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3.530.5275.250
ST Issue 4 - 2015
BSK1
Bellows Sealed Globe Valves
Installation and Maintenance Instructions
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
1. General safety information
2. General product information
3. Transport and storage
4. Installation
5. Commissioning
6. Maintenance
7. Spare parts
8. Fault finding
© Copyright 2015
E X P E R T I S E
S O L U T I O N S
S U S T A I N A B I L I T Y
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Summary of Contents for Spirax Sarco BSK1
- Page 1 3.530.5275.250 ST Issue 4 - 2015 BSK1 Bellows Sealed Globe Valves Installation and Maintenance Instructions The PED Directive 97/23/EC is repealed and replaced by the new PED Directive 2014/68/EU with effect from 19 July 2016. 1. General safety information 2. General product information 3.
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Page 3: General Safety Information
DN 32÷250. The products fall within the following Pressure Equipment Directive categories: Group 1 Group 2 Group 1 Group 1 Product Liquid Liquid DN15÷25 DN32÷50 BSK1 DN65÷125 DN150÷200 DN250 I) The products have been specifically designed for use on steam, compressed air, water and other industrial fluids that are in Group 2 of the above mentioned Pressure Equipment Directive. The products' use on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the product for the application being considered. II) Check material suitability, pressure and temperature and their maximum and minimum values. If the maximum operating limits of the product are lower than those of the system in which it is being fitted, or if malfunction of the product could result in a dangerous overpressure or overtemperature occurrence, ensure a safety device is included in the system to prevent such over-limit situations. -
Page 4: Pressure Systems
The system Consider the effect on the complete system of the work proposed. Will any proposed action (e.g. closing isolation valves, electrical isolation) put any other part of the system or any personnel at risk? Dangers might include isolation of vents or protective devices or the rendering ineffective of controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system shocks. Pressure systems Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that the system has depressurised even when the pressure gauge indicates zero. Temperature Allow time for temperature to normalise after isolation to avoid danger of burns. Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. -
Page 5: Returning Products
1.16 Disposal Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable and no ecological hazard is anticipated with its disposal providing due care is taken. 1.17 Returning products Customers and stockists are reminded that under EC Health, Safety and Environment Law, when returning products to Spirax Sarco they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk. This information must be provided in writing including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous. - Page 6 Steam Mains - Do’s and Dont’s: Prevention of tensile stressing Pipe misalignment: Installing products or re-assembling after maintenance: Do not over tighten. Flange bolts should be gradually tightened across Use correct torque figures. diameters to ensure even load and alignment. 3.530.5275.250...
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Page 7: Thermal Expansion
Thermal expansion: Examples showing the use of expansion bellows. It is highly recommended that expert advise is sought from the bellows manufacturer. Guides Axial movement Fixing point Short distance Axial movement Guides Guides Small lateral Large movement Limit rods lateral movement Medium Fixing point distance Limit rods Large Small lateral lateral movement movement Guides 3.530.5275.250... -
Page 8: General Product Information
Standards These appliances fully comply with the requirements of the European Pressure Equipment Directive 97/23/EC for DN32-250 and bear the mark. Certifications On request, BSK1 valves can be supplied with “Manufacturer’s Typical Test Report” as drawn up by the manufacturer. Note: All certification / inspection requirements must be stated at the time of order placement. Fig. 1 Sizes and pipe connections Flanged EN 1092 PN 16, standard DN15, 20, 25, 32, 40, 50, 65, 80, 100, 125, 150, 200 e 250. - Page 9 Pressure / temperature limits Steam saturation curve Pressure bar The product must not be used in this region Body design conditions PN 16 PMA - Maximum allowable pressure @ 120°C 16 bar TMA - Maximum allowable temperature @ 9,6 bar 300°C Minimum allowable temperature -10°C PMO - Maximum operating pressure @ 195°C 12,9 bar TMO - Maximum operating temperature @ 9,6 bar...
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Page 10: Transport And Storage
3. Transport and storage Our valves are supplied ready-for-use with the plug in closed position and with all connections shielded with suitable protective covers (to be removed upon installation). During transport it is paramount to ensure that valves are not damaged in any way. This applies particularly to the most exposed parts (spindle and handwheel). All valves weights are reported on the relevant technical data sheet (3C.115). Larger valves must be transported properly fixed to the protective bridge covers using suitable handling ropes. Upon delivery, carefully inspect for any damage or defects which must be reported to Spirax Sarco immediately. Furthermore, it is necessary to verify that the technical specifications are in compliance with the plant equipment characteristics, that the manufacturing materials and the operating fluid... - Page 11 Inlet over the plug (DN150, DN200 e 250 Inlet below the plug with balancing disc) Fig. 2 (DN15÷150) Note: The balancing disc is a two-stage internal by-pass device (Fig. 3) which significantly reduces the motion force of the handwheel in the event of high differential pressures. When the first stage opens, it acts as a pre-opening pilot plug and allows a controlled flow of fluid to pass. This gradually reduces the differential pressure present between upstream and downstream the valve and, as a result, reduces the force required to lift the second stage (main plug) from its seat. Typically, large on/off valves are subjected to high differential pressures even under normal operating conditions. Therefore, the closure of these valves would be almost impossible without the balancing disc. 2° 1° stage stage Fig. 3 These valves are not designed to withstand severe stress, so the mounting pipelines should be suitably mounted, aligned and properly supported in order not to transmit any adverse effects of expansion (thrust, torsion and flexing movements may cause leakages, deformation and and/or...
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Page 12: Maintenance
If necessary, all the pipelines should be flushed with the valves in fully open position. 6. Maintenance Note: Before starting any maintenance work, read the "General Safety Instructions" in section 1. Maintenance work on valves should be carried out only by authorised, qualified personnel and in full compliance with Accident Prevention Legislation. BSK1 Valves are designed and manufactured to require minimal maintenance. To ensure proper and safe system operation, (particularly in case of reduced accessibility to the valve or when the valve is occasionally operated and has a limited use) it is recommended to carry out regular sche- duled inspections. Ispections frequency should be determined by the maintenance manager (but it is advisable a monthly frequency, at least) and will depend on the specific valve use and the plant characteristics (nature of the media, operating temperature and pressure etc ...). - Page 13 When reassembling the unit, carefully verify that the surfaces of the gaskets are clean and unda- maged. With the plug in open position, fit a new gasket between the valve body and cover and evenly retighten the cover stud and bolts following the recommended cross-tightening sequence (As shown in the table below). Before reinstalling the valve, check that all the connections are properly tightened and are properly performing. After completing the valve installation, carry out the cold hydraulic test with a water pressure not exceeding 24 bar (equivalent to the maximum design pressure declared).
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Page 14: Spare Parts
Note: always handle the valve body/cover gaskets with care as it has a metal core that can be sharp. How to order spares Always order spares by using the description given in the column headed 'Available spares' and state type and size of valve and its nominal diameter. Example: N° 1 stuffing box and body/cover gasket assembly for a Spirax Sarco BSK1 PN16 DN50 bellows sealed globe valve. Plug with balancing disc group (for DN150, DN200 and 250 only) 3.530.5275.250... -
Page 15: Fault Finding
8. Fault finding Even though valves are very robust, they can be damaged by inappropriate commands, neglected maintenance or by being used for purposes other than their intended use. All maintenance and/or repairs should be carried out by expert, qualified personnel. However, first and foremost, it is always advisable to consult Spirax Sarco. Symptom Possible cause Action Valve closed. Open the valve. - Page 16 SERVICE For technical support, please contact our local Sales Engineer or our Head Office directly: Spirax Sarco S.r.l. - Technical Assistance Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Italy Tel.: (+39) 0362 4917 257 - (+39) 0362 4917 211 - Fax: (+39) 0362 4917 315 E-mail: support@it.spiraxsarco.com LOSS OF GUARANTEE Total or partial disregard of above instructions involves loss of any rights to guarantee. Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307 3.530.5275.250...
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