Đang tải... (xem toàn văn)
Installation, alteration and maintenance work on gas appliances in buildings and properties must only be carried out by the gas authority or their approved agent, ▪ the pipe work must be subject to a pre and main test and a combined load test and valve proving test relative to the pressure range intended (e.g. DVGWTRGI, work sheet G 600), ▪ inform the gas authority about the type and size of plant prior to installation, ▪ local regulations and guidelines must be observed during installation (e.g. DVGWTRGI, work sheet G 600; TRF Band 1 and Band 2), ▪ the gas supply pipe work should be suitable for the type and quality of gas and should be designed in such a way that it is not possible for liquids to escape (e. g. condensate), observe the vaporisation temperature of liquid petroleum gas, ▪ use only approved sealing materials. Observe all process information, ▪ recommission the unit when changing to a different type of gas, ▪ carry out soundness test after each service and fault rectification.
Operating Manual Thermal oil heater, fuel fired Type: wtö 1.750-40-1-A-h ra-p 50-90-100-k ra-p 40-54.50-80-k Year of Manufacturing: 2011 Order No.: 11006200 Customer Project-No.: 262-80077 H TT energy systems GmbH Postfach 1922 Füllenbruchstr 183 x 32009 Herford/Germany x 32051 Herford/Germany Telefon: + 49 ( 0) 2 / - Telefax: + (0 ) 21 / 85 - Internet: www.htt.de x E-Mail: info@htt.de TABLE OF CONTENTS page OPERATING-/ ASSEMBLY MANUAL _ 1.1 GENERAL NOTES 1.1.1 CONTRACTUAL LANGUAGE, DATA CARRIERS 1.1.2 CONFIDENTIALITY 1.1.3 INTRODUCTION 1.1.4 USE ACCORDING TO REGULATIONS 1.1.5 REFERENCE TO THE EC MACHINERY DIRECTIVE _ 1.2 SAFETY AND RESIDUAL RISKS _ 1.2.1 MARKING OF RELEVANT INSTRUCTIONS CONTAINED IN THE OPERATING-/ ASSEMBLY MANUAL 1.2.2 PERSONNEL QUALIFICATION AND TRAINING _ 1.2.3 DANGERS IN CASE OF NON-OBSERVANCE OF THE SAFETY INSTRUCTIONS 1.2.4 SAFETY CONSCIOUS WORKING 1.2.5 SAFETY INSTRUCTIONS TO BE FOLLOWED BY THE OPERATOR/ ATTENDANT 1.2.6 SAFETY INSTRUCTIONS FOR INITIAL START- UP-, MAINTENANCE-, INSPECTION- AND INSTALLATION- OPERATIONS 1.2.7 UNAUTHORIZED CONVERSION AND MANUFACTURE OF SPARE PARTS 1.2.8 INADMISSIBLE MODES OF OPERATION 1.2.9 MANUFACTURER'S LIABILITY 1.3 TECHNICAL DATA _ 10 1.3.1 THERMAL OIL HEATER 1, FUEL FIRED 10 1.3.2 SECONDARY CIRCUIT 13 1.3.3 SECONDARY CIRCUIT 15 1.4 EMISSIONS _ 17 1.4.1 NOISE EMISSION 17 1.4.2 HEAT TRANSFER MEDIUM EMISSION _ 17 1.4.3 HEAT EMISSION _ 17 1.5 DESIGN AND FUNCTION 18 1.5.1 GENERAL DESCRIPTION _ 18 1.5.2 STRUCTURAL DESIGN _ 18 1.5.3 FUNCTION _ 18 1.5.4 DESCRIPTION OF THE MAIN PLANT COMPONENTS _ 19 1.5.5 TEMPERATURE CONTROL AND SAFETY DEVICES 27 1.6 TRANSPORT AND STORAGE 32 1.6.1 PACKING _ 32 1.6.2 CHECKING THE CONTENTS OF THE DELIVERY 32 1.6.3 TRANSPORT 32 1.6.4 STORAGE 33 1.7 INSTALLATION 34 1.7.1 ERECTION _ 34 1.7.2 HEAT TRANSFER MEDIUM CONNECTION _ 38 1.7.3 COOLING WATER CONNECTION _ 42 1.7.4 1.7.5 1.7.6 1.7.7 1.7.8 ELECTRICAL CONNECTION _ 44 TESTING OF PIPEWORK 44 LEAK TEST _ 44 THERMAL INSULATION _ 46 FIRE PROTECTION 47 1.8 COMMISSIONING 49 1.8.1 FILLING THE PLANT 49 1.8.2 BOILING OUT THE PLANT _ 49 1.8.3 COMMISSIONING OF COLD WATER BYPASS VALVE 52 1.8.4 MISCELLANEOUS OPERATIONS _ 53 1.9 OPERATION 55 1.9.1 DAILY START-UP 55 1.10 SHUTDOWN 57 1.10.1 SWITCHING OFF THE PLANT 57 1.10.2 EMPTYING THE PLANT _ 57 1.11 EMERGENCY INSTRUCTIONS _ 58 1.12 MAINTENANCE _ 59 1.12.1 MAINTENANCE INTERVALS _ 59 1.12.2 FIRED HEATER 62 1.12.3 BURNER _ 62 1.12.4 STEEL CHIMNEYS _ 63 1.12.5 HEAT TRANSFER OIL 64 1.12.6 HEAT EXCHANGER 64 1.12.7 COOLING WATER _ 64 1.12.8 MEASURING, CONTROL AND REGULATING DEVICES AND FITTINGS 66 1.12.9 CHECKING THE PLANT FOR LEAKS 66 1.12.10 PUMPS 66 1.12.11 AUXILIARY HEATING _ 66 1.12.12 ELECTRICAL EQUIPMENT _ 66 1.12.13 AUXILIARY EQUIPMENT 67 1.12.14 MISCELLANEOUS 67 1.12.15 INITIAL AND ROUTINE CHECKS 69 SUGGESTED REPLACEMENT PARTS _ 70 1.14 MALFUNCTIONS 76 1.15 REFERENCES TO STANDARDS, REGULATIONS AND GUIDELINES 81 74H 1.13 150H 15H DRAWINGS, PLANS, CERTIFICATES _ 82 INDIVIDUAL OPERATING MANUALS 83 76H 75H 152H 153H OPERATING-/ ASSEMBLY MANUAL 1.1 GENERAL NOTES 1.1.1 CONTRACTUAL LANGUAGE, DATA CARRIERS All translations are done to the best of our knowledge and with due care They do, however, serve only - without guarantee - the purpose of facilitating the application of the German original text which will be binding in all instances HTT can assume no responsibility for the correctness of the translation Operating-/ assembly manuals on data carriers serve only for simpler handling; the paper copy issued is binding 1.1.2 CONFIDENTIALITY The passing on and reproduction of this documentation as well as the utilization and disclosure of its contents are not permitted unless expressly authorized Contraveners are liable for damages All rights reserved for the event of a patent being granted or a design registered 1.1.3 INTRODUCTION ATTENTION This unit must be installed, started and operated with exact observance of this operating-/ assembly manual as well as the currently applicable regulations by fully qualified personnel only Should you fail to observe the instructions of this operating-/ assembly manual, ♦ this could possibly lead to threats to yourself and your colleagues, ♦ the unit could possibly be damaged, ♦ the manufacturer shall not be liable for any damages resulting there from! When working on this unit please bear in mind your responsibility for your fellow men! It is imperative for all installation, operating and maintenance personnel to read this operating-/ assembly manual carefully All notes and instructions contained therein regarding the starting, operation, maintenance and repair of the plant are to be followed The operating-/ assembly manuals for individual components enclosed under Chapter are likewise to be observed by all means The operating-/ assembly manual should at all times be kept near the aggregate within easy reach of the operator In case you have any queries or when difficulties occur please contact our customer service department We assume no liability for damages and operational malfunctions resulting from the nonobservance of the operating-/ assembly manual In addition to the operating-/ assembly manual the operator is to make operating instructions available to the operating staff The standards, prescriptions and directives given in Chapter 1.15 must be observed If the heat transfer plant supplied by HTT energy systems deviates from the plant described in this operating-/ assembly manual or is described differently, HTT energy systems must be consulted immediately All rights reserved for errors and omissions All rights reserved for technical modifications that not detract from the contractually stipulated usability 1.1.4 USE ACCORDING TO REGULATIONS The temperature control unit is dimensioned according to the specifications of the orderer and DIN 4754 and realised as mutually agreed upon The plant is intended exclusively for heating and cooling of a heat consumer - in so far as available - with the operating characteristics defined under TECHNICAL DATA 1.3; the control values must not be changed, otherwise dangers to man and environment could result ATTENTION ! Any use beyond the above shall be considered as failing to comply with the terms agreed upon HTT energy systems shall not be liable for any resulting damage Use in accordance with regulations also includes compliance with the operating-/ assembly manual and regulations for maintenance as prescribed by HTT energy systems Structural and system modifications are to be agreed upon with the manufacturer The plant must be operated in such a way as to ensure that any operationally conditioned leakages of heat transfer medium are kept as low as possible and safely evacuated Prevention of foreseeable misuse ⇒ Heat transfer plants must not be filled and operated with water ⇒ The plant must be operated only if the equipment components required for safety reasons have been activated ⇒ Also only the heat transfer medium specified under 1.3 Technical Data is to be used and the mentioned admissible limitations of use are not to be exceeded 1.1.5 REFERENCE TO THE EC MACHINERY DIRECTIVE According to the EC Machinery Directive 2006/42/EC the product as described and supplied is an „incomplete plant“ as per Article 2, para g) to be certified as such by a declaration of installation The product in the supplied design is determined for installation in a plant / assembly with other plants to one plant The start-up is prohibited until it is determined that the plant in wich the plant is to be installed corresponds to the regulations of the Machinery Directive 2006/42/EC 1.2 SAFETY AND RESIDUAL RISKS This operating-/ assembly manual contains basic instructions which are to be observed during installation, operation and maintenance It is therefore imperative that this operating-/ assembly manual is read by the fitter(s) as well as the responsible personnel/operator(s) prior to any installation and starting operations and that it is kept permanently at their disposal at the installation site of the machine/plant Not only the general safety instructions outlined under this main section safety and residual risks are to be followed, but also those specific safety instructions inserted under the other main sections This also applies to the individual operating manual in Chapter The aggregate is built according to the state of technology and the accepted safety regulations However threats to life or physical condition of the user or third parties at use respectively impairments of the aggregate and other property values are possible 1.2.1 MARKING OF RELEVANT INSTRUCTIONS CONTAINED IN THE OPERATING-/ ASSEMBLY MANUAL The safety instructions contained in this operating-/ assembly manual, the non-observance of which is liable to cause a hazard to persons, are marked with generally comprehensible pictograms, standardised hazard symbols or, in case of further danger, with a descriptive text Warning – Hot surface Warning – Hazardous voltage Warning – Explosible atmosphere Warning – Inflammable materials Warning – Danger zone Warning – Suspended load Dangerous to environment Use protective clothing Use protective shoes Use protective gloves Use eye protection Use face shield Extinguishing No fire, open with water flames and prohibited smoking Safety instructions, the non-observance of which might cause special hazards to persons and/or the machine and its functions are proceeded additionally with the word: ATTENTION! Instructions attached directly to the aggregate such as ♦ sense of rotation arrow ♦ fluid connection identifying marks must be observed by all means and kept in a fully legible state 1.2.2 PERSONNEL QUALIFICATION AND TRAINING The personnel in charge of operation, maintenance, inspection and installation must be adequately qualified to carry out such work Scope of responsibility, competence and the supervision of the personnel must be defined precisely by the Operator If the personnel does not have the necessary knowledge at its disposal, it is to be trained and instructed If necessary, this may be done on behalf of the Operator of the aggregate by the manufacturer/supplier Furthermore is to be ensured by the Operator that the contents of the operating-/ assembly manual are fully understood and applied by the personnel concerned 1.2.3 DANGERS IN CASE OF NON-OBSERVANCE OF THE SAFETY INSTRUCTIONS The non-observance of the safety instructions could result in a danger to persons as well as to the environment and the aggregate The non-observance of the safety instructions could furthermore result in the forfeiture of all rights to claim damages In particular, nonobservance could bring about, for instance, the following hazards: ♦ ♦ ♦ ♦ a failure of important machine/plant functions a failure of prescribed care and maintenance methods a hazard to persons via electrical, mechanical, thermal and chemical effects a hazard to the environment, persons and machinery through the escape of dangerous substances 1.2.4 SAFETY CONSCIOUS WORKING The safety instructions contained in this operating-/ assembly manual, the existing national regulations for the prevention of accidents as well as any internal working, operating and safety regulations of the Operator are to be observed 1.2.5 SAFETY INSTRUCTIONS TO BE FOLLOWED BY THE OPERATOR/ ATTENDANT ♦ Since hot or cold machine components may result in hazards, these components must be protected by the Operator against accidental contact and provided with indications of the danger ♦ The protection against accidental contact for moving parts (e.g coupling) may be removed only when the machine is not operating ♦ Leakages (e.g shaft seal) of dangerous pumping fluids (e.g explosive, toxic, hot) must be evacuated in such a way as to prevent any threat to persons and the environment from occurring The legal regulations are to be complied with ♦ Perils resulting from electric energy are to be excluded (for more details on this subject refer to the VDE regulations as well as those of the local electric supply company) ♦ Plant components in which a pressure or depression may build up due to the infeed of heat or cold must not be shut off or are to be fitted out by the operator with admissible excess/low pressure devices to prevent the permissible operating pressure from being exceeded ♦ When dealing with ladders the regulations for the prevention of accidents, in particular BGV D36, are to be observed ♦ Maintenance platforms and anti-fall safeguards are to be installed when carrying out work above floor level ♦ It is forbidden to walk on the plant ♦ The generally comprehensible pictograms and standardised hazard symbols listed under 1.2.1 are to be installed visibly by the Operator outside the danger area 1.2.6 SAFETY INSTRUCTIONS FOR INITIAL START- UP-, MAINTENANCE-, INSPECTION- AND INSTALLATION- OPERATIONS The Operator is to see to it that all maintenance, inspection and installation operations are carried out by authorised and qualified personnel having adequately familiarised themselves with the necessary procedures by thoroughly studying the operating-/ assembly manual As a matter of principle all work is to be carried out only with the machine standing still and being in cool condition The procedure regarding the shutdown of the machine as out-lined in the operating-/ assembly manual must be observed by all means Should it become necessary for whatever reasons to drain the plant then it must be ensured that the temperature of the medium is below 50 °C in order to avoid accidents Prior to beginning work on the plant the supply of electric power to the plant is to be cut off Pumps or pumping units delivering fluids detrimental to health must be decontaminated Immediately after completion of the work, all safety and protective appliances must be reinstalled or reactivated, respectively Prior to restarting the plant the points listed in the section "Initial Start-Up" must be observed Plant components in which a pressure or depression may build up due to the infeed of heat or cold must not be shut off or are to be fitted out with admissible excess/low pressure devices to prevent the permissible operating pressure from being exceeded Cold plant sections or sections not boiled-out (pipework, consumers, etc.) must not be connected or commissioned as long as the overall plant temperature is < 80 °C See also instructions under 1.2.5 1.2.7 UNAUTHORIZED CONVERSION AND MANUFACTURE OF SPARE PARTS Conversion or modifications of the aggregate are admissible only after consultation with the manufacturer Original spare parts and accessories authorised by the manufacturer serve the purpose of maintaining safety The use of any other parts can entail the exclusion of all liability for any consequences resulting therefrom 1.2.8 INADMISSIBLE MODES OF OPERATION The operational safety of the aggregate supplied is warranted only when used for the purposes outlined in the section "General Field of Application" of the operating-/ assembly manual The admissible operating data and setting values indicated under 1.3 TECHNICAL DATA must not be exceeded under any circumstances 1.2.9 MANUFACTURER'S LIABILITY The manufacturer's liability is defined in the delivery contract If this operating-/ assembly manual is not complied with, liability may cease Should the operating conditions (e.g different heat transfer medium, voltage, frequency, speed of rotation, viscosity, temperature etc.) change after delivery, HTT energy systems will have to examine each case individually and, if necessary, confirm that the plant is suited to such conditions Unless any special agreements have been made, units supplied by HTT energy systems must only be opened or modified by HTT energy systems or by customer service workshops authorised by HTT energy systems, otherwise liability for any faults shall cease to exist 201469_2 Betriebsanleitung 05 07.11.2005 • For liquids the blow-off pipe should point downwards so that the medium can completely drain out of the blow-off chamber • The outlet flange of safety valves or blow-off pipes must be directed so that no danger is caused by the medium blowing off The following options are available: - Blowing off into a container - Safety valve and blowing-off pipes without direct access - Design with silencer 12.10 Unfavourable environmental conditions All LESER safety valves which may corrode are coated with a protective coating during manufacture which protects the safety valve during storage and transport In corrosive environments a further corrosion protection is required (refer to section 12.13) For extreme conditions, LESER recommends stainless steel safety valves The supplementary loading system must not be given a protective coating! External media (e.g., rain water or dirt/dust) must not enter the blowing-off pipe or come in contact with functional components (e.g., guides with open bonnets) have to be avoided By analogy, the statements made in section apply Simple preventive measures are possible: • Protection of the blow-off chamber from extraneous media and dirt • Protection of the parts important to operating from external media and dirt 12.11 Leaks caused by foreign bodies Foreign bodies must not remain in the installation (e.g., welding beads, sealing material such as hemp tape, PTFE tape, screws, etc.) One option for avoiding foreign bodies in the system is to flush it before commissioning If leaks are caused by contamination between the sealing surfaces, the safety valve can be vented to clean the surfaces If this does not stop the leak, one of the sealing surfaces is probably damaged In this case the safety valve has to be serviced 12.12 Protection during storage and transport All protective devices for transport and handling have to be removed before installing the safety valve After installation, the protection for the lever must be removed from the bonnet as otherwise the safety valve cannot be vented The lever must move freely, i.e it must be in its initial position and the coupling at the spindle must not be connected to the lever 16:54 Uhr Seite 25 In the case of lever safety valves, the wooden wedge, which protects the sealing surfaces from damage during transport, has to be removed 12.13 Corrosion protection Moving parts and parts important to the operating of the valve must not be impaired in their motion, e.g the blowing-off chamber The spindle guide must not be varnished The supplementary loading system must not be coated with protective paint (refer also to section 15) 12.14 Maintenance Safety valves may only be serviced by skilled staff Maintenance intervals cannot be specified by LESER as they depend on many factors: • Corrosive, aggressive and abrasive media lead to rapid wear and require shorter maintenance intervals • Frequent operating requires shorter maintenance intervals • Maintenance intervals have to be agreed between the operator, the inspector and the manufacturer Inspections must be carried out at the time of the regular external and internal checks of the pressure equipment 12.15 Identification of safety valves Before assembling safety valves the documentation must be checked in order to ensure that the correct valve has been selected for the assembly 12.16 Lever safety valves The set pressure of lever safety valves is defined by the mass and the position of the loading weights It is not allowed to change them No additional loading weights must be added The lever must not be used for suspending any parts, e.g for hanging clothes on 13 Setting instructions for spring loaded safety valves The following operating instructions only apply to valves without additional equipment If there is additional equipment (such as O-ring dampers, proximity switches, bellows, ) please refer to the corrosponding assembly instructions 13.1 Lifting device H3 Remove shaft (40.4) Pull lever (40.6) out to the side Loosen hexagonal head screw (40.3) Unscrew and remove lever cover (40.1) 25 E 201469_2 Betriebsanleitung 05 07.11.2005 16:54 Uhr Loosen the lock nut (19) of the adjusting screw (18) 1) Turn the adjusting screw (18) anticlockwise to remove all spring tension Remove the hex nuts (56) from the flange of the bonnet (9) Lift off the bonnet (9) Remove the upper spring plate (16) 10 Lift off the spring (54) and remove lower spring plate (16) and split rings (14) 11 Remove spindle (12) with guide (8) and disc (7) 12 Carefully clean seat (5) and disc (7), and if required body internals 13 Refit spindle (12) with guide (8) and disc (7) 14 Fit the split rings (14) into spindle groove and retain with the securing ring (59); slip on lower spring plate (16) to locate on split rings (14) 15 Replace spring (54) 16 Slip on the upper spring plate (16) onto the spindle (12) 17 Align adjusting screw (18), and bonnet (9) over the spindle (12) and refit 18 Fit and tighten the hex nuts (56) 19 1) Load the spring (54) to obtain the required set pressure Clockwise rotation of adjusting screw (18) increases pressure Anticlockwise rotation of adjusting screw (18) reduces pressure 20 Tighten the lock nut (19) onto the adjusting screw (18) 21 Refit and secure spindle cap (40.12) by pin (40.13) and securing ring (40.14) 22 Screw-on the lever cover (40.1) 23 Pull the lever (40.6) towards the middle so that the lifting fork (40.5) is pushed under the spindle cap (40.12) 24 Test spindle will lift correctly by pulling lever Loosen lock nut (19) 1) Turn adjusting screw (18) to the required set pressure Pay attention to the admissible pressure range of the spring! Clockwise turning of adjusting screw increase the spring tension, giving a higher set pressure Anticlockwise turning of adjusting screw reduces the spring tension, giving a lower set pressure Reassemble in reverse order and lock at the set pressure E 19 19 40.4 40.1 40.3 40.3 18 Seite 26 40.6 40.6 Fig 13.2 Lifting device H4 Loosen the spring cover (40.1.1) and simultaneously press the lever (40.1.6) in the direction of the bonnet so that the lifting fork (40.1.5) comes free Remove the lever cover (40.1.1) Loosen the lock nut (19) 1) Turn adjusting screw (18) as described in lifting device H3 Pay attention to the admissible pressure range of the spring! Reassemble in reverse order and lock at the set pressure 40.1.6 40.1.5 18 These instructions are applicable for relief valves, safety valves and safety relief valves 19 1) 40.1.1 Fig 13.3 Spring replacement The following items refer to the figures shown in the LESER Product Catalogue Loosen the existing lead seal Press the lever (40.6) towards the middle until it reaches the stop so that the lifting fork (40.5) no longer holds the spindle cap (40.12) Loosen and remove the lever cover (40.1) Loosen the spindle cap (40.12) from the spindle (12), remove the securing ring (40.14) and the pin (40.13) 26 Caution: During all work the spindle has to be secured against twisting in order to prevent damage to the sealing surfaces The following points should be noted: The pressure setting is wire-locked and sealed against unauthorized alteration The rules and standards, agreed by the manufacturer, require the fitting of a name plate stating the correct valve data The manufacturer cannot be held responsible for any changes to set pressure or other alterations after despatch from the factory Necessary modifications should only be made by authorised distributors of LESER or under the supervision of the TÜV or any other competent inspection authority 201469_2 Betriebsanleitung 05 07.11.2005 14 Handling There is a risk of injury from sharp edges and burrs For this reason all parts have to be handled with caution There is a risk from safety valves falling over They always have to be secured adequately During dismantling the spring must not be tensioned Otherwise there is danger of injury from flying parts Observe the assembly instructions for the relevant safety valves! Before dismantling you should always check whether there is, or could be, any medium in the bonnet; also check what the medium is There is a great risk of injury, chemical burns or poisoning if there is any remaining medium inside the safety valve One should use conventional high quality tools in order to minimise the risks arising from bad quality tools or inadequate tools Any necessary special tools are indicated in the assembly instructions Safety valves may only be dismantled and assembled by skilled staff The training can be carried out: • In the workshop by experienced staff • At LESER training seminars • By means of LESER documentation, e.g., videos, operating instructions, catalogues, assembly instructions The maintenance staff must be informed about the risks during dismantling and installing the safety valves Contamination and damage to the safety valve must be avoided Suitable cartons, protective covers for the flanges, wrapping foil, shipping palettes etc have to be used The packaging must be completely removed before installation as otherwise the function of the safety valve cannot be guaranteed Safety valves have to be handled with care as otherwise the vulnerable sealing surfaces can be damaged or the safety valve might even be rendered useless Safety valves must be stored in a dry place The optimum storage temperature is °C to 40 °C For o-ring discs temperatures below freezing should be avoided, if possible The temperature resistance, in particular of the o-ring materials, has to be taken into account Upper limit for storage: 50 °C Lower limit for storage: -10 °C 16:54 Uhr Seite 27 15 Supplementary loading system Even if the external energy supply (compressed air) fails, the direct-loaded safety valve is still fully functional In this case the function is equivalent to the LESER standard safety valve without supplementary loading system The compressed air filter must be serviced at regular intervals as specified in the maintenance instructions The installation should contain an air dryer The compressed air should have a dew-point of minimum +2 °C The maximum pressure of the air supply is 10 bar, the minimum pressure is 3.5 bar If the pressure rises above or falls below the specified interval, this may lead to temporary or permanent failure of the supplementary loading system As a result the safety valve does not function or it will work as a standard valve without the supplementary loading system The supplementary loading system should be serviced and checked at least once a year by specially trained staff For this essential work LESER offers a maintenance service which may be incorporated in a service agreement Training and experience with handling the supplementary loading system in combination with the safety valves are essential The supplementary loading system has to be fitted in accordance with the rules and standards and the specifications distributed by LESER If serviced correctly, failures due to contamination of the pressure and control lines can be excluded The control unit is to be protected from contamination It has to be ensured that it is always closed For special applications LESER offers an encapsulated box sealing the control unit The actuator on the safety valve itself as well as sliding parts inside an open bonnet must be protected from contamination Otherwise there is the danger of jamming Temperatures: The controls and actuators are designed for applications between °C and 60 °C • At temperatures above 60 °C the compressed air connections must be as long as possible and equipped with a water seal • The control unit and actuators have to be positioned in a way that their temperature will not exceed 60 °C • At a temperature below °C there may be danger of icing-up, therefore it may be necessary to heat control unit, control lines and tapping lines The supplementary loading system is 27 E 201469_2 Betriebsanleitung 05 07.11.2005 connected to the safety valve via a coupling The coupling must not be blocked by objects It is neither necessary nor permitted to apply a protective coating to the actuator The pressure tapping lines must not be shut off If there are shut-off devices they have to be designed in such a way that they cannot be closed, e.g., by means of locking bars or seals LESER control units are equipped with a shut-off device for maintenance purposes They are secured against shutting-off by means of a locking bar This locking bar must not be removed E The pressure switches are wire-locked and sealed This seal indicates that the setting has not been changed It is not permitted to manipulate the pressure switches (e.g., by opening the seal and modifying the adjustment or by opening the switching contacts, )! 16:54 Uhr Seite 28 17 Unexpected conditions Not all errors can be prevented entirely However, their consequences must be estimated and reduced by: • A risk analysis for the complete installation • An estimate of the risk and potential damage • Instructions about the measures to be taken in the case of malfunctioning • Staff training at the manufacturer’s and at the operator’s • Protective measures for people and for the environment 18 Product overview For the product overview please refer to the “Declaration of conformity” 19 Assembly instructions If a test gag is used during pressure testing of the installation it must be removed after the test 16 Combined Safety Valve and Bursting Disc The type test approval of the combination of bursting discs of a certain manufacturer with LESER safety valve ensures that both the functional and performance requirements are met If you require information on the tested combinations, please contact LESER Combinations of LESER safety valves and bursting discs of other manufacturers are permissible, if they meet the safety requirements This shall be certified for each individual case The following points should be noted in particular: • Operating instructions for the bursting disc • Safety valves must not lose their function by placing the upstream bursting disc • The space between the rear side of the bursting disc and safety valve inlet should be monitored • The bursting disc should be designed in a way that it cannot be installed incorrectly • The bursting disc has to open free of fragments Bursting disc components must not enter the inlet connecting pieces of the safety valve thus impairing the function • Sets of rules with reference to bursting discs (AD 2000-Merkblatt A1, ASME, ) 28 In addition to the Operating Instructions there is a number of type-specific assembly instructions, which are listed in the “Request form LESER Assembly Instructions” In detail the type-specific assembly instructions have to be observed 20 Disclaimer The manufacturer reserves the right to make technical changes or improvements at any time 201469_2 Betriebsanleitung 05 07.11.2005 16:54 Uhr Seite 29 additional drain pipe in case of prepared drainhole incorrect! Fig E correct! Fig 29 201469_2 Betriebsanleitung 05 07.11.2005 16:54 Uhr Seite 30 The Safety Valve Declaration of Conformity/Konformitätserklärung according to Pressure Equipment Directive 97/23/EC nach Druckgeräterichtlinie 97/23/EG LESER GmbH & Co KG Wendenstr 133-135 20537 Hamburg/Germany E Name and address of the manufacturer/Name und Anschrift des Herstellers Nominal pipe size/ Nennweite Type* NPS DN EC-type examination No./ EG-Bauteilprüfnummer 411 ¾" - 6" 20 - 150 07 202 0111Z0008/0/02 421 1"- 4" 25 - 100 07 202 0111Z0008/0/03 424 – 25 - 200 07 202 0111Z0008/0/04 427, 429 ½" - 6" 15 - 150 07 202 0111Z0008/0/05 431, 433 ½" - 6" 15 - 150 07 202 0111Z0008/0/06 440 – 20 - 150 07 202 0111Z0008/0/07 441, 442, 444 ¾" - 16" 20 - 400 07 202 0111Z0008/0/08-2 SVL 606 ¾" - 16" 20 - 400 07 202 0111 Z0008/0/08-2 447 1" - 4" 25 - 100 07 202 0111Z0008/0/09 448 1" - 4" 25 - 100 07 202 0111Z0008/0/10 455, 456 1" - 4" 25 - 100 07 202 0111Z0008/0/11 457, 458 1" - 6" 25 - 150 07 202 0111Z0008/0/12 459 ½" - 1" 10 - 20 07 202 0111Z0008/0/13 462 ¾" - 1" 15 - 20 07 202 0111Z0008/0/14 Description of the pressure equipment/Beschreibung des Druckgerätes Nominal pipe size/ Nennweite Type* NPS 532, 534 538 539 543, 544 546 483, 484, 485 437, 438, 439, 481 700 522 450/460 488 SVL 488 526 486, 586 DN EC-type examination No./ EG-Bauteilprüfnummer ½" - 6" 20 - 150 07 202 0111Z0008/0/15 ½" 10 07 202 0111Z0008/0/16 ½" - ¾" 10 - 15 07 202 0111Z0008/0/17 2" - 4" 50 - 100 07 202 0111Z0008/0/18 1" - 4" 25 - 100 07 202 0111Z0008/0/19 1", 2" 25, 40 07 202 0111Z0008/0/20 ½", ¾", Ǫ" – 07 202 0111Z0008/0/21-2 – – 07 202 0111Z0008/0/22 2" - 4" 50 - 100 07 202 0111Z0008/0/23 ¾" - 1" 15 - 20 07 202 0111Z0008/0/24 1" - 4" 25 - 100 07 202 0111Z0008/0/25-1 1" - 4" 25 - 100 07 202 0111Z0008/0/25-1 1" - 8" 25 - 200 07 202 1111Z0012/2/26 1" - 3" 25 - 80 * See name plate/siehe Bauteilprüfschild Kategorie IV/Category IV Applied category according to article and annex II/Angewandte Kategorie nach Artikel und Anhang II Module/Modul B D/D1 Conformity assessment procedures/ Konformitätsbewertungsverfahren EC type-examination/EG-Baumusterprüfung Production quality assurance/Qualitätssicherung Produktion Certificate number/ Bescheinigungsnummer See table/siehe Tabelle 07 202 0111Z0008/0/01-2 Conformity assessment procedures according to article 10/Angewandte Konformitätsbewertungsverfahren nach Artikel 10 TÜV CERT - Zertifizierungsstelle für Druckgeräte der TÜV NORD GRUPPE Identification number 0045, Große Bahnstr 31, 22525 Hamburg/Germany Name and address of the notified body (monitoring a.m conformity assessment procedures) Name und Anschrift der benannten Stelle (Zertifizierung/Überwachung nach o.g Modulen) LWN 248.13 -06/04 The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this pressure equipment meet the requirements of the Pressure Equipment Directive Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses Druckgerätes den Anforderungen der Druckgeräterichtlinie entsprechen DIN EN 12516, DIN EN 1503, DIN EN 12953, DIN EN 12266, DIN EN ISO 4126-1, EN 13463-1, EN 13463-5, EN 1127-1 Applied harmonized standards/Angewandte harmonisierte Normen AD 2000-Merkblatt A2, AD 2000-Merkblatt A4, TRB 403, TRD 421, TRD 721, DIN 3320, DIN 3840, VdTÜV SV 100 Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen 25.11.2004 Date LESER GmbH & Co KG Hamburg HRA 82 424 GF · BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr 133-135 20506 Hamburg, P.O Box 26 16 51( ) 30 Manufacturer stamp Fon +49 (40) 251 65 - 100 Fax +49 (40) 251 65 - 500 E-Mail sales@leser.com Internet www.leser.com Authorized subscriber Bank Vereins- und Westbank AG, Hamburg BLZ 200 300 00, Konto · Account 3203171 SWIFT: VUWBDEHHXXX IBAN: DE64 2003 0000 0003 2031 71 USt-ID · VAT-Reg DE 118840936 LESER - The Safety Valve 201469_2 Betriebsanleitung 05 07.11.2005 16:54 Uhr Seite 31 The Safety Valve Declaration of Conformity/Konformitätserklärung according to Pressure Equipment Directive 97/23/EC (PED) nach Druckgeräterichtlinie 97/23/EG (DGR) Potentially Explosive Atmospheres 94/9/EC (ATEX) Explosionsgefährdete Bereiche 94/9/EG (ATEX) E LESER GmbH & Co KG Wendenstr 133-135 20537 Hamburg/Germany Name and address of the manufacturer/Name und Anschrift des Herstellers Nominal pipe size/ EC-type examination No./ Nennweite EG-Bauteilprüfnummer NPS DN 411 ¾" - 6" 20 - 150 07 202 0111Z0008/0/02 421 1"- 4" 25 - 100 07 202 0111Z0008/0/03 424 – 25 - 200 07 202 0111Z0008/0/04 427, 429 ½" - 6" 15 - 150 07 202 0111Z0008/0/05 431, 433 ½" - 6" 15 - 150 07 202 0111Z0008/0/06 440 – 20 - 150 07 202 0111Z0008/0/07 441, 442, 444 ¾" - 16" 20 - 400 07 202 0111Z0008/0/08-2 455, 456 1" - 4" 25 - 100 07 202 0111Z0008/0/11 457, 458 1" - 6" 25 - 150 07 202 0111Z0008/0/12 459 ½" - 1" 10 - 20 07 202 0111Z0008/0/13 462 ¾" - 1" 15 - 20 07 202 0111Z0008/0/14 532, 534 ½" - 6" 20 - 150 07 202 0111Z0008/0/15 Description of the pressure equipment/Beschreibung des Druckgerätes Type* Type* 538 539 543, 544 546 483, 484, 485 437, 438, 439, 481 700 522 450/460 488 526 Nominal pipe size/ Nennweite NPS DN ½" 10 ½" - ¾" 10 - 15 2" - 4" 50 - 100 1" - 4" 25 - 100 1", 2" 25, 40 ½", ¾", Ǫ" – 2" - 4" 50 - 100 ¾" - 1" 15 - 20 1" - 4" 25 - 100 1" - 8" 25 - 200 EC-type examination No./ EG-Bauteilprüfnummer 07 202 0111Z0008/0/16 07 202 0111Z0008/0/17 07 202 0111Z0008/0/18 07 202 0111Z0008/0/19 07 202 0111Z0008/0/20 07 202 0111Z0008/0/21-1 07 202 0111Z0008/0/22 07 202 0111Z0008/0/23 07 202 0111Z0008/0/24 07 202 0111Z0008/0/25 07 202 1111Z0012/2/26 * See name plate/siehe Bauteilprüfschild Category IV/Kategorie IV (PED/DGR) Applied category according to article and annex II/Angewandte Kategorie nach Artikel und Anhang II Module/Modul B D/D1 Conformity assessment procedures/ Konformitätsbewertungsverfahren EC type-examination/EG-Baumusterprüfung Production quality assurance/Qualitätssicherung Produktion Certificate number/ Bescheinigungsnummer See table/siehe Tabelle 07 202 0111Z0008/0/01-2 Conformity assessment procedures according to article 10/Angewandte Konformitätsbewertungsverfahren nach Artikel 10 TÜV CERT - Zertifizierungsstelle für Druckgeräte der TÜV NORD GRUPPE Identification number 0045, Große Bahnstr 31, 22525 Hamburg/Germany Name and address of the notified body (monitoring a.m conformity assessment procedures) Name und Anschrift der benannten Stelle (Zertifizierung/Überwachung nach o.g Modulen) LWN 248.21 -06/2004 Group II, Category 1, and 3/Gruppe II, Kategorie 1, und (ATEX) The signing manufacturer declares that in compliance with the Directive 94/9/EC, the products detailed above are suitable for use as equipment group II categories 1, and and have been manufactured acc to Annex VIII "Internal control of production" Der unterzeichnende Hersteller bestätigt, dass in Übereinstimmung mit der Richtlinie 94/9/EG, die oben aufgeführten Produkte für die Verwendung als Geräte der Gruppe II, Kategorien 1, und geeignet sind und entsprechend Anhang VIII "Interne Fertigungskontrolle" hergestellt wurden DIN EN 12516, DIN EN 1503, DIN EN 12953, DIN EN 12266, DIN EN ISO 4126-1, EN 13463-1, EN 13463-5, EN 1127-1 Applied harmonized standards/Angewandte harmonisierte Normen AD 2000-Merkblatt A2, AD 2000-Merkblatt A4, TRB 403, TRD 421, TRD 721, DIN 3320, DIN 3840, VdTÜV SV 100 Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen June 30, 2004 Date/Datum LESER GmbH & Co KG Hamburg HRA 82 424 GF · BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr 133-135 20506 Hamburg, P.O Box 26 16 51( ) Manufacturer stamp/Herstellerstempel Fon +49 (40) 251 65 - 100 Fax +49 (40) 251 65 - 500 E-Mail sales@leser.com Internet www.leser.com Authorized subscriber/Authorisierter Unterzeichner Bank Vereins- und Westbank AG, Hamburg BLZ 200 300 00, Konto · Account 3203171 SWIFT: VUWBDEHHXXX IBAN: DE64 2003 0000 0003 2031 71 USt-ID · VAT-Reg DE 118840936 LESER - The Safety Valve 31 201469_2 Betriebsanleitung 05 07.11.2005 16:54 Uhr Seite 32 The Safety Valve Declaration of Conformity/Konformitätserklärung according to Pressure Equipment Directive 97/23/EC nach Druckgeräterichtlinie 97/23/EG E LESER GmbH & Co KG Wendenstr 133-135 20537 Hamburg/Germany Name and address of the manufacturer/Name und Anschrift des Herstellers Type* Material/ Werkstoff 0.6025 GG-25/ GJL-250 Nominal pipe size/ Nennweite DN Applied category in acc to article and annex II/ Angewandte Kategorie nach Artikel und Anhang II Conformity assessment procedures according to article 10/ Angewandte Konformitätsbewertungsverfahren nach Artikel 10 CEmarking/ CE-Kennzeichnung Art Par Art Abs Not necessary Nicht erforderlich No Nein Kat I Cat I A Yes Ja 15-32 Art Par Art Abs Not necessary Nicht erforderlich No Nein 40-100 Kat I Cat I 15-50 65-100 612 1.0619 GS-C 25/ GP 240 GH Description of pressure equipment/ Benennung des Druckgerätes Pressure Reducer Druckminderer Description of the pressure equipment/Beschreibung des Druckgerätes Yes Ja * See name plate/siehe Bauteilprüfschild Conformity assessment procedures/ Konformitätsbewertungsverfahren D1 Production quality assurance/Qualitätssicherung Produktion Certificate number of module D1/Zertifikatsnummer Modul D1 Module/Modul A Certificate number/ Bescheinigungsnummer 07 202 0111Z0008/0/01-2 TÜV CERT - Zertifizierungsstelle für Druckgeräte der TÜV NORD GRUPPE Identification number: 0045, Große Bahnstr 31, 22525 Hamburg/Germany Name and address of the notified body (monitoring a.m conformity assessment procedures) Name und Anschrift der benannten Stelle (Zertifizierung/Überwachung nach o.g Modulen) The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this pressure equipment meet the requirements of the Pressure Equipment Directive Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses Druckgerätes den Anforderungen der Druckgeräterichtlinie entsprechen DIN EN 1503-1, DIN EN 1503-3, DIN EN 10213-1, DIN EN 10213-2 Applied harmonized standards/Angewandte harmonisierte Normen LWN 248.14 -06/04 DIN 3840, DIN 1691, DIN EN 1561 Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen 30.06.2004 Date LESER GmbH & Co KG Hamburg HRA 82 424 GF · BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr 133-135 20506 Hamburg, P.O Box 26 16 51( ) 32 Manufacturer stamp Fon +49 (40) 251 65 - 100 Fax +49 (40) 251 65 - 500 E-Mail sales@leser.com Internet www.leser.com Authorized subscriber Bank Vereins- und Westbank AG, Hamburg BLZ 200 300 00, Konto · Account 3203171 SWIFT: VUWBDEHHXXX IBAN: DE64 2003 0000 0003 2031 71 USt-ID · VAT-Reg DE 118840936 LESER - The Safety Valve Temperaturfühler HTT WF Ausführungsvarianten A B C D Messeinsatz x Pt 100 x Pt 100 Messumformer Ex-geschützt Position1 Widerstandsfühler Pt 100 mit Messeinsatz Durchmesser mm zum Einbau in Einschweißhülse Position gemäß beigefügter Zeichnung für -50 … +400 °V`C Betriebstemperatur Messwiderstand nach DIN, Toleranzklasse b Einschraublänge 115 mm Fühlerdurchmesser mm Anschlusskopf aus Aluminium, Form BUS mit Klemmbügel und Keramikklemmstein, 3-Leiteranschluss für die Temperaturmessung sind max 20 mm in der Fühlerspitze wirksam Halbwertzeit nach DIN LEC 751 inclusiv Einschweißhülse T 05 = 14,5 sec mit Sandfüllung T 05 = 6,8 sec Einschraubverschraubung M14x1,5 zum Einsatz in WT-Anlagen nach DIN 4754 geeignet Position Einschweißschutzhülse zur Aufnahme des Temperaturfühlers Position1 Hülse nach DIN 43767 Form D Zum Einsatz in WT-Anlagen nach DIN 4754 geeignet Temperaturbereich -50 … +400 °C Betriebsdruck bis 10 bar aus Werkstoff C 22 mit Abnahmeprüfzeugnis 3.1 EN 10 204 Stand 08/2006 Temperature sensor HTT WF equipment options A B C D gauge insert x Pt 100 x Pt 100 measuring transductor ex-protected Position resistance sensor Pt 100 with gauge insert diameter mm for installation in welding case Position according to enclosed drawing for -50 … +400 °C operating temperature measuring resistor according to DIN, class of tolerance b thread reach 115 mm sensor diameter mm connecting head from aluminium, form BUS with clamp strap and ceramic terminal block, 3-wire connection For the temperature measuring max 20 mm in the top of the sensing element are effective half-life period according to DIN JEC 751 including welding case T 05 = 14,5 sec with sand filling T 05 = 6,8 sec pipe union M14x1,5 suitable for application in thermal oil plants according to DIN 4754 Position weld-in protection sleeve for inserting the temperature sensor Position sleeve according to DIN 43767 form D designed for thermal oil plants according to DIN 4754 temperature range -50 … +400 °C operating pressure up to 10 bar from material C 22 with inspection control 3.1 EN 10 204 Version 08/2006