Spirax Sarco BSA3HP Bedienungsanleitung

IM-P184-17 CMGT Issue 3 1

1. Safety information

2. General product information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

Printed in GB

1847050/3

BSA3HP

Bellows Sealed High Pressure Stop Valve

Installation and Maintenance Instructions

IM-P184-17

CMGT Issue 3

IM-P184-17 CMGT Issue 3

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Safe operation of these products can only be guaranteed if they are 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.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, product markings 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 and carries the mark when so required.

The products fall within the following Pressure Equipment Directive categories:

BSA 3HP Size Group 1

Gases

Group 2

Gases

Group 1

Liquids

Group 2

Liquids

DN15 - DN25 SEP SEP SEP SEP

DN32 2 SEP 2SEP

DN40 - DN100 212SEP

i) These products have been specifically designed for use on steam, air or condensate/water,

which is 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, 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. Safety information

IM-P184-17 CMGT Issue 3 3

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 opened and closed progressively to avoid system shocks.

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 the 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.

IM-P184-17 CMGT Issue 3

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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 may reach temperatures in excess of 400 °C (752 °F).

Many products are not self-draining. Take due care when dismantling or removing the product 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.

1.15 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.

1.16 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-P184-17 CMGT Issue 3 5

2.1 General description

The BSA3HP is a carbon steel bodied high pressure in-line non throttling stop valve, having a multi-ply bellows

and unbalanced or balanced options. These valves are rated to EN 1092 PN100 or ASME class 600 for use

with both saturated and superheated steam applications and a range of other industrial gases and fluids.

Range and options

Size Unbalanced Balanced

PN100 Class 600 PN100 Class 600

DN15 - DN50 • •

DN65 - DN100 • • • •

Standards

The product fully complies with the requirements

of the European Pressure Equipment Directive and

carries the mark when so required.

Certification

The BSA3HP is available with certification to EN

10204 3.1.

Note: All certification/inspection requirements must

be stated at the time of order placement.

Note: For further product data see the following

Technical Information sheet TI-P184-15.

Fig. 1 BSA3HP bellows sealed high pressure stop valve

2. General product information

IM-P184-17 CMGT Issue 3

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0 20 40 60 80 100

400

300

200

100

-10

Steam

saturation

curve

Temperature °C

Pressure bar g

PN100

A-B-C

The product must not be used in this region or beyond the parameter of the PMA or TMA of the

relative end connection.

Body design condition PN100

PMA Maximum allowable pressure 100 bar g @ 50 °C

TMA Maximum allowable temperature 400 °C @ 59.5 bar g

Minimum allowable temperature -10 °C

PMO Maximum operating pressure for saturated steam service 70.5 bar g @ 287.3 °C

TMO Maximum operating temperature 400 °C @ 59.5 bar g

Minimum operating temperature -10 °C

Designed for a maximum cold hydraulic test pressure of: 150 bar g

2.2 Sizes and pipe connections

DN15, DN20, DN25, DN32, DN40, DN50, DN65, DN80 and DN100

Flanged EN 1092 PN100 and ½", ¾", 1", 1¼", 1½", 2", 2½", 3" and 4"

Flanged ASME class 600

2.3 Seat leakage

Plug to seat shut-off conforms to EN 12266-1 Rate A leakage.

2.4 Kvvalues

Size DN15

(½")

DN20

(¾")

DN25

(1")

DN32

(1¼")

DN40

(1½")

DN50

(2")

DN65

(2½")

DN80

(3")

DN100

(4")

Kv3.1 7. 6 8.6 24 28 36.8 80 86 134

For conversion:

Cv(UK) = Kvx 0.963

Cv(US) = Kvx 1.156

2.5 Pressure/temperature limits (ISO 6552)

IM-P184-17 CMGT Issue 3 7

0 20 40 60 80 102.1

0 200 400 600 800 1000 1200 1400

425

400

300

200

100

-29

700

500

300

100

Temperature °C

Temperature °F

Pressure bar g

Pressure psi g

Steam

saturation

curve

Class 600

A-D-E

The product must not be used in this region or beyond the parameter of the PMA or TMA of the

relative end connection.

Body design condition Class 600

PMA Maximum allowable pressure 102.1 bar g @ 38 °C 1 481psi g @ 100 °F

TMA Maximum allowable temperature 425 °C @ 57.5 bar g 797 °F @ 834 psi g

Minimum allowable temperature -29 °C -20 °F

PMO Maximum operating pressure for saturated

steam service 79.8 bar g @ 295.8 °C 1 156 psi g @ 564.4 °F

TMO Maximum operating temperature 425 °C @ 57.5 bar g 797 °F @ 834 psi g

Minimum operating temperature -29 °C -20 °F

Designed for a maximum cold hydraulic test pressure of: 154 bar g 2 233 psi g

IM-P184-17 CMGT Issue 3

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

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

check that the product is suitable for the intended installation:

3.1 Check materials, pressure and temperature and their maximum values. If the maximum operating

limit of the product is lower than that of the system in which it is being fitted, ensure that a safety

device is included in the system to prevent overpressurisation.

3.2 Remove the protective covers from all connections.

3.3 Install the valve in the direction of flow given by the arrow on the body. The preferred position is with

the spindle vertical. The valve can be installed from the vertical to the horizontal plane (see Figure 3).

3.4 Always open isolation valves slowly to avoid system shocks.

3.5 Note: It is advisable that when work is being carried out downstream of a valve installation, double

isolation (block and bleed) should be fitted. In addition when installed as the final valve in a pipeline,

as a safety precaution, a blanking plate or blank flange must be fitted to the outlet flange of the valve.

3.6 Important note: When a Balanced Valve is installed, the valve body should be mounted with the

upstream fluid flowing into the upper valve chamber first (as per flow arrow), so that the fluid pressure

acts on top of the Balancing Plug. This is opposite to normal installation. If a Balancing Plug is

upgrading or replacing a standard plug, the original valve body must be turned around in the pipeline

and permanently marked with a new flow arrow indicating the changed direction of flow.

Do not mount the valve upside down.

What is a balancing plug, how does it work and why use it?

-A balancing plug is a two stage on/off mechanism

-(See Figure 2) The pre-lifting plug (A) acts as

a pilot valve and is opened first, allowing the

medium to pass through at a controlled rate.

The differential pressure then reduces across

the valve - allowing the main valve plug (B) to

be easily lifted off its seat. To assist closing

the valve the flowing medium must enter

on the 'Bellows' side, this is the opposite to

normal installation.

-This device is fitted in the first instance to allow

easy closure of the larger valves. In normal flow

conditions it is very difficult on large valves and

high differential pressure to close the valve. By

reversing the flow and installing a pilot valve,

this problem is overcome.

Fig. 2

3. Installation

IM-P184-17 CMGT Issue 3 9

After installation or maintenance ensure that the system is fully functioning. Carry out tests on any alarms

or protective devices.

4. Commissioning

5. Operation

5.1 The bellows sealed isolation valve plays an

important role in the conservation of energy

by eliminating fugitive stem seal emissions.

5.2 The valve is operated manually by a

handwheel. Special care must be taken to

ensure that the movement is made in the

correct direction.

To open the valve fully, it is recommended to

turn the handwheel until the shaft is raised

to the maximum position, indicated by the

(+) on the bonnet, then turn the handwheel

clockwise 1¼turns to remove any backlash.

This is to prevent the possibility of

attempting to force open a valve, which is

already fully open, resulting in damage to

the stem, bellows unit or other components.

Spirax Sarco BSA valves are fitted with a

position indicator which can be found on

the stem, and on the bonnet support pillars

(+ = fully open/- = fully closed).

5.3 The use of valve keys is not recommended,

however if used care must be taken not to

damage the valve.

Fig. 3 Incorrect installation Correct installation

IM-P184-17 CMGT Issue 3

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All the internals of the bellows sealed valve can be replaced (See Section 7, Spare parts).

Note: Before actioning any maintenance programme observe the data in Section 1 'Safety information'.

Warning

Before undertaking any maintenance on the valve, ensure that any pressure is isolated and safely vented

to atmospheric pressure. The valve should then be allowed to cool. When reassembling, ensure that all

joint faces are clean.

6.1 Replacing the handwheel

1. Remove circlip (15) with circlip pliers.

2. Slide off existing handwheel.

3. Ensure that thrust washer (13) is still present

on top face of bonnet (5).

4. Ensure that all contact surfaces of the valve

are clean and free of dirt to accept new

handwheel.

5. Align flat of 'D' drive of new handwheel and

that of the bonnet bush. Slide new handwheel

into place.

6. Fit replacement circlip with circlip pliers.

7. Test operation of valve by rotating the valve

between fully open and fully closed several

times to ensure it is working properly before

returning the valve to service.

Fig. 4

Fig. 5

6.2 Replacing the bellows, stem, plug and seat assembly

1. Loosen the gland nut (11) by a couple of turns.

2. Open the valve (using the handwheel) by a single rotation.

3. Loosen and remove the bonnet nuts (20).

4. Carefully lift the top half of the valve including the bonnet, handwheel, stem and plug assembly.

5. Lift the bellows housing (4) off of the studs.

6. Maintenance

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