MD-955TC-ATEX User manual
Contents
1. L U UHMWPE 5 d ert N D 50 STAINLESS STEEL 2 i AWN NI w i Tk PCT VT S 5 Ct eee be Le Se Gar TEMPERATURE Temp 2000 Bar 20 to 0 124 1 0 to 50 119 8 50 to 100 103 4 100 to 150 93 7 150 to 200 86 1 4 Delivery Condition and Storage Valves stay in the open condition during the transportation Valves must store in an indoor warehouse to avoid dusts and other foreign object Do not take off the dust cover except ready to install immediately Installation and Operation 5 1 Cleaning Even the valves was transported under a clean environment operator must check is there any foreign body or dusts inside the bore If yes clean it before installation Operator clean the valves by water compression air or steam automation valve shall be cleaned only with water or steam the compression air is not allowed 5 2 Valve Installation Install to the pipeline system me pes al d n d n al le Vi f amp B y E sony END CAP cLAMP sik FRAN END Bony END CAP aale be STRANY END a Direction Ball valve does not restrict the flow direction Just consider the natural sequence to do opening and close t2. equipment is the plastic handle grip The surface resistance of the material does not exceed 1GO at 23 2 C 50 5 relative humidity The equipment also designed and constructed with an electrical continuity design between ball stem and body Any occurrence of efficient electro static charge will be earthed through the pipe line earthing Containing light metals Materials used in the construction of external parts do not contain light metals more than 7 5 of magnesium Equipment was tested in factory according to high pressure leakage test before delivery It will not release flammable gases to explosive atmosphere outside the equipment The internal parts such as seals and packing can be adversely affected by some solvents List of solvents which are known to be compatible with the seal and packing material are provided in the corrosion data information The equipment also conforms to Pressure Equipment Directive 97 23 mechanical strength of the structure can withstand the hazard cause by internal pressure 11 Marking Mfg logo MD Mfg location TAICHUNG Taiwan Mfg year 2009 CE mark CE for DN 25 and smaller CE 0035 for DN 32 and larger Max working pressure For 2000psi 124 1bar at 20C 86 1bar at 1806 II2DGc Group ll category 2 equipment Dust amp Gas application Constructional safety according to EN 13463 5 2003 T F ref No ATEX TF 0701 T
3. The possibility of material deterioration in service and the need for periodic inspections is depended on the contained fluid Carbide phase conversions to graphite oxidation of ferrite materials will decrease in ductility of carbon steels at low temperature are among those items However information about corrosion data is provided together with this user manual the user is requested to take attention or consideration to determine the suitability of material in their application Pressure Temperature rating The rating is considered for static pressure Please refer to P amp T rating section 3 for actual application The allowable temperature is between 20C and 1806 Do not exceed the temperature range to avoid danger Fluid thermal expansion It is possible when the ball valve is in closed condition the sealed cavity within the valve body to be filled with liquid If this liquid is not released by partially opening the valve or some other means and it is subject to a temperature increase excessive pressure sufficient to cause pressure boundary failure can be occurred However our products have pressure self relief seat to prevent pressure built up user is recommended to prevent that the pressure in the valve will not exceed that allowed pressure by means of piping design installation or operation procedure Electro Static effect The ball valves are designed with electrica
4. for the wear caused by movement between stem and stem packing Disassembly NOTE replacement of all seats and seals is recommended If complete disassembly is necessary 1 To dismantle the valve must follow the procedure below 2 It doesn t matter where the position of valve located is usually it contained the seal up fluid so operator must be very carefully when moving the valve on the pipe It must open the ball a little and let the fluid come out slowly it also need to watch out the poisonous and inflammability objects if there is any 3 It must turn the ball in the close position before dismantle the valve ball cannot be taken out from valve body if the ball is in the open or semi open position The right position for store the valve is put the flange end on the ground f it is valve with the hand wheel than it must dismantle the hand wheel from the valve first than put the valve flange end on the ground This procedure is protecting the surface of the ball 4 To dismantle the valve body and end cap release retainer with a special tool It must be careful to dismantle the ball to avoid the seat retainer fall down from end cap 5 To lift the ball by hoist it must make the protection on corner to avoid the ball damaged by metal contacted d Parts inspection maintenance and replacement 1 Check the surface of ball if it is scraped use the PT for inspection if nece
5. 2 General description of the product a Technical specification Model 3PC Port Tube Bore End connection T CLAMP END Service fluid Dangerous or non dangerous gas or liquid Service temp 200 to 1800 Nominal Size NPS 12 3 4 T 1 2 Nominal Size DN 15 20 25 40 50 Nominal pressure psi 000 2000 000 000 2000 Shell Material SS316L Note 1 User shall consider the material s anti corrosion feature of components which directly contact with the fluid The corrosion data information is available in this user manual e Equipment category according to PED Directive 97 23 EC b Safety features Appropriate shell strength E Anti blow out stem design E Anti static design S E P Category II ressure Pressure release hole at ball DN 15 2000psi DN 20 21 Pressure release channel at ball seat DN 25 DNSO Dimensions and Parts list See the following drawing for the detailed external dimensions of each nominal size the components list and materials available User shall consider the material s anti corrosion feature of seals and packing which directly contact with the fluid The corrosion data information is available in this user manual Equipment category according to ATEX Directive 94 9 EC Designed constructed to good engineering practice and the ignition hazard assessment ensure that the equipment does not contain any effective i
6. Document No MD QO 04 113 civ Date 2009 09 10 DIN EN ISO 9001 Version 1 0 Certificate 01 100 039207 PED MODULE H z 202 ROC Q 03 MD 955TC 3 Piece High Purity Ball Valves Tube Bore Tri Clamp USER MANUAL 1 1 Modentic Industrial Corporation 14 1 57 Rd Taichung Taiwan R O C Email modentic ms9 hinet net http www modentic com tw WARRANTY Modentic warrants its products against defects in manufacturing if the products Are used for the purposes for which they are manufactured and sold This warranty Shall expire one year from date of shipments 1 To use for company in Europe who will place the product on the market please amend which necessary FN 2 Modentic reserves the right to change any details without prior notice Contents 1 General Precautions 2 General Description of Product 3 Pressure Temperature Ratings 4 Delivery Condition and Storage 5 Installation and Operation 6 Putinto service 7 Dangers of inappropriate use 8 Maintenance 9 Corrosion Data 10 Use in potential explosive atmosphere areas 11 Marking Importer Agent or Distributor responsible for servicing 1 General Precautions a Operation Ball valve is a kind of isolating valve used in a pipe line system which intended for use only in the closed or fully open position In the open position it allows the flow passes through Material Selection
7. echnical file reference number provided by certification body Other identification such as DN size in mm Shell Material 1 4408 or 1 4308 or 1 0619 PN bar Heat number are marked on the shell respectively 1 MARK ENLARGE OR REDUCE ACCORDING TO THE ABOVE SKETCH BUT THE MIN HIGHT IS 5 mm 0035 IS THE ID OF TUV 2 COMPANY LOGO MUST COME WITH COMPANY LOGO OR CUSTOMER S LOGO APPOINTED BUT MUST ILLUSTRATE ON THE CERTIFICATE 3 YEAR OF MANUFACTURE SHOW ON PROPER PLACE 4 EXTRA MARKING REQUIRED BY CUSTOMER 5 9 SYMBOL FOLLOWED BY EQUIPMENT GROUP AND CATEGORY n T2 T T5 T6 450 C 300 200 C 135 C 0046 85 112 G D EEx c T3 1 Methane WA Acetone Ethylalcoho Benzene Acetaldehyde SEA TEM Ethane n Butane Diesel fuel PROTECTION METHOD Ammonia n Butyl alcohol n Hexane Benzo Dicloroethane Fuel oil Acetic acid Methanol Propane Toluene PROTECTION LEVEL CATEGORY Towngas Ethylene Ethyl ether Ethylene oxide MC Hydrogen Acetylene Carbon disulphide GAS 0 DUSTS PED 5 DN15 DN25 3 m 1 ATEXSAISIEC site PRESSURE IATERIAL COMPANY RAND HEAT NO RATING PED CE MARK DN40 DN50 IE t N M HAT
8. gnition sources in normal operation and during expected malfunctions Therefore we classified as Group Category 2 equipment of ignition protection is c constructional safety according to EN 13463 5 2003 f Dimensions Parts List ON MODENTIC IND CORP TAIWAN OFF DIMENSIONS Size__ PORT H H4 C OK DN15 102 4 132 8 4 9 15 32 4 20 9 5 x DN50 171 4 204 2 114 9 MATERIALS LIST T MATERIAL CAP SS316L 1 4 4 1 2 PS 4 2 P 3 Pressure Temperature Ratings The pressure temperature rating of ball valves are determined not only by valve shell materials but also by sealing materials used for ball seats stem packing and body seal Sealing materials may be high molecule elasticity and hardness however the choice is limited by the characteristics of the service fluid temperature pressure velocity of fluid frequency of valves operation and sizes of ball valves etc User shall notice the maximum temperature labeled on the name plate Followings are the general rating charts for non shock fluid service for floating ball valves by nominal pressure Stainless Steel Ball Valves 2000 Psi Pressure Temperature Chart 2000 5 553161 BODY RATING 2000 4 138 0 1800 j 124 2 553161 1 00 1104 N P VIRGIN PTFE 1400 lt 9 6 R 15 GLASS FILLED
9. he valve b Position Ball valve can be installed in any position but the operator shall consider the load of the pipe line system not to apply at the connection area It will cause deformation and leakage c Connecting to pipeline Select the correct specification of pipeline Tight the ball valve to the pipeline adequately 5 3 Actuator installation The ball valves are designed with ISO 5211 actuator attachment Following is the mounting flange sizes The sizes of actuator and setting of the input power or pressure of actuator are depended on the operation torque The following table lists the maximum torque values of each flange type User is recommended to refer to the instruction from actuator s supplier Overload torque applied by the actuator may transfer the un intended load to ball valve itself or to the piping joints Setting of the input power or pressure of the actuator is better not to exceed 1 5 times the Maximum torque of the valve Nominal Size stud DN 15 F03 32 DN 20 F03 32 DN 25 F04 63 DN 40 F05 125 DN 50 F05 125 5 4 Operation a For manual operation shift the handle counter clockwise direction for opening and clockwise for close If the handle is in parallel position with the flow direction the valve is open If the handle is in right angle position with the flow direction the valve is close When installing actuator the user should ensure the pos
10. ition of the valve whether open or close The rectangular shape of the stem top or the direction mark at the stem top is in parallel with the flow direction means the valve is opened OPEN CLOSE 6 Put into service a After install to the pipeline it is necessary to check the function of the product Thus operate the valve about 3 times to ensure the function b Systems hydrostatic test Before delivery valves are tested 1 5 times the allowable working pressure at ambient temperature in open position After installation the pipe line system may subject to system tests as condition not to exceed the maximum working pressure c After pressure testing user shall operate the valve again about 3 times to ensure the function 7 Dangers of inappropriate use a Never uses the product exceed its allowed condition such as pressure temperature and fluid b If the product has any inappropriate use the product was damage however there are no signals occurs immediately User shall change the product to avoid danger in the future 8 Maintenance a Maintenance frequency The maintenance frequency is determined upon the application User shall consider the time interval depend on the kinds of fluid flow velocity operation frequency high pressure effect and high temperature effect etc Adjustment of the Gland Tighten the gland nut about turn periodically to compensate
11. l continuity for ball stem body to prevent electro static discharge The user is responsible for ensuring the earthing of the pipeline system Fire safe condition Fire safe certificates are only available upon request Liquids with high fluid velocity The ball valves might be operated frequently with very high velocity liquids a check shall be made with the valve distributor or manufacturer for appropriate advice to minimize the possibility of seat deformation especially when they are highly pressurized on high temperature line Throttling service Ball valves are generally not recommended for throttling service where both the fluid flow and the leading edge of the ball can damage or deform the resilient ball seats causing leakage High fluid velocity or the presence of solid particles in suspension will further reduce seat life in throttling applications i Do not open the bonnet or cap when bearing pressure Valve is not equipped with pressure access device User should check it by other method through its piping system j Do not touch the surface of valve at high temperature condition Not allowed for unstable fluid otherwise specified with PED catogory in Declaration of conformity or and in this user manual Lock design on the handle to avoid the valve by un intended operated by un authorized person m Use in potential explosive atmosphere safely see section 10 for detail
12. ssary f there is any damage on the surface then find out the root cause such as the dirt fluid etc avoid the damage factors as far as possible as we can 2 The damage of the ball surface to gauge if it is locate on the contacting area of ball and ball seat If it is the case then the ball must take a fine milling If it cause a heavy damaged then it must welded and re machined If it cannot be repaired then change a new ball 3Jf the scraped area is not at the location described in the item 2 above then it must re fine milling the damage area again Otherwise the ball will damage the soft seat during the open and close operation or it will dig out the ball seat and cause a heavy damage to ball and seat 4 Check the thickness of valve body and cap As defined in section 1 the body and cap material may wear be cause of the status of fluid User should decide the frequency for checking thickness 5 inspect the surface of soft seat if there is it any scrap mark concave dust including weld dregs iron bit sands etc abrasion abnormal press scrape and a tiny scrap Usually the scrape mark and damage by dust will occur in the same time with ball damage It is the root cause for leakage If the leakage occurs before the repairing then this is suggest to change a new soft seat PTFE or RTFE The mark from press or fine scrap happen in an abnormal operation pressure It must be reconsidered to choice a right val
13. tle process The must in the close position during assembling the body and end cap the stopper must be located at the right place otherwise the open and close operation will be opposite 9 Corrosion Data CF8M 1 4408 SS316 Stainless steel is suitable for the general Application of corrosion but below conditions 5 b e f 10 hall be concerned HCL in humid or high temperature is more corrosive wet HCL is more corrosive than dry HCL under 700 F while the corrosive wet HCL and dry HCL are almost the same above 700 F the max tolerance for dry is 320 C Hydrofluoric acid corrosion easy cause corrosion Phosphoric acid under 65 Cis applicable in any thickness And so is the boiling Phosphoric acid in 40 2504 in normal temperature the thickness under 20 or above 85 are applicable but the thickness between 20 and 85 are not Under 50 Cthe thickness must be under 10 when reach boiling point the thickness should be under 1 under 2 in low temperature Used in seawater minimum content should be more than 2 75 Use in potential explosive atmosphere areas Maximum surface temperature It is depends on the heated fluid inside the valve The limitation of the application temperature is marked on the label There is no additional temperature raise cause by normal operation and expected malfunction Electro static charges The only non conductive part of the
14. ve 6 To check the worm gear if it can be operated correctly the operated correctly means people can use one finger to turn the wheel when the torque higher then 25KG M if must open the gear box and check the connection of the tooth of gear To check has there is any grease spoiled grease water oxidation or dust in the box 7 Worm gear operator has a switch of open close indicator get back to the original location after dismantle or assembly It must do the pressure inspection before install onto pipe line otherwise it will become very difficult to do adjustment on the pipe line The stem packing must be replaced by new parts after dismantle the valve Its material has PTFE Graphite and Carbon Fiber The material of new packing must be the same as the old one To tight the gland nut it must pass the 1 5 times water pressure test without leakage Do not make the gland nut too tight to avoid the higher torque 8 To do the final inspection for a valve 10 times of open and close operating must be done to ensure all the parts are assembled correctly To ensure the torque is in a same value during the open close operation If the torque is not the same in operation then there may has some parts in an correct position or interference please dismantle and re assembly Otherwise the valve will get damaged easily when working on pipeline under higher pressure e Assembly For assembly process it takes the opposite way of disman
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