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Operation and maintenance manual HON HSV086

5 Maintenance

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5.1

General

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5.2

Lubricants

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5.3

Pressure converters SM ........................................................................................ 21

5.4

Valve and body HON HSV ................................................................................... 24

5.5

Valve and body HON HSVS ................................................................................ 28

5.6

Spare-part sets ...................................................................................................... 29

5.7

Parts list shut-off device ........................................................................................ 32

5.8

Parts list valve and body ....................................................................................... 33

5.9

Parts list switch and reset mechanism SVC086 .............................................. 35

5.10

Parts list pressure converters SM ................................................................... 37

6 Failure solutions

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7 Accessories

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7.1

Accessories, general ...................................................................................... 41

7.2

By-pass

pipeline

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Appendix

HSV086 safety manual rev 01 .................................................................................. page 1 to 6

Revision Description

Date

Revised

01 Update

lubrication

09-07-2018

J.Tong

While great care has been taken in composing the text and illustrations, Honeywell does not accept liability for any
inaccuracies.

Содержание HON HSV086

Страница 1: ...Safety Shut off Valves HON HSV086 Operation Maintenance Manual Honeywell Process Solutions Honeywell Gas Technologies GmbH Osterholzstr 45 34123 Kassel Germany 49 0 561 5007 0 General www honeywellprocess com Document number 8098060403010 Document name HON HSV086 manual Revision 01 ...

Страница 2: ... Choice of pressure converter and setpoint springs 9 1 7 Type indication 9 2 Operation 10 2 1 General 10 2 2 Switch and reset mechanism 11 2 2 1 Overpressure protection 12 2 2 2 Underpressure protection 12 2 2 3 Operation of the emergency button 12 2 3 Releasing and opening 13 3 Installation instructions 15 3 1 Connection of the signal lines 15 3 2 Some remarks 15 4 Operational guidelines 16 4 1 R...

Страница 3: ... 32 5 8 Parts list valve and body 33 5 9 Parts list switch and reset mechanism SVC086 35 5 10 Parts list pressure converters SM 37 6 Failure solutions 39 7 Accessories 41 7 1 Accessories general 41 7 2 By pass pipeline 42 Appendix HSV086 safety manual rev 01 page 1 to 6 Revision Description Date Revised by 01 Update lubrication 09 07 2018 J Tong While great care has been taken in composing the tex...

Страница 4: ...y high pressure AG 1 between 20 95 bar AG 2 5 between 1 23 17 bar low pressure AG 10 between 0 15 bar Temperature range 20 up to 60 C Closing time 1 sec Building in position horizontally with switch and reset mechanism up PIN DVGW No HON HSV S CE 0085BS0202 1 2 Materials Valve body Cover A352 Gr LCC A350 S355NL P355N or equal Valve rod X17CrNi16 2 Guides X17CrNi 16 2 QT800 or X2CrNiMoN 22 5 3 Valv...

Страница 5: ...65 960 30 45 65 105 195 295 455 600 216 292 356 432 559 660 787 838 555 615 655 665 715 867 965 960 33 45 70 115 210 320 550 660 381 546 711 841 1000 968 668 853 961 913 1083 958 132 480 660 1050 1240 1325 254 371 473 546 711 841 1000 1146 642 668 668 853 961 913 965 958 37 78 tbd 580 780 1260 1340 1900 Table I Dimensions L and H mm and weight W kg RF or RTJ to be requested For dimensional drawing...

Страница 6: ... DN ANSI 300 RF ANSI 600 RF ANSI 900 1500 RTJ Size L H W L H W L H W 16 20 24 990 1397 1397 990 1397 1397 1375 1340 1500 1290 1540 1820 1375 1340 1500 1240 1500 1780 990 1375 1290 Table II Dimensions L and H mm and weight W kg For dimensional drawing see figure 1b barring alterations Figure 1b Dimensional drawing ...

Страница 7: ...apacity rate d relative density air 1 Tu inlet temperature of the gas oC qn gas density Tu 273 K 0oC DN 1 2 3 4 6 8 10 12 16 20 24 Cg 480 1950 4300 7050 15100 26060 40800 60050 104150 166640 287953 Table II Capacity rates Cg up to 600 high pressures on request To limit the flow forces we would advise not to exceed the following flow rate You have to use the formula below for this purpose in which ...

Страница 8: ...e SM Color Code nr 1 9A 1 4A 1 2A 2 2500 90 bar bar bar bar mbar Green 8501114120470 0 to 0 8 0 to 1 8 0 to 3 0 to 7 0 to 90 Yellow 8501114120480 0 6 to 1 5 1 3 to 3 2 2 to 5 5 5 to 12 70 to 170 Black 8501114120490 1 4 to 3 8 3 to 8 2 5 to 14 10 to 40 230 to 450 White 8501114120500 3 7 to 7 1 7 8 to 15 13 to 25 30 to 60 430 to 830 Orange 8501114120510 6 2 to 9 6 13 5 to 20 22 to 35 50 to 80 730 to...

Страница 9: ...alue the minimum threshold value should be deducted from the maximum The pressure difference determines the selection of the maximum spring Using the calculated pressure difference you select from table IV the setpoint spring of the maximum threshold value Example of selection of the setpoint springs for the minimum and maximum threshold value Given Minimum threshold value 2 bar Maximum threshold ...

Страница 10: ...ng trajectory so that the threshold value may be relatively close to the set pressure of the regulator At an undesired failure in the pressure converter or an impulse line the valve shuts automatically Owing to the application of two pressure converters and two minimum maximum springs a one of the two redundancy is possible for each shut off valve Standard the safety shut off device has been equip...

Страница 11: ...switch and reset mechanism The switch and reset mechanism SVC086 is used standard on all HON HSV safety shut off devices When the stroke of the HON HSV is smaller than 110 mm the SVC086 may be mounted directly onto the body Figure 2 Working principle of the switch and reset mechanism SVC086 ...

Страница 12: ... switch on the valve or the second stage Switching on the second stage see chapter 4 1 The safety device is now locked Even when pressure Pa drops below the threshold value valve S remains shut 2 2 2 Underpressure protection When pressure Pa of pressure converter D is lower than the set threshold value of spring V1 diaphragm C moves upwards The top of V2 by means of the spring seat now presses aga...

Страница 13: ...llows this movement In order to make the HON HSV ready for operation again the switch and reset mechanism must first be reset and then the second stage if 16 and larger Here follows a short description of the actions for releasing and opening the HON HSV Solve the failure Bring the pressure to be protected to a normal value between the higher and lower threshold values Ensure that no gas is taken ...

Страница 14: ...HSVS Handle arm H2 has now moved upwards This moved support D3 against the force of the two draw springs F2 into groove R4 Push in hand wheel H3 and turn anti clockwise When hand wheel H3 has been turned sufficiently a notch in valve rod S2 automatically snaps shut into support D3 clearly audible Let go of hand wheel H3 so that it is disconnected from valve rod S2 Check the open position of the va...

Страница 15: ...hragm of the pressure converter is installed to outside In this way no gas can get into the installation space when a diaphragm fractures The vent pipeline should be no longer than 40 m 3 2 Some remarks Mind the following when mounting the HON HSV When there is a possibility that filth detach from the pipeline between dust filter and safety valve it is advisable to fit a simple wire mesh filter ri...

Страница 16: ...lly compressed don t block c Set the pressure in the pressure converter between lower and higher threshold value at approx half the value of the higher threshold value d Screw in set screw S until the balance handle H is horizontal The balance handle should not have any play now at the points of support N and Q and at the balance jaw P Fix the set screw with lock nut T e Lift valve shaft L with ha...

Страница 17: ...m spring seat G down until SVC086 disconnects j Place balance handle H horizontally again by adjusting the pressure in the pressure converter as described in point c k Repeat steps e to j resp steps e h i and j when accessory A9 is used a number of times and adjust maximum spring seat G if necessary Check that the SVC086 disconnects at the right higher threshold value Remark When the lower thresho...

Страница 18: ... several times Checking the higher threshold value Bring the pressure in the pressure converter to a value between the lower and higher threshold values Let the pressure in the pressure converter increase slowly When the higher threshold value has been reached the system has to switch Bring the pressure in the pressure converter back to a value between the lower and the higher threshold values Bri...

Страница 19: ...ou can t fail to close the valve an automatic bypass valve is supplied standard When the required outlet pressure has been reached the outlet valve can slowly be opened The installation is now operational When commissioning the installation the bypass valve of the HON HSV bypass must be closed Remark Before first commissioning an installation the threshold values of the HON HSVs should be checked ...

Страница 20: ...ful life of 6 to 7 years You can find all required parts for maintenance work in the parts list added 5 2 Lubricants Mind the following during all maintenance work Unless otherwise indicated all screw connections are to be greased with a suitable grease Honeywell advises weicon anti seize All O rings are to be greased with a suitable grease Honeywell advises krytox GPL 309 or Klueber unisilikon TK...

Страница 21: ... in this component Diaphragm 02 O ring 16 O ring 18 To replace these parts the following steps are to be taken Disconnect impulse line 21 Unscrew screw connections 15 Remove cover 01 Remove diaphragm 02 Remove bottom seat 05 to replace O ring 18 Replace O ring 18 Replace O ring 16 Fit bottom seat 05 new diaphragm 02 and cover 01 with O ring 16 Tighten screw connection 15 even and diagonally Connec...

Страница 22: ...replace these parts the following steps are to be taken Disconnect impulse line 21 Unscrew screw connections 15 Remove cover 01 Remove cylinder 03 to replace O ring 16 Remove plunger 05 to replace O ring 18 Replace O ring 18 Replace O ring 16 Fit plunger 05 cylinder 03 and cover 01 Tighten screw connection 15 even and diagonally Connect impulse line Figure 6b Pressure converter SM2 2500 ...

Страница 23: ...to be taken Disconnect impulse line 21 Unscrew screw connections 15 Remove cover 01 Remove diaphragm 02 Remove diaphragm plates 05 and 07 with diaphragm 02 and nuts Remove nut 03 Remove disk 05 Replace the diaphragm 02 disk 05 and nut 03 use Loctite 243 blue Place the complete diaphragm assembly back Place cover 01 Tighten screw connection 15 even and diagonally Connect impulse line Figure 6c Pres...

Страница 24: ...neath cover 09 Place cover 09 with valve 12 on a surface which guarantees that valve 12 with cover 09 lies horizontally Remove retainer set 02 from connection rod 04 Replace O ring of retainer set 21 Slowly lift cover 09 with guide from valve rod above 08 by the load frame 37 provided for this purpose not shown in figure 7a and lift over connection rod 04 Place cover 09 on the same surface as the ...

Страница 25: ...ng 32 and slowly and carefully mount valve seat 15 in the body of valve 16 Slowly lower cover 09 with valve 12 hanging underneath it into body 16 Fit screw connection 28 Mount the complete SVC086 on cover 09 by means of screw connection 47 Connect impulse line of the pressure converter Recommission the line if no other maintenance work is necessary Remark Check the threshold values of the HON HSV ...

Страница 26: ...he complete second stage Detach connection rod 04 figure 7a from top coupling section 07a Unscrew screw couplings 38 53 28 Lift cover 09 from body 16 by load frame 37 provided for this purpose not shown in figure 7a To simplify detachment of the cover 09 from body 16 you may use lock screws 55 having released plug 56 When you have used the lock screws 55 you should tighten them again and fit plug ...

Страница 27: ...ction rod 04 with retainer set 02 and suspension screw 03 back to valve rod top 14 fix suspension screw 03 with LOCTITE 243 Unscrew screw connection 31 and disconnect securing plate 13 Replace O ring 30 Connect screw connection 31 use new screws and securing plate 13 Re fit compression spring on valve Slowly and carefully lower cover 09 with guide of valve rod top 08 over connection rod 04 Work ve...

Страница 28: ... safeguarded against turning at the bottom Lift guide of valve rod bottom 20 upwards from bottom cover 46 Replace O ring 42 Fit guide of valve rod bottom 20 back in bottom cover 46 Fit bottom cover 46 and guide valve rod bottom 20 by means of nut 43 lock nut 43 with LOCTITE 243 Slowly lower cover 09 with valve 12 hanging below it into body 16 In doing so slowly lower valve rod bottom 19 over the g...

Страница 29: ...rt set consists of 1x diaphragm 02 1x seal 09 Valve and valve body HON HSV086 see figure 7a and partslist page 30 This spare part set consists of 2x O ring retainer set 21 1x O ring rod 22 1x O ring guide 23 1x O ring top cover 26 1x O ring valve 30 1x O ring valve seat 32 2x O ring 40 1x Safety nut 41 Valve and valve body HON HSVS086 see figures 7b and 7c and partslist page 31 This spare part set...

Страница 30: ...DY Pos Name Pos Name 01 02 03 04 05 06 07 09 10 11 12 13 14 15 16 17 Filler block Retainer set Coupling Connection rod Connection rod guide Ring Retainer holder Top cover Locking pin Name plate Valve Retaining plate Valve stem Valve seat Valve body By pass line 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 40 41 O ring retainer set 2x O ring connection rod O ring guide Countersunk screw Retaining r...

Страница 31: ...ne Valve stem bottom Valve stem guide bottom Compression spring Support plate Bottom cover Cover plate Plug 21 22 23 24 25 26 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 47 48 49 50 51 53 54 55 57 O ring retainer set 2x O ring rod O ring guide Socket screw 4x Retaining ring O ring top cover Stud bolt O ring valve Socket screw 12x O ring valve seat Set screw with tap Seal Sealing screw Hammer d...

Страница 32: ... 2017 Honeywell International Inc Operation and maintenance manual HON HSV086 32 Figure 7a Valve and valve body HON HSV086 ...

Страница 33: ... 2017 Honeywell International Inc Operation and maintenance manual HON HSV086 33 Figure 7b valve and valve body HON HSVS086 ...

Страница 34: ...oneywell International Inc Operation and maintenance manual HON HSV086 34 Figure 7c Detail of connection rod and connection rod guide Remark Check the set pressures of the safety device after each maintenance ...

Страница 35: ...mn max Pressure pin Assy handle max min Nut Set screw Cover plate Retaining sleeve Shaft handle Split pin Bolt Cover plate Gasket Button Lifting arm Gear shaft Dirt scraper Hexagon bolt Cover plate 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 68 97 Compression spring Gear wheel Reducer nut Reset button Socket screw Compression spring Reset pin Spring cl...

Страница 36: ... 2017 Honeywell International Inc Operation and maintenance manual HON HSV086 36 Figure 8 Control and switch mechanism SVC 086 ...

Страница 37: ...te Gasket Fillister head screw O ring Sealing rings O ring Hammer drive screw Fillister head screw Straight screw connection Seal Recommended spare parts Tables IXa parts list pressure converter SM PARTS LIST PRESSURE CONVERTER SM2 2500 Pos Name 01 03 04 05 06 09 15 16 18 19 20 21 22 Cover Bush Bottom cover Plunger Name plate Gasket Fillister head screw O ring O ring Hammer drive screw Fillister h...

Страница 38: ... LIST PRESSURE CONVERTER SM90 Pos Name 01 02 03 04 05 06 09 15 19 20 21 22 Cover Diapragm Nut Bottom cover Top diaphragm plate Name plate Gasket Bolt Hammer drive screw Fillister head screw Straight screw connector Plug Recommended spare parts Tables IXc parts list pressure converter SM ...

Страница 39: ... line Control and switch mechanism cannot be reset Handle H figure 2 is not horizontal so that switch pin M cannot be locked Check that the pressure in the pressure converter is below the higher resp above the lower threshold value If necessary place handle H horizontally After the valve has dropped the outlet pressure increases Pressure converter seal is leaking Inspect seal and seat of the valve...

Страница 40: ...n valve position K1 and indication on body cover indicate valve closed but valve position indication in SVC086 indicates valve open Mechanical problem to the valve Check locally whether the valve has dropped second stage handle H2 has dropped and if necessary carry out extensive maintenance work Table VII Summary of possible failures ...

Страница 41: ...ummary of all accessories On request special accessories are of course available NAME A1 Cover plate plexiglas front A2 Cover plate plexiglas front and back A3 End switch in SVC086 A4 End switch with connector in SVC086 A5 Cover plate front with single proximity switch A6 Cover plate front with double proximity switch Table X Accessories general ...

Страница 42: ... optional accessories the by pass line can also be adapted to the requirements of the customer By pass tubing is available in 10mm 12mm and 1 2 It can be Parker or Swagelock Standard up to 600 rating the spring return push button valve ZVC is mounted Other possibilities are spring return ball valves for higher pressures ...

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