Flanged Ball Valves
2
H24 Series
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
•
Differential pressure above 70bar
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 is 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.
As the extent of applications that these valves can be used in, is
large, it is not possible to cover all installation and maintenance
instructions for service of the valves. It is the user’s responsibility
to use the valves as recommended and in accordance with the
pressure and temperature limits as stated in this manual. Where in
doubt, please consult with Habonim.
Any unstable fluid or gas should be identified by its manufacturer
and must not be used with 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.
Note: The valve body rating can be higher than the seat rating.
Valve surface temperature may become extremely hot or cold
due to ambient or 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. LONG TERM STOREAGE
5.1.
It is advisable to store the valves in waterproof conditions.
Ball valves should be protected to safeguard against humidity,
moisture, dust, dirt, sand, mud, salt spray, and sea water.
5.2.
Manual ball valves must remain in the open position during
the period of storage.
5.3.
Actuated valves (fail to close position) remain in closed
position during this time.
5.4.
Valves may be stored as shipped, provided the above storage
location and equipment orientation instructions are followed
5.5.
In order to prevent damage, protective covers on valve ends
should not be removed until immediately prior to installation.
5.6.
Visual inspection should be performed on a semi-annual
basis and results recorded.
5.7.
If the actuated valve (fail to close position) is planned for long
storage after dispatch it will be necessary to operate once in
6 months for fully open/close position.
5.8.
Ball valves should be operated for at least two complete
cycles before installing or returning to storage.