Spirax Sarco M33 ISO Series Bedienungsanleitung

IM-P133-65 CMGT Issue 2 1

1. Safety information

2. General product information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

Printed in GB

BAC13365

M33F ISO, M33S ISO and M33V ISO

Ball Valves

Installation and Maintenance Instructions

IM-P133-65

CMGT Issue 2

IM-P133-65 CMGT Issue 2

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, 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 Pressure Equipment Directive

(PED) and carry the mark when so required. The products fall within the following Pressure

Equipment Directive categories:

Product Size Group 1

Gases

Group 2

Gases

Group 1

Liquids

Group 2

Liquids

M33F ISO,

M33S ISO

and

M33V ISO

DN50 212SEP

DN65 212SEP

DN80 212SEP

DN100 212SEP

DN150 222SEP

DN200 222SEP

i) The product has 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.

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. Safety information

IM-P133-65 CMGT Issue 2 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 turned on and off in a gradual way 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 danger of burns.

If parts made from PTFE have been subjected to a temperature approaching 260 °C (500 °F) or

higher, they will give off toxic fumes, which if inhaled are likely to cause temporary discomfort.

It is essential for a no smoking role to be enforced in all areas where PTFE is stored, handled or

processed as persons inhaling the fumes from burning tabacco contaminated with PTFE particles

can develop 'polymer fume fever'.

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.

IM-P133-65 CMGT Issue 2

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 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, with the

exception of PTFE.

PTFE:

-Can only be disposed of by approved methods, not incineration.

-Keep PTFE waste in a separate container, do not mix it with other rubbish, and consign it to

a landfill site.

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-P133-65 CMGT Issue 2 5

2.1 General description

The full bore two-piece body ball valves that are covered in this document have a floating ball as standard

and are produced in accordance with API 6D. They have been designed for use as isolating valves, not

control valves.

ISO mounting

As standard, all the valves in this document have an integral ISO body mounting which allows the valve to

be automated without losing seal integrity, as the body does not require disassembly. Manual to remote

control may therefore be easily accomplished by fitting a BVA300 series pneumatic actuator available from

Spirax Sarco. For further details contact Spirax Sarco.

Available types and applications

M33F2 ISO Has an API 607 firesafe design, zinc plated carbon steel body and PDR 0.8 seats (for

high temperatures)

M33F3 ISO Has an API 607 firesafe design, stainless steel body and PDR 0.8 seats (for high

temperatures)

API 607 firesafe design - In normal working conditions, the ball rests against two PDR

0.8 seats ensuring total closure. When the valve is submitted to temperature above the

limits the seats can withstand, the seat becomes deformed and renders to extrusion. When

the seats have been totally destroyed, the ball will come to rest firmly against the metal

seat in the cap, producing a metal-to-metal closing. This secondary seat in the valve cap

ensures the valve will operate to international API 607 standards.

Applications

Designed for use with the majority of industrial fluids on applications,

which include steam, condensate, water, oil, gases, and other fluids

within its operating range.

M33S2 ISO Zinc plated carbon steel body and PDR 0.8 seats (for high temperatures)

M33S3 ISO Stainless steel body and PDR 0.8 seats (for high temperatures)

Applications

Designed for use with the majority of industrial fluids on applications,

which include steam, condensate, water, oil, gases, and other fluids

within its operating range.

M33V2 ISO Zinc plated carbon steel body and PTFE seats

M33V3 ISO Stainless steel body and PTFE seats

Applications Designed for use on applications at low temperatures which use natural

gas and most of the hydrocarbon fluids in the OPC refinery sites.

Standards

This product fully complies with the requirements of the Pressure Equipment Directive (PED) and carries

the mark when so required.

Certification

These products are available with material certification to EN 10204 3.1.

Note: All certification/inspection requirements must be stated at the time of order placement.

2. General product information

IM-P133-65 CMGT Issue 2

Fig. 1 M33_ ISO

2.2 Sizes and pipe connections

DN50, DN65, DN80, DN100, DN150 and DN200.

Standard flange ASME B 16.5 Class 150 and 300 with face-to-face dimensions according to B 16.10.

IM-P133-65 CMGT Issue 2 7

0 100 200 300 400 500 600 700

230

200

150

100

-29

400

300

200

100

0 10 20 30 40 51

0 100 200 300 400 500 600 700

260

200

150

100

-29

500

400

300

200

100

0 10 20 30 40 51

2.3 Pressure/temperature limits

A - BFlanged

ASME 300

A - CFlanged

ASME 150

Body design conditions ASME B 16.34

PMA Maximum allowable

pressure

ASME 150 19 bar g @ 38 °C 275 psi g @ 100 °F

M33V ISO ASME 300 51 bar g @ 45 °C 740 psi g @ 113 °F

M33F ISO and M33S ISO

ASME 150 20 bar g @ 38 °C 290 psi g @ 100 °F

ASME 300 51 bar g @ 38 °C 740 psi g @ 100 °F

TMA Maximum allowable

temperature

M33V ISO 230 °C @ 0 bar g 446 °F @ 0 psi g

M33F ISO and M33S ISO 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

M33V ISO 10 bar g 145 psi g

M33F and M33S ISO 17.5 bar g 254 psi g

TMO Maximum operating

temperature

M33V ISO 230 °C @ 0 bar g 446 °F @ 0 psi g

M33F ISO and M33S ISO 260 °C @ 0 bar g 500 °F @ 0 psi g

Minimum operating temperature -29 °C -20 °F

PMX Maximum differential pressure is limited to the PMO

Designed for a maximum cold hydraulic test pressure of:

ASME 150 28.5 bar g 413 psi g

ASME 300 76.5 bar g 1109 psi g

Steam

saturation

curve

Pressure bar g

Temperature °C

Steam

saturation

curve

M33F ISO

and

M33S ISO

M33V ISO

Pressure psi g

Temperature °F

Pressure bar g

Temperature °C

Pressure psi g

Temperature °F

The product must not be

used in this region.

The product must not be

used in this region.

IM-P133-65 CMGT Issue 2

Note: Before actioning any installation observe 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.

Valves are for on/off applications and may be operated manually.

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 handle in a suitable position. The preferred position is with the spindle vertical. The

valve can be installed in any position for gas service (see Figure 3 below).

When used on steam services:

1. Fit a trapped drain pocket upstream of the valve.

2. Open valve slowly to prevent the risk of waterhammer damage.

Fig. 3 Correct installation for gas service

Do not mount the valve upside down

for liquid service (Figure 2).

Fig. 2 Incorrect installation for

liquid service

Valves should be installed into the

pipeline in the fully closed position.

Always open valves slowly to avoid

system shocks.

3. Installation

IM-P133-65 CMGT Issue 2 9

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

or protective devices.

The valve is operated manually by a handle. Special care must be taken to ensure that the movement is

made in the correct direction.

The valve can be used as an on/off valve, and can be operated fully open, or fully closed.

4. Commissioning

5. Operation

IM-P133-65 CMGT Issue 2

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

6.1 General information

As with all mechanical devices, regular maintenance is the most efficient means of ensuring continued

operational efficiency.

Regular scheduled inspection of all valves is essential, especially on valves which are operated only

occasionally.

6.2 General maintenance

Isolate the unit - Before removing the M33 ISO ball valve from the pipeline to action any maintenance work,

isolate it both upstream and downstream and wait for the unit to reach ambient temperature before handling.

The complete body assembly can then be removed and any new parts fitted - See Section 7.

6.3 How to replace the stem seats:

-Remove the ball valve from the pipeline observing the 'Safety information' in Section 1.

Warning: Isolate the ball valve both upstream and downstream and wait for the unit to reach ambient

temperature before handling.

-Remove the nuts (20) from the studs (19) and split the main body (1) from the insert (2).

-Remove the seats (4) and the ball (3).

-Withdraw the stem (6) and replace the lower stem seal (7) and the 'O' ring (8).

-Reassemble the unit using a new body gasket (5). The nuts and studs (19, 20) and gland nut (13) should

be tightened to the recommended torque, see Table 1, page 12.

Please note - When the seats and lower stem seal have been replaced and the valve has been reassembled

it is advisable to conduct a cold hydraulic test to the valve body as follows:

-ASME 150 28.5 bar g (410 psi g)

-ASME 300 76.5 bar g (1010 psi g)

It is also advisable to conduct a seat leakage test using compressed air at 7 bar g (101 psi g).

After 24 hours in service, retighten nuts (20 and 13) and check for leaks.

6. Maintenance

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