosphere and must be stored protected for damps and
contamination. Furthermore, please take care that the valves are not used for higher
temperatures and pressures as indicated. A guarantee for a certain period can only be granted
under these conditions. Only parts, underlying a natural wearing through corrosion, erosion etc.
are excluded. In case of a longer downtime the valves must be drained when you have frozen
mediums in use, and for expanded mediums you have to provide for a pressure balance. By
appearing leaks, the torques of the body or stem packing screws are to be checked according
table 1,2. In case of longer downtimes or only a few operations, we recommend a minimum use
of 6 x / year to increase the fatigue life.
table 1: tightening torque of the stem packing screw
size
1/4"
3/8"
3/4"
1"
1 1/4"
1
2"
2
3"
4"
torque (Nm)
11
11
23
23
50
50
60
60
120
120
160
tolerance (Nm)
+5
+5
+5
+5
+5
+5
+5
+5
+ 10
+ 10
+ 15
Version 21.5.2001
torque (Nm)
tolerance
10
10
20
20
35
35
55
55
100
100
130
+ - 10 %
page 3 of 5
Generals:
GEROI ball-valves are suitable for gas and arc welding processes. A tightness can only be
granted for weldings carried out by an expert.
Mounting instruction
GEROI ball-valves may be integrated into the line system in whatever position desired. The
installation, however, must be in "open position". The types S30, F30 may be
integrated into the line system in assembled condition.
How to install welded ball valves of type S30B
Due to the short overall length a too high temperature appears in the sealing element area during
the welding process.
For that reason, the vall valve must be dismounted before you start with the welding process.
* valve to be tacked with weld points into the line system
* body connecting bolts to be removed
* body middle piece to be taken out
* we recommend to screw in a separator of the same size as the body part, to keep the
welding caps plane parallel during the welding process. Furthermore, please take care
that the line system is alignment truly axial at the sectioning part.
* connecting piece to be welded with the line system by an expert
* after cooling, please disasemble the separator insert the body middle piece and fix with
the connecting bolts
* ball set to "closed position"
* body connecting bolts to be tightened with the indicated torques (table 2)
* performance check
Version 21.5.2001
page 4 of 5
Version 21.5.2001
page 5 of 5
Edition 03-2006
GEROI
F 201
2-pieces Ball valve
DN 6 DN 100, Full Port
PN 63, -28,9 C to 205 C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Body
Stem
Thrust washer
Ball seat
Ball
Ball seat
Joint gasket
End cap
Stud
Nut
Gland packing
Gland ring
Disc washer
Adjust nut
Stop washer
Handle
Locking handle
Handle cover
Handle nut
Stop pin
Stop nut
Page 1 of 7
Edition 03-2006
OPERATING INSTRUCTION
GEROI ball valves are delivered in "open position". The ball-valves may only be
stored in closed storage rooms, in non-aggressive atmosphere and must be stored
protected for damps and contamination. Furthermore, please take care that the
valves are not used for higher temperatures and pressures as indicated. A guarantee
for a certain period can only be granted under these conditions. Only parts,
underlying a natural wearing through corrosion, erosion etc. are excluded. In case of
a longer downtime the valves must be drained when you have frozen mediums in
use, and for expanded mediums you have to provide for a pressure balance. By
appearing leaks, the torques of the body or stem packing screws are to be checked
according table 1, 2. In case of longer downtimes or only a few operations, we
recommend a minimum use of 6 x / year to increase the fatigue life.
CAUTION
1. Before installing or performing maintenance, be sure line pressure has been
relieved and any hazardous liquid, gas, or steam is drained or purged from the
system.
2. The maximal temperature for our ball valve with the PTFE is 200 C the
minimum temperature is -23 C. But the pressure has to match the pressure
and temperature shown in the chart of pressure-temperature. The principle is
that high temperature goes with low pressure. Remember that different
temperature goes with different pressure.
3. When the valve is used at high temperature, the proper protection equipment,
for example anti-heating gloves, is highly suggested. Do not tough the valve
directly.
4. Any unsuitable operation action will cause the leaking or other problems. If
that happens, the first step is to turn of the pipe fluid and valve. Then,
disassemble the valve.
5. This valve is not used for unstable gases, H2SO4, HF, HCL and other
dangerous fluid. (any problem about for the used fluid, please contact the
manufactory).
Page 2 of 7
Edition 03-2006
MAINTENANCE
Periodically observe the valve to be sure of proper performance more frequent
observation is recommend under extreme operating condition.
Routine maintenance consists of tightening the stem nut turn periodically to
compensate for the wear caused by the stems turning against the resilient PTFE
seal.
DISASSEMBLY
Note: If complete disassembly becomes necessary, replacement of all seats and
seals is recommend refer to service kit chart.
1.
2.
3.
4.
Close the valve. Then remove the upper handle nut, handle.
Remove the stop washer, adjustment nut, disc washer, and gland ring.
Unscrew and remove nuts, end cap, and joint gasket, heat may be required
If the ball, and ball seat, do not fall from the body with the ball in the fully
closed position, use a piece of wood, or some other soft material to gently tap
the ball. This will unseat these parts without damaging the ball.
5. Press the stem, from the top into the valve body and remove it through the
end cap end of the body.
6. Using a pointed instrument, pry out and discard the old gland packing, thrust
washer, if applicable. Be very careful not to scratch any sealing surfaced in the
valve body ( surfaces on which seats and seal rest).
Page 3 of 7
Edition 03-2006
INSTALLATION
Install the raise face flanged end, turn two opposite end diameter nuts of the flanged
end firstly, and do the same number of turning until all the nuts are finished. Use
hands to tighten the spanner from 1 or 3 or 4 turning to the nuts, and then do the
same number of turning to tighten every nut. Please refer to procedure repeats for
several times till the degree of the tightening meets your rewuest. The raise face will
have the equal stress, please reduce the leakage of the sealing.
ASSEMBLY
1. Clamping valve body, drop in an ball seat, with the flat surface on the bottom.
2. Insert from the inside a trust washer, into the lower stem bore.
3. Insert the stem, trough the open end of the body, being careful not to scratch
thrust washer, and thrust washer surface. Press it gently up into the stem hole.
4. Holding the trust washer, in place from inside the valve, install three gland
packing, the gland ring, disc washer, adjustment nut, and threaded until the
stem starts to turn.
5. Place a wrench through the body on the bottom of the stem blade to hold the
stem stationary. Place another wrench on the adjustment nut, and turn down
until the seals bottom and the stem comes snugly in place tighten the gland
ring, disc washer, until snug, plus an additional - turn.
6. align the stem blade inside the valve body, with the ball, insert the ball, and
rotate the stem, to the ball fully closed position.
7. Screwed all bolts, and insert second ball seat, into the end cap, so that the
sealing surface of the seat is towards the ball insert the joint gasket.
8. cover the end cap, and tighten the nuts, to the required torque, see table for
body bolts torque specification.
9. place the stop washer, handle, and handle nut, over the stem, tighten the
handle nut, until snug and put the stop pin.
10. Cycle the valve slowly twice to ensure permanent position of the ball between
the two seats.
Page 4 of 7
Edition 03-2006
Torque (Nm)
10,1
10,1
17,9
17,9
43,9
43,9
43,9
43,9
43,9
Tolerance (%)
+10
+10
+10
+10
+10
+10
+10
+10
+10
Page 5 of 7
Edition 03-2006
Page 6 of 7
Edition 03-2006
BREAK N.m.
4,41
4,41
4,90
7,84
15,68
21,56
34,30
47,04
66,64
82,32
161,70
OPERATING N.m.
2,74
2,74
2,94
3,92
7,06
8,82
15,68
18,62
29,40
41,16
98,00
Page 7 of 7
FINAL DOCUMENTATION
SALALAH INDEPENDENT WATER AND POWER PLANT PROJECT
B3
"EDIENUNGSANLEITUNG
)NSTRUCTIONSDE3ERVICE
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7ARNSOFAPOTENTIALLYDANGEROUSSITUATION
Failure to observe the warning may result in serious injuries or
death.
WARNING!
7ARNSOFANIMMEDIATEDANGER
Failure to observe the warning may result in a fatal or serious injury.
ENGLISH
DESIGNATESAPROCEDUREWHICHYOUMUSTCARRYOUT
REFERSTOINFORMATIONINTHESEOPERATINGINSTRUCTIONSORIN
OTHERDOCUMENTATION
7ARNSOFDAMAGETOPROPERTY
Failure to observe the warning may result in damage to the device
or the equipment.
DESIGNATESADDITIONALSIGNIFICANTINFORMATIONTIPSANDREC
OMMENDATIONSWHICHAREIMPORTANTFORYOURSAFETYANDTHE
PROPERFUNCTIONOFTHEDEVICE
NOTE!
4HEOPERATINGINSTRUCTIONSCONTAINIMPORTANTSAFETYINFORMATION
CAUTION!
7ARNSOFAPOSSIBLEDANGER
Failure to observe this warning may result in a moderately severe
or minor injury.
/0%2!4).').3425#4)/.3
4HEOPERATINGINSTRUCTIONSDESCRIBETHEENTIRELIFECYCLEOFTHEDEVICE
+EEP THESE INSTRUCTIONS IN A LOCATION WHICH IS EASILY ACCESSIBLE TO
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)FEXPORTINGTHESYSTEMDEVICEOBSERVEANYEXISTINGRESTRICTIONS
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AHAZARDTOPEOPLENEARBYEQUIPMENTANDTHEENVIRONMENT
The device is designed for the controlled flow of liquid and
gaseous media. Operation is possible only in combination with a
suitable activation unit.
The admissible data, the operating conditions and conditions of
use specified in the contract documents, operating instructions and
on the rating plate are to be observed during use. The designated
application cases are specified in the chapter entitled Product
description.
The device may be used only in conjunction with third-party devices
and components recommended and authorised by Brkert.
Correct transportation, correct storage and installation and careful
use and maintenance are essential for reliable and problem-free
operation.
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2ISKOFINJURYWHENOPENINGTHEACTUATORHOUSING
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Before reaching into the device, switch off the power supply and
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4OPREVENTINJURYENSURETHAT
the system cannot be activated unintentionally.
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manner.
The device may be operated only when in perfect condition and
in consideration of the operating instructions.
The general rules of technology apply to application planning and
operation of the device.
'ENERALHAZARDOUSSITUATIONS
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ENGLISH
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4HEVALVESEATSARESCREWEDIN!REDUCTIONINTHENOMINALWIDTHSOF
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Observe minimum control pressure
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See chapter entitled Operating Conditions / Pressure Ranges
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3AFETYINSTRUCTIONS
2ISKOFINJURYFROMUNINTENTIONALACTIVATIONOFTHESYSTEMAND
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Secure system from unintentional activation.
Following assembly, ensure a controlled restart.
2ISKOFINJURYFROMIMPROPERINSTALLATION
Installation may be carried out by authorised technicians only and
with the appropriate tools!
WARNING!
2ISKOFINJURYDUETOELECTRICALSHOCK
Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
Observe applicable accident prevention and safety regulations
for electrical equipment!
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)NSTALLATION
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2EMOVEACTUATORBEFOREWELDINGINTHEVALVEHOUSING
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ENGLISH
!SSEMBLYWITHUNSUITABLETOOLSORNON
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For installation use an open-end wrench, never a pipe wrench.
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2ISKOFINJURYFROMIMPROPERINSTALLATION
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SEETABLEg4IGHTENINGTORQUESOFVALVEHOUSINGNIPPLESs
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In specific applications, e.g. oxygen or analysis applications, use
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$ANGERIFINCORRECTLUBRICANTSUSED
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4HEPROCEDUREISDESCRIBEDINTHECHAPTERENTITLEDg0NEUMATIC
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Use only hoses which are authorised for the indicated pressure
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Observe the data sheet specifications from the hose manufacturers.
2ISKOFINJURYFROMUNSUITABLECONNECTIONHOSES
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$ANGERkHIGHPRESSUREINTHEEQUIPMENT
Before loosening the lines and valves, turn off the pressure and
vent the lines.
)NSTALLATION
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)FTHEDIRECTIONOFROTATIONISINCORRECTTHEINTERFACEBETWEENTHE
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To align the connections, ROTATETHEACTUATORANTI
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2ISKOFINJURYFROMDISCHARGEOFMEDIUMANDPRESSURE
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)TISDANGEROUSTOREMOVEADEVICEWHICHISUNDERPRESSUREDUETO
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Before removing a device, switch off the pressure and vent the
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2ISKOFINJURYFROMDISCHARGEOFMEDIUMANDPRESSURE
4
HESPECIALKEYIDENTIFICATIONNUMBER ISAVAILABLEFROMYOUR
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www.burkert.com
Quickstart
QUICKSTART
WARNING!
Important Safety Information!
Read Quickstart carefully and thoroughly. Study in particular the chapters entitled General Safety Instructions and
Correct Use.
Quickstart must be read and understood.
Quickstart for positioner Type 8692 / 8693 explains, for
example, how to install and start-up the device.
A detailed description of the device can be found in the
operating instructions for positioner Type 8692 / 8693. These
instructions also include the warranty terms and details about
the correct disposal of the device.
The operating instructions can be found on the enclosed CD and on the Internet at:
www.burkert.com !"!Documentation !"!
manuals / data sheets !"! Type 8692 / Type 8693
SYMBOLS
The following symbols are used in these instructions.
DANGER!
Warns of an immediate danger!
Failure to observe the warning may result in a fatal or
serious injury.
WARNING!
Warns of a potentially dangerous situation!
Failure to observe the warning may result in a serious or
fatal injury.
CAUTION!
Warns of a possible danger!
Failure to observe this warning may result in a moderately severe or minor injury.
NOTICE! (without hazard symbol)
Warns of damage to property!
Important tips and recommendations for safe and
problem-free operation of the device.
English
English
CORRECT USE
WARNING!
Incorrect use of the positioner Type 8692 and
Type 8693 can be dangerous to people, nearby equipment and the environment.
The device must not be used outside.
The device must not be exposed to direct sunlight.
The device may be used only in conjunction with thirdparty devices and components recommended and authorised by Brkert.
In view of the wide range of possible application cases,
check whether the positioner is suitable for the specific
application case and check this out if required.
Correct transportation, correct storage and installation,
and careful operation and maintenance are essential for
reliable and problem-free operation.
Use the positioner Type 8692 and Type 8693 only as
intended.
Forseeable Misuse
The positioner Type 8692 and Type 8693 must not be used
in areas where there is a risk of explosion.
Do not introduce any aggressive or flammable media into
the system's media connections.
Do not introduce any liquids into the media connections.
Do not put any loads on the housing (e.g. by placing objects
on it or standing on it).
Do not make any external modifications to the device housings. Do not paint the housing parts or screws.
Follow the instructions, the conditions of use and the permitted data for positioner Type 8692 and Type 8693 which
are specified in the chapter entitled Technical Data in these
instructions and in the valve instructions for the respective
pneumatically actuated valve to ensure faultless operation
and long service life of the device.
4
English
English
English
WARNING!
Hazardous situations can arise during installation and
maintenance work.
This work may be carried out by authorised technicians
only and with the appropriate tools!
After an interruption in the power supply or pneumatic
supply, ensure that the process is restarted in a defined
or controlled manner!
CAUTION!
The general rules of technology apply to applications
planning and operation of the device!
Failure to observe these rules may result in injuries and/
or damage to the device, and possibly its environment as
well.
Observe the general rules of technology!
The positioner Type 8692 / Type 8693 was developed
with due consideration given to the accepted safety
rules and is state-of-the-art. However, dangers can
still arise.
Operate the device only when it is in perfect condition and
in accordance with the operating instructions. Failure to
observe these instructions and unauthorised tampering with
the device release us from any liability and also invalidate the
warranty covering the devices and accessories!
English
NOTICE!
GENERAL INFORMATION
Product Package
Check immediately upon receipt of delivery that the contents
are not damaged and that they correspond to the type and
quantity as indicated on the delivery note or packing list.
If there are any discrepancies, please contact us immediately.
Germany
Contact address:
Brkert Fluid Control Systems
Sales Center
Chr.-Brkert-Str. 13-17
D-74653 Ingelfingen
Tel.: 07940 - 10 111
Fax: 07940 - 10 448
E-mail: info@de.buerkert.com
International
Contact addresses can be found on the final pages of
these operating instructions.
And also on the internet at:
www.burkert.com
Brkert
English
Company
Locations
English
Actuator drive
Valve
Functions
Position controller Type 8692
The position of the drive (stroke) is regulated according to
the position set-point value. The position nominal value can
be specified by an external unit signal.
Process controller Type 8693
The positioner is integrated into a control loop. The stroke
of the valve is calculated from the process nominal value
and the process actual value via the control parameters
(PID controller). The process set-point value can be set by
an external signal.
Positioners Type 8692 and Type 8693 are electropneumatic positioner controllers for pneumatically actuated control
valves with single-action or double-action drives.
The positioner, together with the pneumatic drive, make up
an optical and functional unit.
The control valve systems can be used for a wide range of
control tasks in fluid technology and, depending on the application conditions, different process valves from the Brkert
range can be combined with the positioner. Slanted seat
valves, straight seat control valves, diaphragm or ball valves
are suitable.
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Operating Conditions
TECHNICAL DATA
Structure of positioner
WARNING!
Risk of injury from overheating of the control head.
Heating above the permitted temperature range can endanger people, the device and the environment.
Ensure that the device is not exposed to direct sunlight
or other heat sources.
Ambient temperature 0 ... + 55 C
Protection class
IP 65 / IP 67 according to
EN 60529
(only if cables, plugs and sockets
have been connected correctly)
Mechanical Data
Exhaust air
connection
(connection: 3)
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Supply pressure
connection 3 ... 7 bar
(connection: 1)
Dimensions
Housing material
Sealing material
NBR / EPDM
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Pneumatic Data
Electrical Data
Control medium
Connections
Power supply
24 V DC 10 %
max. residual ripple 10 %
Power input
<5W
max. 25 mg/m
Temperature range
of the compressed air
0 ... + 50 C
Pressure range
3 ... 7
connections
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7 lN / min
(for aeration and deaeration)
(QNn value according to definition
when pressure drop from
7 to 6 bar absolute)
optional: 130 lN / min
(for aeration and deaeration)
(only single-action)
Input resistance
for actual value signal 180 # at 4 - 20 mA /
Resolution 12 bit
17 k# when frequency,
0 ... 1000 Hz / 1
of measured value
> 300 mVss sine, square,
triangle
PT 100 - 20 ... + 220 C,
resolution < 0.1 C
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