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Series 77 & 78 Installation, Operating & Maintenance
2. SIL
Under normal operating conditions the Habonim valve should be
inspected for proper functioning and signs of deterioration every
50,000 cycles or 6 months (whichever comes first). Under severe
operating conditions inspection should be more frequently; detected
defects should be repaired promptly.
Severe operating conditions can be defined as:
•
Application temperature less than -20 deg C
•
Application temperature higher than +230 deg C
•
Flow velocity higher than 5 m/sec for liquids, and 200 m/sec
for gaseous
•
Acidic media PH < 5 or alkaline media PH > 9
Habonim recommend a proof test interval of 12 months; in case of
Fail to Open ESD system, a partial stroke is acceptable to confirm
that the installation is functioning properly.
For ESD systems with a Fail-To-Close demand, it is necessary to
plan a system shut-down; de-energize the system and inspect the
valve turning to its fully closed position.
It is essential to log-in the following parameters on site QA records
as a proof for preserving SIL capabilities: date, hour, name and
signature of the responsible engineer, air pressure on site, time to
close the valve, time to open the valve.
Habonim recommend valve full maintenance operation every 500,000
cycles or 4 years, whichever comes first (refer to Para. 7 in this IOM
for maintenance instructions). The combined corrosion and erosion
allowance for the valve body wall thickness is 1 mm. When this allowance
has been eroded or corroded, mechanically removed or otherwise, the
valve should no longer be used. Inspect the valve wall thickness every
time the valve is maintained. Refer to Habonim Corrosion Data Chart
T-614 to determine the corrosion rate for your application.
The estimated mean time to repair (MTTR) a valve, i.e. time net
(line draining or cooling down time excluded from the valve MTTR)
of replacing old valve with a new one is 60 minutes. Maintenance
team must read and understand the Habonim product IOM before
starting the operation. In case of a doubt please consult the Habonim
engineering team.
When a valve has been repaired or any maintenance was performed,
check the valve for proper function (proof testing). Any failures
affecting functional safety should be reported to the Habonim factory.
Client should consult the Habonim factory in order to obtain the
product assessment, FMEDA report, and other associated statistical
data to satisfy SIL level.
3. LIMITATIONS
The correct selection of materials of construction, seats and seals,
internal valve components and pressure/temperature ratings
determines the safe use of the valves and the particular performance
requirements for the application. This information can be found on
the nameplate welded to the valve body.
It is not possible to cover all installation and maintenance instructions
for service of the valves, as the extent of applications that these
valves can be used in, is large. It is the user’s responsibility to use
the valves as recommended and in accordance with the pressure
and temperature limits as stated on this tag. Where in doubt, please
consult with Habonim engineering team.
Unstable fluids or gases are prohibited for use in Habonim valves.
CAUTION:
The valves should be used in a well designed, adequately protected
system to
ensure that external and internal pressure and
temperature limits do not exceed the valve limits.
The valve rating is defined as the lower rating of the seat and valve body.
Valve surface temperature may become extremely hot or cold due
to operating conditions. Prevent any type of direct contact with the
valve that may cause harm or injury .Avoid direct contact with the
valve by wearing protective gloves.
The valves should be used in a well designed, adequately supported
piping system such that it will not be subjected to undue forces,
stresses or shock loads during service.
The valves are not designed to operate during or after earthquakes
or under fatigue conditions. It is the responsibility of the owner to
determine if fatigue conditions exist.
Do not allow dust layers to build up on the equipment.
The process fluid temperature shall not exceed the ignition
temperature of the dust.
4. STORAGE
Prior to storage, inspect the valve for shipping damage. Keep all
protective packaging, flange covers and end caps attached to the
valves during storage. It is recommended to keep the valves in a
clean and dry environment until ready for use.
Carbon Steel valves have a “black oxide” and oil dipped finish. This
nontoxic process is performed to retard rusting during storage. It is
not a substitute for paint or other means of protective coating to be
applied to the valve once installed.
Stainless steel valves have their natural finish and do not require
additional protection once installed.
5. OPERATING INSTRUCTIONS
Habonim Valves provide tight shut off when used under normal
conditions and in accordance with Habonim’s published pressure/
temperature chart. If these valves are used in a partially open
(throttled) position, seat life may be reduced. Consult with Habonim
for the proper seat material selection.
On manual operated valves, the valve operation is done by turning
the valve handle 90°. A 90° turn counter clockwise is for opening,
while 90° turn clockwise is for closing the valve. On manual
operated valves, the open position is when the stem flats or handle
are parallel with the pipeline, and the closed position is when handle
or stem flats are perpendicular to the pipeline. On valves above 2”,
the indication is by a groove on the square headed shaft.
All standard valves are bidirectional and as such, can be installed
for flow in either direction. Valves which are unidirectional will have
a flow direction arrow welded to the body and separate assembly
instructions.
A silicone-based lubricant is applied to assist valve break in. The
lubricant, if unacceptable, may be removed by a solvent wash.
If a shut-off valve is installed for end of line service, it must be
ensured that it is closed with a blind end connection and the valve is
