Spirax Sarco ABV21i Manual de usuario

IM-P405-46 EMM Issue 5 1

1. Safety information

2. General product

information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

8. Fault finding

Printed in GB

IM-P405-46

EMM Issue 5

4057650/5

ABV21i and ABV40i

Air Actuated Boiler Blowdown Valves

Installation and Maintenance Instructions

IM-P405-46 EMM Issue 52

1. Safety information

Safe operation of this product can only be guaranteed if it is properly installed,

commissioned, used and maintained by qualified personnel (see Section 1.11)

in compliance with the operating instructions. General installation and safety

instructions for pipeline and plant construction, as well as the proper use of

tools and safety equipment must also be complied with.

WARNINGS

Before commencing any dismantling work on a boiler, depressurise, drain,

and vent the boiler to atmosphere.

Pipelines must be adequately isolated, depressurised, and drained. Isolation

valves must be turned on and off gradually to avoid system shocks.

Ball valves can trap pressurised media in the body, so make sure there is no

pressure to the valve body, or any pressure remaining in the body, before

loosening or removing the flange bolts. The actuator must belated both

pneumatically and electrically before any maintenance is carried out.

Do not attempt to service the actuator without first consulting the Installation

and Maintenance Instructions, as the end caps contain springs under pressure.

Failure to follow the instructions could result in injury. The actuator must be

vented before dismantling.

If the valve should seize in the partly open position, the springs in the actuator

will still be partly compressed, and will consequently be storing a large

amount of energy, which could cause injury if released suddenly. If there is

any possibility that this is the case follow the instructions given in the

'Maintenance' section of this booklet - 'Dismantling a seized valve assembly'.

Maximum supply pressure 8 bar g (116 psi g)

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical

Information Sheet, check that the product is suitable for the intended use / application.

The products listed below comply with the requirements of the European Pressure

Equipment Directive 2014/68/EU and carry the mark when so required.

The products fall within the following Pressure Equipment Directive categories:

Product Group 2

Gases

Group 2

Liquids

ABV21i and ABV40i

DN25 SEP SEP

DN32 SEP SEP

DN40 - DN50

ABV21i 1SEP

ABV40i 1SEP

DN65 1 SEP

IM-P405-46 EMM Issue 5 3

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.

iii) Determine the correct installation situation and direction of fluid flow.

iv) Spirax Sarco products are not intended to withstand external stresses that may

be induced by any system to which they are fitted. It is the responsibility of the

installer to consider these stresses and take adequate precautions to minimise

them.

v) Remove protection covers from all connections and protective film from all name-

plates, where appropriate, before installation on steam or other high temperature

applications.

1.2 Access

Ensure safe access and if necessary a safe working platform (suitably guarded)

before attempting to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some

previous time. Consider: flammable materials, substances hazardous to health,

extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,

extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive

noise, moving machinery.

1.6 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.

IM-P405-46 EMM Issue 54

1.7 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.

1.8 Temperature

Allow time for temperature to normalise after isolation to avoid danger of burns.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and / or consumables

available. Use only genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and / or others in the vicinity require any protective clothing

to protect against the hazards of, for example, chemicals, high / low temperature,

radiation, noise, falling objects, and dangers to eyes and face.

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person.

Installation and operating personnel should be trained in the correct use of the

product according to the Installation and Maintenance Instructions.

Where a formal 'permit to work' system is in force it must be complied with. Where

there is no such system, it is recommended that a responsible person should know

what work is going on and, where necessary, arrange to have an assistant whose

primary responsibility is safety.

Post 'warning notices' if necessary.

1.12 Handling

Manual handling of large and / or heavy products may present a risk of injury. Lifting,

pushing, pulling, carrying or supporting a load by bodily force can cause injury

particularly to the back. You are advised to assess the risks taking into account the

task, the individual, the load and the working environment and use the appropriate

handling method depending on the circumstances of the work being done.

1.13 Residual hazards

In normal use the external surface of the product may be very hot. If used at the

maximum permitted operating conditions the surface temperature of these products

may reach temperatures of 260 °C (500 °F).

These products are not self-draining. Take due care when dismantling or removing

them from an installation (refer to 'Maintenance instructions').

1.14 Freezing

Provision must be made to protect products which are not self-draining against frost

damage in environments where they may be exposed to temperatures below freezing

point.

IM-P405-46 EMM Issue 5 5

1.15 Safety information - Product specific

Hydraulic locking

Ball valves are prone to lock-up when used on certain heating / cooling applications

where both steam and liquid will pass through the valve. This is caused by liquid

trapped in the ball during closure being heated to create a high hydraulic pressure

inside the ball cavity. To prevent this, during manufacture, a minute hole is drilled

in the ball, so, that in the closed position, any excess pressure will be relieved. Spirax

Sarco ball valves for these applications are clearly marked to allow the valve to be

correctly installed, such that, when closed, the hole is facing the steam source.

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.

IM-P405-46 EMM Issue 56

2. General product information

2.1 General description

The Spirax Sarco ABV21i and ABV40i are one piece end entry, reduced bore ball valves

having ISO mounting as standard. They are fitted with a 90°rotary spring return pneumatic

actuator, and a limit switch box. They are used in conjunction with a Spirax Sarco blowdown

timer to provide timed control of bottom blowdown, ensuring that the recommended boiler

blowdown cycles occur with minimum heat loss, avoiding duplication or omission.

The valve is suitable for a maximum pressure of 17.25 bar g @ 208 °C (250 psi g at 406 °F).

A NAMUR (VDI / VDE 3845) solenoid valve is also required, and may be selected from the

Spirax Sarco MV range. Alternatively, an air supply (maximum pressure DN25 8 bar (116 psi),

DN32 to DN65 6 bar (87 psi)) may be connected directly to the actuator port 'A' (¼" BSP), for

applications where it is necessary to install the solenoid valve remote from the actuator.

A standard ¼" BSP 3-way solenoid valve may also be used.

ISO mounting

The integral ISO body mounting allows the valve to be automated without losing seal intregrity,

as the body does not require disassembly.

2.2 Product availability

Valve type Valve size Actuator Switch box

ABV21i and ABV40i

DN25 BVA315S /14 LSB31

DN32 BVA320S /14 LSB31

DN40 BVA325S /14 LSB31

DN50 BVA325S /14 LSB31

DN65 BVA330S /14 LSB31

2.3 Actuator

The actuator uses a rack and pinion system with a quarter-turn operation. A position indicator

is fitted to the top of the pinion shaft, below the switch box. BVA actuators are factory

lubricated, and do not require a lubricated air supply. The air must, however, be dry and clean.

Any other non-corrosive gas can be used as the operating medium.

2.4 Switch box

LSB limit switch boxes are normally used for indicating valve open or valve closed position.

They also allow switching points to be adjustable over the full range of actuators. There is an

open / closed valve position indicator mounted at the end of the switch box axis, at the top

of the cover. LSB's include a stainless steel linkage kit for direct mounting to BVA300 series

actuators.

IM-P405-46 EMM Issue 5 7

3/2

5/2

Fig. 1 ABV21i

Solenoid override screw

Fig. 2

Solenoid valve

MV11 / MV12 / MV11 / MV12

General view

Air inlet port

Use '3/2' adapter plate for this application

Inlet port 'A'

LSB31 limit switch box

BVA300 series pneumatic actuator

IM-P405-46 EMM Issue 58

The product must not be used in this region.

Valve

Body design conditions PN40

PMA Maximum allowable pressure 40 bar g @ 120 °C (580 bar g @ 248 °F)

TMA Maximum allowable temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)

Minimum allowable temperature -29 °C (-20 °F)

PMO Maximum operating pressure for

saturated steam service 17.25 bar g @ 208 °C (250 psi g at 406 °F)

TMO Maximum operating temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)

Minimum operating temperature -29 °C (-20 °F)

Note: For lower operating temperatures consult Spirax Sarco

PMX Maximum differential pressure is limited to the PMO

Designed for a maximum cold hydraulic test pressure of: 60 bar g (870 psi g)

Actuator

Maximum ambient temperature 80 °C (176 °F)

Minimum ambient temperature 0 °C (32 °F)

Maximum air supply pressure 8 bar g (116 psi g)

Minimum air supply pressure is dependant on operating conditions

MV series solenoid

Maximum ambient temperature 50 °C (122 °F)

Minimum ambient temperature 0°C (32 °F)

Temperature °C

Pressure bar g

Steam

saturation

curve

2.5 ABV21i - Pressure / temperature limits

Pressure psi g

Temperature °F

IM-P405-46 EMM Issue 5 9

2.6 ABV40i - Pressure / temperature limits

Steam

saturation

curve

Pressure bar g

Temperature °C

Pressure psi g

Temperature °F

The product must not be used in this region.

Valve

Body design conditions ASME 300

PMA Maximum allowable pressure 51 bar g @ 38 °C (739 bar g @ 100 °F)

TMA Maximum allowable temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)

Minimum allowable temperature -29 °C (-20 °F)

PMO Maximum operating pressure for

saturated steam service 17.25 bar g @ 208 °C (250 psi g at 406 °F)

TMO Maximum operating temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)

Minimum operating temperature -29 °C (-20 °F)

Note: For lower operating temperatures consult Spirax Sarco

PMX Maximum differential pressure is limited to the PMO

Designed for a maximum cold hydraulic test pressure of: 76.5 bar g (1 109 psi g)

Actuator

Maximum ambient temperature 80 °C (176 °F)

Minimum ambient temperature 0 °C (32 °F)

Maximum air supply pressure 8 bar g (116 psi g)

Minimum air supply pressure is dependant on operating conditions

MV series solenoid

Maximum ambient temperature 50 °C (122 °F)

Minimum ambient temperature 0°C (32 °F)

IM-P405-46 EMM Issue 510

3. Installation

Note: Before actioning any installation read the 'Safety information' in Section 1.

Although the valve has great structural integrity, severe misalignment and/or the pulling

effect of incorrect pipe length will have a detrimental effect on the valve and must be avoided.

Particular attention should be paid to correct pipe alignment such that the inlet pipework and

valve are all on the same axis.

Wherever practicable, valves should be installed where there is adequate space available so

that they can be conveniently operated and maintained.

Before installing a valve, check to ensure that size, pressure rating, materials of construction,

end connections, etc. are suitable for the service conditions of the particular application.

Care must be taken to ensure that all dirt which may have accumulated in the valve during

storage is removed before installation, maintain cleanliness during installation since the

introduction of dirt can result in damage to the valve seats and operating mechanism. To

minimise the danger of abrasive particles damaging the seats, pipeline strainers should be

fitted upstream of the valves.

Install the valve with the actuator uppermost. The preferred position is with the stem vertical.

The air supply to the solenoid valve/actuator must be in 10 mm ( ") minimum diameter pipe.

The air inlet connection is ¼" BSP (G).

Table 1 Maximum air pressure

Valve size Actuator Maximum air pressure

DN25 BVA315S /14 8 bar g (116 psi g)

DN32 BVA320S /14 8 bar g (116 psi g)

DN40 and DN50 BVA325S /14 8 bar g (116 psi g)

DN65 BVA330S /14 8 bar g (116 psi g)

3.1 To fit an MV type solenoid assembly to the valve actuator:

-Turn the spring loaded solenoid override screw anticlockwise to release it for normal

working.

-Fit the screwed location pin from the MV kit in the top centre position above the actuator

ports (see Figure 3). Ensure the pin is screwed far enough into the actuator to allow a

good seal to be made i.e. that it is not holding the solenoid away from the actuator.

-Use the '3/2' adapter plate supplied with the solenoid assembly. Discard the '5/2' plate.

Note: Earlier versions used a double-sided plate. For this type, align the arrow on the

plate with the '3/2' on the valve assembly.

-Fit the solenoid assembly to the actuator using the 2 screws provided in the kit. Do not

overtighten the screws as this could distort the plastic body and prevent proper working.

-Connect the air supply to port 1 (¼" BSP). Note that port 3 is blanked for this application.

The unmarked port near the override screw is not connected in this application.

The solenoid override is operated by using a screwdriver to push the spring loaded plastic

screw inwards and turning it clockwise to lock it in the 'override' position. This bypasses

the solenoid and allows the ABV to be operated without an electricity supply. The screw is

released by turning it anticlockwise.

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