TYPE 2388 HS-ISO PRESSURE VALVE - Pres-Vac Engineering Aps
TYPE 2388 HS-ISO PRESSURE VALVE - Pres-Vac Engineering Aps
TYPE 2388 HS-ISO PRESSURE VALVE - Pres-Vac Engineering Aps
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
OWNER:<br />
INSTRUCTION MANUAL FOR<br />
<strong>TYPE</strong> <strong>2388</strong><br />
SYSTEM DESCRIPTION<br />
AND OPERATING/MAINTENANCE<br />
INSTRUCTIONS FOR<br />
<strong>HS</strong>-<strong>ISO</strong><br />
<strong>PRESSURE</strong> <strong>VALVE</strong><br />
REV. 4<br />
CUSTOMER INFORMATION<br />
HULL NO.: PRES-VAC REF. NO.:<br />
PRES-VAC ENGINEERING A/S PHONE: +45 4817 4055<br />
SVANEVANG 3-5 TELEFAX: +45 4817 1788<br />
DK-3450 ALLERØD E-mail: presvac@pres-vac.com<br />
DENMARK
INSTRUCTION MANUAL<br />
CONTENTS<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 2 of 25<br />
Rev. 4 October 5, 2004<br />
Page<br />
1. Functional System Description ....................................................................................... 3<br />
1.1. General ................................................................................................................... 3<br />
1.1.1. Ordering Information ................................................................................................ 3<br />
1.2. Design .................................................................................................................... 3<br />
1.2.1. Product Suitability .................................................................................................... 3<br />
1.3. Function .................................................................................................................. 4<br />
1.3.1. Inspection ...............................................................................................................4<br />
1.4. Capacity .................................................................................................................. 4<br />
2. Operating Instructions ................................................................................................... 4<br />
2.1. Installation .............................................................................................................. 4<br />
2.1.1 Service Restrictions .................................................................................................. 4<br />
2.2. Operation ................................................................................................................ 5<br />
2.2.1 Drainage ................................................................................................................. 5<br />
2.2.2. Deposit Indicator ..................................................................................................... 6<br />
2.2.3. Damaged Seals ....................................................................................................... 6<br />
2.2.4. Relief <strong>Pres</strong>sure Adjusting Mechanism........................................................................... 6<br />
2.2.5. Prime Causes For Possible Misbehaviour Of <strong>Pres</strong>sure Valve ............................................ 6<br />
2.2.6. Flushing Port............................................................................................................7<br />
2.2.7. Greasing Nipples ...................................................................................................... 7<br />
2.2.8. Optional Features ..................................................................................................... 8<br />
2.2.9.Change to High <strong>Pres</strong>sure Unit ..................................................................................... 9<br />
3. Maintenance Instructions.............................................................................................. 10<br />
3.1. General .................................................................................................................. 10<br />
3.1.1. Inspection .............................................................................................................. 10<br />
3.2. Corrosion Protection................................................................................................. 10<br />
3.2.1. Coating Repair ........................................................................................................ 10<br />
3.3. Safety Regulations For Maintenance Work .................................................................. 10<br />
3.4. Onboard Verifying Of Set-<strong>Pres</strong>sure............................................................................. 11<br />
3.5. Change Of Blow-down Value ..................................................................................... 11<br />
3.6. Directions For Disassembly / Assembly And Cleaning ................................................... 12<br />
4. Spares ........................................................................................................................... 15<br />
DRAWING NO. <strong>2388</strong>-122 (Spare Part Ordering List) ........................................................... 16<br />
5. Trouble-Shooting........................................................................................................... 17<br />
6. Laboratory Report, Summary ........................................................................................ 20<br />
Enclosures:<br />
(1) Flow Charts<br />
(2) Product Review Document<br />
(3) Certificates<br />
(4) Workshop Test Certificate<br />
(5) Maintenance Log Sheet
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
1. Functional System Description<br />
1.1. General<br />
Page 3 of 25<br />
Rev. 4 October 5, 2004<br />
The purpose of this high velocity pressure valve is to provide automatic control of the pressure conditions<br />
during loading, voyage, and ballasting without any manual operation. This is done in such a way that the<br />
efflux velocity of the flow cannot be less than 30 m/s under all flow rates and the actual conditions of<br />
installation. Furthermore, this high velocity pressure valve provides active protection against fire and<br />
explosions on deck in terms of preventing the passage of flame into the protected tank.<br />
1.1.1. Ordering Information<br />
Ordering information according to <strong>ISO</strong> 15364 should be provided by the customer, if not, it is the<br />
customer´s responsibility that service restrictions, tank pressure limitations, etc. are adhered to.<br />
1.2. Design<br />
The high velocity pressure valve consists of a valve housing with a movable pressure disc, stem, and<br />
valve top. Correct function of the valve is tested, by check-lifting the movable parts, by means of turning<br />
the check-lift handle approximately half a revolution. The check-lift is designed to be self-closing.<br />
WARNING! The attending crew must be familiar with the normal friction in the system in<br />
order to valuate when cleaning is required. Being able to turn the check-lift<br />
handle itself by applying great force does not mean that the moveable parts are<br />
freely moving. If a lever system is used to break the disc free, the gas-passage<br />
way is likely clogged.<br />
This valve is specifically designed with a view to address in-service maintenance, allow inspection of all<br />
vital parts from the outside without the use of tools, and allow wear parts to be replaced in-situ. Essential<br />
functions are reflected by indicators, which are clearly visible from the outside at all times. Thanks to the<br />
patented control system for opening and closing pressures, the valve conforms to requirements for nonhammering<br />
and non-oscillation. The control system combines the simplicity of a weight-loaded design<br />
with the low dynamic pressure drop of a traditional magnet operated design, while adding the in-service<br />
advantages of large net clearances through the gas passage-ways to minimize clogging due to fouling<br />
from residue/condensate. The control system further allows the designer of the venting system to<br />
implement piping of lesser diameter than normal.<br />
1.2.1. Product Suitability<br />
Besides from complying with <strong>ISO</strong> 15364 a valve design has to be elaborated on in a Product Review<br />
Document, a product drawing, and a manual. The <strong>ISO</strong> standard does not provide any measures against<br />
which a design can be constructed and considered as being “in conformity”. The standard merely<br />
provides general guidelines and, in particular, recommendations for maintenance. It is exclusively the<br />
owner´s/user´s responsibility to ensure that the valve is adequate for the actual installation and the<br />
usage intended. The owner/user shall do this on basis of:<br />
- A product Review Document describing the valve on basis of <strong>ISO</strong> 15364.<br />
- A product drawing.<br />
- IMO MSC/Circ. 677/1009 certification.<br />
- Certified service instructions.<br />
- This manual.<br />
It is the owner´s / user´s responsibility to review and establish that the selected valve is correctly sized<br />
according to USCG (VECS) rules and IMO MSC/Circ. 731, and made in a design that will match the<br />
available efforts for maintenance. Various types of valves with different maintenance requirements are<br />
available in the PRES-VAC range with escalating prices for less maintenance requiring types.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 4 of 25<br />
Rev. 4 October 5, 2004<br />
1.3. Function<br />
<strong>Pres</strong>sure build-up in the cargo tank forces the pressure disc from its seat (opening pressure). When the<br />
excessive tank pressure is relieved to a preset level, the disc will re-seat (closing pressure). For details of<br />
the performance characteristics, please refer to the flow charts as enclosed.<br />
The opening and closing pressures are adjustable see section 3.6. Contact PRES-VAC in case adjusting<br />
the pressure-tuning knob is not enough.<br />
1.3.1. Inspection<br />
Due to the relatively large net clearance through the valve, the inner parts are much less sensitive to<br />
deposits than ordinary designs. If no thick deposits are detected by means of the fouling indicator pins<br />
and by visual inspection after removal of the seat-beds in case of any doubts, the valve is in working<br />
condition and no further precautions are necessary. The allowable thickness of deposits before further<br />
inspection and, as appropriate, cleaning is necessary at a total diameter of 12 mm. This measure,<br />
however, is only indicative and does not substitute visual inspection after removal of seat-bed. See<br />
section 2.2.2.<br />
1.4. Capacity<br />
The valve's capacity is rated in standard air. For conversion to maximum loading rates for different<br />
cargoes, please refer to the MASTER'S LOADING CHART as per latest revision of IMO MSC/CIRC. 731.<br />
2. Operating Instructions<br />
CAUTION! Transport, storage and handling of the valve shall take place in upright position.<br />
2.1. Installation<br />
Remove all packing material.<br />
Installation is accomplished by bolting the valve flange to the tank vent pipe's mating flange with a<br />
suitable gasket between. Check-lift to verify unobstructed movement of disc. Follow IMO MSC/Circ. 731<br />
pressure drop calculation during system check to verify correct function.<br />
2.1.1 Service Restrictions:<br />
See CE certificate for:<br />
1. Maximum run-up pipe length.<br />
2. Minimum run-up pipe diameter.<br />
3. Minimum MESG of cargo vapour.<br />
4. Minimum pressure relief setting.<br />
5. Maximum outer ice-layer according to <strong>ISO</strong> 15364.<br />
6. Maximum fouling level: See the Product Review Document.<br />
7. Maintenance procedures must be observed for proper function of the equipment.
INSTRUCTION MANUAL<br />
2.2. Operation<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 5 of 25<br />
Rev. 4 October 5, 2004<br />
Before loading, discharging, and ballasting the valve must be check-lifted to ascertain free movability of<br />
the valve disc. Correct check-lifting is accomplished by turning the check-lift handle from its vertical<br />
position (fig.1) to its upper position (fig. 2) and back again. The check-lift is self-closing when in proper<br />
maintained condition. If not, it should be cleaned and the rest of the valve inspected/cleaned.<br />
WARNING! The attending crew must be familiar with the normal friction in the system in<br />
order to valuate when cleaning is required. Being able to turn the check-lift<br />
handle itself by applying great force does not mean that the moveable parts are<br />
freely moving. If a lever system is used to break the disc free, the gas-passage<br />
way is likely clogged.<br />
Referring to the International Safety Guide for Oil Tankers and Terminals (ISGOTT) cold weather<br />
precautions include checking the vents regularly, i.e. maintaining the valve operational at all time. These<br />
precautions may be a check-lifting cycle that break the ice coverings and prevents the valve from being<br />
blocked by ice.<br />
The maximum allowed ice thickness for this valve type is 20mm within the breaking capability of the<br />
check-lift.<br />
Fig. 1. Check-lift closed Fig. 2. Check-lift open<br />
2.2.1. Drainage<br />
The valve is self-draining due to large net clearances and no horizontal surfaces on the inside of the<br />
valve.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 6 of 25<br />
Rev. 4 October 5, 2004<br />
2.2.2. Deposit Indicator<br />
To examine for build-up of residue in the valve, unscrew the Plug with the cleaning indicator (pos. 26 on<br />
fig. 18, page 12) and check it for residue thickness. If the residue thickness is over 1 mm, cleaning of the<br />
interior of the valve is necessary. The cleaning method depends on the cargo type. For certain<br />
crystallizing cargoes, heating arrangement may be necessary according to the chemical Code. If the<br />
upper part of the spindle (exposed when check-lifting) is dirty, it must be wiped with a cloth and the<br />
lifting/cleaning procedure repeated until the stem is thoroughly cleaned.<br />
2.2.3. Damaged Seals<br />
It is of utmost importance that the seals are kept in a good condition and are changed before<br />
reassembly, as necessary, to maintain leakage-free operation.<br />
Consequences of damaged or missing seals are as follows:<br />
Type of seal Damaged seal Missing seal<br />
O-rings in flange connections Small leak of cargo or inert gas. Leak of cargo or inert gas.<br />
Small salt water ingress in tank.<br />
O-rings in Disc unit Small leak of cargo or inert gas. Leak of cargo or inert gas.<br />
Small salt water ingress in tank.<br />
Gasket in Plug w. deposit indicator Small leak of cargo or inert gas. Leak of cargo or inert gas.<br />
Small salt water ingress in tank.<br />
Packing in Plug for check-lift Leak of cargo or inert gas. Leak of cargo or inert gas.<br />
Small salt water ingress in tank.<br />
2.2.4. Relief <strong>Pres</strong>sure Adjusting Mechanisms<br />
In order to maintain the relief pressure adjusting mechanisms correct, the Nut (pos. 11 on fig. 18 page<br />
12), must not be dismounted. If dismounted, the relief pressure adjusting mechanism has to be adjusted<br />
again by PRES-VAC or by means of a calibration tool, which can be purchased from PRES-VAC or<br />
elsewhere, see section 3.6.<br />
During normal voyage, the high velocity pressure valve type <strong>HS</strong>-<strong>ISO</strong> operates automatically and relieves<br />
pressure caused by thermal variations.<br />
WARNING! As per SOLAS-requirements, check-lifting must be carried out before loading,<br />
discharging and ballasting is commenced. If the valve disc does not move<br />
freely, the cause should be determined and corrected immediately. If a lever is<br />
used, cracking the valve open would not be adequate evidence that it is in<br />
proper working condition. It is likely clogged.<br />
2.2.5. Prime Causes For Possible Misbehaviour Of <strong>Pres</strong>sure Valve<br />
Chattering, hammering, and fluttering are serious situations and known to cause incidents and lack of<br />
flame arresting capability. Reasons may be:<br />
1. Valve is oversized.<br />
2. Valve is sized for maximum flow, but operational flow is only minor and the valve´s reasonable<br />
field of acceptable performance is insufficient.<br />
3. <strong>Pres</strong>sure drop in the upstream piping is too high (the opposite effect on some constructions).<br />
4. The valve is mounted on too small diameter piping, which causes excessive flow turbulence or<br />
pressure fluctuations (resonance).<br />
See section 5, Trouble-shooting.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 7 of 25<br />
Rev. 4 October 5, 2004<br />
2.2.6. Flushing Port<br />
When loading a new cargo for which cleaning of the <strong>HS</strong>-<strong>ISO</strong> High Velocity <strong>Pres</strong>sure Valve and vent pipe is<br />
required, this procedure is to be followed:<br />
1) Unscrew the flushing plug (pos. 26 on fig. 18) (only when the tank is depressurized).<br />
2) Connect the hose with the cleaning fluid to the flushing port.<br />
3) Start cleaning.<br />
4) Remove the hose and mount the flushing plug.<br />
Fig. 3: Flushing of <strong>HS</strong>-<strong>ISO</strong> <strong>Pres</strong>sure Valve<br />
2.2.7. Greasing Nipples<br />
Fig. 4. : <strong>Pres</strong>sure check-lift with grease nipples<br />
WARNING !<br />
The flushing system may only<br />
be used when it is otherwise<br />
safe to clean the piping.<br />
WARNING !<br />
Be aware that the lubricant is<br />
compatible with the cargo.<br />
*) A clean and check-lifted<br />
valve does not get jammed.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
2.2.8. Optional Features<br />
Optional accessories for special requirements are available.<br />
Page 8 of 25<br />
Rev. 4 October 5, 2004<br />
Fig. 5: Proximity switch for Fig. 6: Fixture for forced Fig. 7: Zero emission kit<br />
stand-by valves closing for PO service for special cargo<br />
Fig. 8: Heating Arrangement Fig. 9: Side mounted Fig. 10: Dual nozzle for im-<br />
(other versions are Gas Freing Cover proved gas disper-<br />
available depending sion of small volume<br />
on size)<br />
Fig. 11: Self closing valve Fig. 12: Gas freeing Cover Fig. 13: Dessicator to prevent<br />
to prevent cargo damage to hygroscopic<br />
escape from sun- cargo<br />
ken vessel
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
2.2.9. Change to High <strong>Pres</strong>sure Unit (Optional)<br />
Page 9 of 25<br />
Rev. 4 October 5, 2004<br />
If the <strong>Pres</strong>sure valve has been delivered with a High <strong>Pres</strong>sure Unit, it is possible to replace the existing<br />
Low pressure Top Unit with a High <strong>Pres</strong>sure.<br />
This is done in the following way (refer to figure 18 on page 12):<br />
1. Remove the screws (pos. 40) and washers (pos. 41) from the top flange connection.<br />
2. Remove the Low pressure upper valve house unit.<br />
3. Mount the High pressure upper valve house unit.<br />
4. When the high pressure unit is in use cover the marked setting on the original pressue valve with<br />
Duct Tape or similar.<br />
The High <strong>Pres</strong>sure Upper valve house unit is marked with the corresponding opening pressure.<br />
The Top Unit not in use, should be stored in vertical up-right position. The best solution is to mount them<br />
on a piece of pipe next to the venting pipes.<br />
Fig. 14: Low <strong>Pres</strong>sure Top Unit Fig. 15: High <strong>Pres</strong>sure Top Unit
INSTRUCTION MANUAL<br />
3. Maintenance Instructions<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 10 of 25<br />
Rev. 4 October 5, 2004<br />
3.1. General<br />
As per SOLAS-requirements, the following service intervals shall be followed as a minimum:<br />
A.<br />
After 6 months of operation, the valve shall be inspected for proper function and, if necessary, be<br />
cleaned. However, we recommend that the valve be inspected more often depending on the cargo type.<br />
If the check-lift handle does not operate absolutely freely, cleaning is required.<br />
B.<br />
After further 6 months of operation, the valve shall be taken apart and cleaned.<br />
Dismounting the upper valve house, see fig. 18 on page 12, provides access to do the necessary<br />
cleaning. It is advantageous to have a spare upper valve house to reduce the time on deck for<br />
maintenance to a bare minimum in regard to keeping the gas-sealing parts in good condition.<br />
3.1.1 Inspection<br />
Due to the relatively large net clearance through the valve, the inner parts are much less sensitive to<br />
deposits than ordinary designs. If no thick deposits are detected by means of the fouling indicator pins<br />
and by visual inspection after removal of the seat-beds in case of any doubts, the valve is in working<br />
condition and no further precautions are necessary.<br />
NOTE! The need for inspection and cleaning may increase depending on operation<br />
conditions, the loading frequency, the type of cargo etc. Making sure that the<br />
exposed part of the stem is clean is the primary maintenance issue.<br />
3.2. Corrosion Protection<br />
When repairing the coating follow the instructions from the producer of the coating type referred to in the<br />
vessel´s general manual.<br />
3.2.1. Coating Repair<br />
Due to the large inner clearance the valve will not block because of surface corrosion, and repairing of<br />
the coating is therefore not necessary from a valve functional aspect, only if the cargo vapor is damaging<br />
to the main body parts.<br />
3.3. Safety Regulations For Maintenance Work<br />
Spark free tools should be used if maintenance work is carried out while the valve is mounted on the<br />
cargo tank.<br />
WARNING! All maintenance work must be carried out with necessary precautions in<br />
regard to the cargo’s flammability and toxicity.<br />
NOTE! Before dismounting the seat bed and replacing with a new one – the tank pressure<br />
should be lowered to the same level as when performing ullage measurement<br />
through an open deck valve.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 11 of 25<br />
Rev. 4 October 5, 2004<br />
3.4. Onboard Verifying Of Set-<strong>Pres</strong>sure<br />
After overhaul, verifying of the set-pressure is recommended if the internals of the pressure disc have<br />
been taken apart, which is normally not required. This can be accomplished by either controlling the pullweight<br />
of the pressure disc with a PRES-VAC Dynamometer and confer with PRES-VAC or use the PRES-<br />
VAC Test Rig, type TR or TRM, see fig. 16 and 17 below.<br />
The actual valve set-pressure is stamped on the valve body.<br />
The Test Rig, type TR or TRM, is used for onboard verifying of the set-pressure as well as measurement<br />
of the leakage rate to ensure compliance with environmental regulations.<br />
For further details on type TR or TRM and Dynamometer, please refer to a separate manual. This<br />
equipment can be purchased from PRES-VAC.<br />
Fig. 16: Test Rig Fig.17: Dynamometer<br />
(Mechanical and Ex versions are also available)<br />
3.5. Change Of Blow-down Value<br />
There are two possibilities of changing the blow-down value for a given <strong>HS</strong>-<strong>ISO</strong> valve.<br />
1. Change the setting of the pressure adjusting mechanism (see section 3.6)<br />
2. Change the booster plate.<br />
In case of need for changing an existing <strong>HS</strong>-<strong>ISO</strong> valve, please consult PRES-VAC.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 12 of 25<br />
Rev. 4 October 5, 2004<br />
3.6. Directions For Disassembly / Assembly And Cleaning<br />
Normal cleaning and inspection, see fig. 18:<br />
1. Unscrew the Nut (pos. 16).<br />
2. Remove the Valve top (pos. 7).<br />
3. Pull out the Split pin (pos. 15) and unscrew the Nut (pos. 14).<br />
4. Remove the Screws (pos. 40) and Washers (pos. 41) from the top flange connection.<br />
5. Remove the Upper valve house unit.<br />
6. Inspect and clean all parts. Repair or replace damaged parts as appropriate.<br />
6<br />
Fig. 18: Assembly Drawing for Inspection and Cleaning of <strong>HS</strong>-<strong>ISO</strong> <strong>Pres</strong>sure Valve<br />
NOTE! For cleaning we recommend a thin lubrication oil and a brush. If damage on any<br />
parts is observed, repair or replacement must take place.<br />
Assembly after normal cleaning and inspection<br />
1. Assembly is done in the opposite sequence.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 13 of 25<br />
Rev. 4 October 5, 2004<br />
Replacement of pressure seat (pos. 3 on fig. 18)<br />
1. If a spare upper valve house unit with seat-bed is available with a fresh seat, lower tank<br />
pressure to ullage gauging level, unbolt seat-bed and replace.<br />
2. Bring used upper valve house unit with seat-bed to work shop and unscrew seat.<br />
This is done in the following way:<br />
1. Unscrew bolts (pos. 12)<br />
2. Pull off the disc house unit including the o-ring (pos. 19)<br />
3. Unscrew the nut (pos. 9)<br />
4. Pull off the pressure adjusting part (pos. 8)<br />
5. Pull off the disc (pos. 4)<br />
6. Unscrew seat by means of a key between the ribs.<br />
7. Clean thread and insert new seat after surface lapping.<br />
Assembly<br />
1. Assembly is done in the opposite sequence.<br />
NOTE: Seat-beds can be re-used from PRES-VAC at cost of lapping and re-coating, as necessary.<br />
In order to maintain the relief pressure adjusting mechanisms correct, the Nut (pos. 11 on fig. 18), must<br />
not be dismounted. If dismounted, the relief pressure adjusting mechanism has to be adjusted by means<br />
of a calibration tool, which can be purchased from PRES-VAC or elsewhere.<br />
Adjusting the pressure adjusting mechanism<br />
The relief pressure adjusting mechanisms are adjustable within the span given for the approved<br />
configuration. This requires the equipment mentioned in section 3.4.<br />
It is done in the following way:<br />
1. Unlock the lock washer (pos. 10) and unscrew the nut (pos. 11)<br />
A. To increase the opening pressure setting, turn the adjusting screw (pos. 6) clock-wise.<br />
B. To decrease the opening pressure setting, turn the adjusting screw anti-clock-wise.<br />
2. Remount the washer (pos. 10), mount the nut (pos. 11) and lock with the lock washer again.<br />
RECOMMENDATION<br />
It is recommended to have a spare upper valve house unit available with a fresh seat. This will enable<br />
replacement in a matter of 1-2 minutes and minimum-leakage alignment is ensured.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 14 of 25<br />
Rev. 4 October 5, 2004<br />
Assembly/disassembly of check-lift<br />
1. Remove the <strong>Vac</strong>uum unit.<br />
2. Remove the Screw (pos. 38 on fig. 19).<br />
3. Pull out the Plug for the lift (pos. 31) together with the o-ring.<br />
4. Loosen the screw (pos. 39) fastening the Lifter to the Stem for the check-lift.<br />
5. Slide the Lifter (pos. 29) to one of the sides and remove the Key (pos. 30).<br />
6. Before pulling out the Stem for the check-lift (pos. 28) completely, remove the loose parts (Lifter<br />
and Screw).<br />
Assembly of check-lift<br />
1. Assembly is done in the reverse order.<br />
General<br />
Screws and bolts not protected from loosening, should be secured by a suitable adhesive, such as PRES-<br />
VAC part no.: 1323-8.<br />
Fig. 19: Check-lift Assembly<br />
RECOMMENDATION<br />
Fill in the maintenance log sheet in connection with inspection and service. See back of manual.
INSTRUCTION MANUAL<br />
4. Spares<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 15 of 25<br />
Rev. 4 October 5, 2004<br />
There are no class requirements for carrying spares on board. If spares are required, please use the<br />
following procedure:<br />
1. Take a copy of the inserted drawing no. <strong>2388</strong>-122.<br />
2. Identify the components and write the required quantities on the part list.<br />
3. Advise builder of ship and new building number.<br />
4. Advise Vessel name.<br />
5. Advise serial number punched into the flange of the valve.<br />
Fax the drawing to our office in DENMARK.<br />
When we have the above information, our files contain all further details.<br />
Our telefax and E-mail are open 24 hours a day<br />
Telefax No........ +45 48 17 17 88<br />
E-mail.............. presvac@pres-vac.com<br />
Our telephone is open during normal office hours<br />
Telephone No.: . +45 48 17 40 55<br />
Our postal address:<br />
PRES-VAC ENGINEERING A/S<br />
Svanevang 3-5<br />
DK-3450 Allerød<br />
Denmark
INSTRUCTION MANUAL<br />
SPARE PART ORDERING LIST<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 16 of 25<br />
Rev. 4 October 5, 2004
INSTRUCTION MANUAL<br />
5. Trouble-shooting<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Problem Remedy<br />
Page 17 of 25<br />
Rev. 4 October 5, 2004<br />
Tank pressure is too high A.<br />
Check in vessel’s Master Loading Chart according to<br />
IMO MSC/Circ. 731 what the maximum permissible<br />
loading rate is and the corresponding loading rate<br />
with corrections for vapor density and vapor growth<br />
rate. Lower loading rate if necessary.<br />
B.<br />
Check that the valve is clean inside and take care of<br />
maintenance as per Section 3 if necessary.<br />
B.1.<br />
Check that the valve disc is able to travel full stroke<br />
by hand-lifting.<br />
B.2.<br />
Check that pressure seat/disc contact area (width)<br />
is not exceeding manufacturer’s recommendations<br />
to avoid a “aero-dynamic” lock (like blowing<br />
between two sheets of paper) as a consequence of<br />
“home-made” repairs.<br />
C.<br />
Check that the piping is unobstructed by cargo<br />
residue etc.<br />
D.<br />
Check that the pressure-tuning knob has not been<br />
tampered with by use of a calibrated test<br />
instrument.<br />
E.<br />
Contact PRES-VAC to check if the configuration of<br />
magnet-power and booster disc arrangement can<br />
be changed for a more suitable performance for the<br />
actual conditions of installation.<br />
Tank vacuum is too high<br />
A.<br />
Check in vessel’s Master Loading Chart according to<br />
IMO MSC/Circ. 731 what the maximum permissible<br />
discharge rate is. Check that pump is running with<br />
the intended delivery head to avoid unintended high<br />
rates. Lower pump rate if necessary.<br />
B.<br />
Check that the valve is clean inside and take care of<br />
maintenance as per Section 3 if necessary.<br />
B.1.<br />
Check that the valve disc is able to travel full stroke<br />
by hand-lifting.<br />
B.2.<br />
Check that vacuum seat/disc contact area (width) is<br />
not exceeding manufacturer’s recommendations to<br />
avoid a “aero-dynamic” lock (like blowing between<br />
two sheets of paper) as a consequence of “homemade”<br />
repairs.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 18 of 25<br />
Rev. 4 October 5, 2004<br />
Tank vacuum is too high (continued) B.3.<br />
Check that the vacuum disc’s contact area is dry to<br />
avoid a hydraulic lock.<br />
C.<br />
Check that the piping is unobstructed by cargo<br />
residue etc.<br />
D.<br />
Contact PRES-VAC.<br />
Not fully lifting pressure disc:<br />
Due to the relative large venting capacity required<br />
according to USCG regulations on Vapor Emission<br />
Control Systems, which for some cargoes are nearly<br />
doubling the actual loading rate, valves may in fact<br />
be handling far less than designed for. Especially<br />
when the sizing procedure did not allow the VECS<br />
capacity to be present at an elevated tank pressure<br />
just below the maximum working pressure. In other<br />
words; a generous provision for venting capacity is<br />
a problem and the valve performance might appear<br />
as chattering or fluttering and can severely reduce<br />
the lifetime of seats and discs.<br />
The remedy available is to consult PRES-VAC for<br />
guidance on adjusting the opening setting and/or<br />
the configuration of the booster plate arrangement.<br />
In extreme cases, for instance for slop tanks<br />
equipped similar to the main cargo tanks, it may be<br />
necessary to install a dual, small capacity unit with<br />
a differing setting making the too large original<br />
valve a stand-by safety unit for the rare maloperating<br />
event.<br />
The valve is leaking A.<br />
Clean valve discs and seats.<br />
B.<br />
Check pressure check-lift seal.<br />
C.<br />
Overhaul or replace seats and discs as appropriate.<br />
D.<br />
Contact PRES-VAC.<br />
The valve is hammering A.<br />
Check that installation is within the service<br />
restrictions shown in the certification issued by the<br />
CE Notified Body ( FORCE TECHNOLOGY). If not,<br />
contact PRES-VAC.<br />
B.<br />
If the valve is grossly over-sized for the actual<br />
capacity vented, the opening and closing cycle may<br />
reduce the expected lifetime of the sealing parts. If<br />
the differential between the capacity of the valve<br />
based on USCG VCS requirements is too far from<br />
the actual volume vented, the lifetime of the<br />
sealing parts is reduced.
INSTRUCTION MANUAL<br />
<strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
Page 19 of 25<br />
Rev. 4 October 5, 2004<br />
The valve is hammering (continued) C.<br />
Check Section 2.2.5 on “Valve Misbehaviour.”<br />
Hammering is by definition non-intended full stroke<br />
movement of the pressure disc and should not be<br />
misunderstood for non-fluttering.<br />
C.1.<br />
Hammering is not an issue with vacuum valves as<br />
these are modulating and therefore unstable in the<br />
opening phase. Since flash-back protection is not<br />
connected with a high velocity nozzle, disc<br />
movement is no concern, save from a lifetime<br />
aspect.<br />
D.<br />
Contact PRES-VAC to check if the configuration of<br />
magnet-power and booster disc arrangement can<br />
be changed for a more suitable performance for the<br />
actual conditions of installation.
LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009<br />
6. Laboratory Report, Summary<br />
SUBJECT: <strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong><br />
The following report is part of the Instructions Manual as required by MSC/Circ. 677, paragraph 4.3 and<br />
should be kept on board the tanker.<br />
The report contains in a condensed form all conducted tests and results obtained, as well as all further<br />
information required, according to the IMO-rules, MSC/Circ. 677 as amended by Circ. 1009 and <strong>ISO</strong><br />
15364.<br />
The complete Laboratory Report and test data including video documentation is on file with Force<br />
Technology, the CE Notified Body. The following tests were completed successfully as indicated on the<br />
attached certificates of Type Approval from Force Technology.<br />
Test<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
Description<br />
Corrosion test<br />
Hydraulic pressure<br />
test<br />
Hammering test<br />
Flow test<br />
Flash-back test<br />
Endurance<br />
burning test<br />
Ice test<br />
MSC/Circ.<br />
677/1009<br />
3.5.1<br />
3.5.2<br />
2.3.6 1<br />
3.3.2<br />
3.3.3.1<br />
3.2.3.2/2.3.6<br />
2.3.4<br />
Remarks:<br />
The corrosion tests were carried out on a test rig as<br />
shown on drawing no. 1194-26. The test results were to<br />
the satisfaction of the Notified body.<br />
The hydraulic tests were carried out on a test rig as<br />
shown on drawing no. 1194-317. The test results were<br />
to the satisfaction of the Notified body.<br />
The hammering tests were carried out on a test rig as<br />
shown on drawing nos. 1194-162 and 1194-163. In no<br />
case did hammering occur on the pipe lengths indicated<br />
in the certificate.<br />
The flow tests were carried out on a test rig as shown on<br />
drawing nos. 1194-148 and 1194-149. The results obtained<br />
appear from the inserted flow curves as enclosed.<br />
The flash-back tests were carried out on a test rig as<br />
shown on drawing no. 1194-159. In no case did flashback<br />
occur.<br />
The endurance burning tests were carried out on a test<br />
rig as shown on drawing no. 1194-158. In no case did<br />
flash-back occur.<br />
The ice test was carried out on a test rig as shown on<br />
drawing no. 1194-161. The test valve was covered with<br />
ice of a thickness of 20-50mm. Hereafter the valve was<br />
check-lifted, and it was seen that the ice broke off at the<br />
outlet, and the valve was fully operative. Heating<br />
arrangements are not required, unless for crystallizing<br />
cargoes.<br />
Additionally, separate flow testing has been performed in accordance with API 2000 Standard because<br />
flow testing as per MSC/Circ. 677/Circ. 1009 and <strong>ISO</strong>15364 does not automatically qualify for API 2000<br />
requirements since higher pressure and vacuum conditions are necessary for some valve configurations.<br />
Please refer to the attached Certificates of Type Approval from Force Technology.<br />
1<br />
If length-restrictions are violated, the ability to arrest flame is uncertain as fire tests were<br />
performed adhering to the stated pipe configuration.
Drawing no.: 1194-26, Corrosion Test
LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009<br />
Drawing no.: 1194-317, Hydraulic <strong>Pres</strong>sure Test<br />
Drawing no.: 1194-162, Hammering test<br />
SUBJECT: <strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong>
LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009<br />
Drawing no.:1194-163, Hammering test<br />
Drawing no.: 1194-148, Flow Test<br />
SUBJECT: <strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong>
LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009<br />
Drawing no.: 1194-149, Flow test<br />
Drawing no.: 1194-159, Flash-back Test<br />
SUBJECT: <strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong>
LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009<br />
Drawing no.: 1194-158, Endurance Burning Test<br />
Drawing no.: 1194-161, Ice Test<br />
SUBJECT: <strong>HS</strong>-<strong>ISO</strong> <strong>PRESSURE</strong> <strong>VALVE</strong>