Spirax Sarco SafeBloc DBB3 Bedienungsanleitung

IM-P184-09 CMGT Issue 4 1

1. Safety information

2. General product information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

Printed in GB

1849050/3

Spirax SafeBlocTM DBB3 Double Block and Bleed

Bellows Sealed Stop Valve

Installation and Maintenance Instructions

IM- P184-09

CMGT Issue 4

IM-P184-09 CMGT Issue 4

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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.

Warning

The body/bonnet gaskets (11a and 11b) contain a thin stainless steel support ring which may cause

physical injury if not handled and disposed of carefully.

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 product listed below

complies with the requirement of the Pressure Equipment Directive (PED) and carries the

mark when so required. It should be noted that products that are in category 'SEP' are required by

the Directive not to carry the mark.

Product Group 1

Gases

Group 2

Gases

Group 1

Liquids

Group 2

Liquids

Spirax SafeBlocTM

PN40

DN15 - DN25 SEP SEP SEP SEP

DN40 - DN50 2 1 SEP SEP

DN65 - DN100 212SEP

ANSI 300

DN15 - DN25 SEP SEP SEP SEP

DN40 - DN100 212SEP

i) The product has been specifically designed for use on steam, compressed air and water/

condensate which 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) A number of products are supplied for the intention of the end user (or agent thereof) modifying

the flange configuration from that supplied. It is the responsibility of the organization carrying

out the modification to do so in accordance with the internationally recognized standards and

to ensure that the design rating and operation of the product are not compromised. Spirax

Sarco will not be held responsible for any unapproved modification or consequential liability

resulting in failure to observe these requirements.

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

v) 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.

vi) Remove protective covers from all connections and protective film from all name-plates, where

appropriate, before installation on steam or other high temperature applications.

1. Safety information

IM-P184-09 CMGT Issue 4 3

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.

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.

IM-P184-09 CMGT Issue 4

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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.

Although the bonnet and handwheel will support the weight of the valve, it is recommended the

slings for lifting are positioned around the back of the pipe flanges on the main body.

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 some products may reach temperatures

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-P184-09 CMGT Issue 4 5

2.1 Description

The Spirax SafeBlocTM is a double block and bleed bellows sealed

stop valve, which has been designed for use as an in-line double

isolation valve on steam, gas, liquid, condensate and water systems.

Available types

DBB3 steel body and bonnet with PN40 and ANSI 300 connections.

Bleed valve options

A bleed valve connection is provided to depressurise the downstream when the upstream valve is isolated.

This can be supplied with either a DN15 flanged, ½" screwed BSP or ½" socket weld connection and must

be stated at the time of order placement.

Standards

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

the mark when so required.

Certification

This product 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 additional information see Technical Information Sheet, TI-P165-01-EN-ISS1.

2.2 Sizes and pipe connections

DN15, DN20, DN25, DN40, DN50, DN65, DN80 and DN100 flanged EN 1092 PN40 and ANSI B 16.5 Class 300.

Face-to-face dimensions conform to EN 558-1 (PN) and EN 558-2 (ANSI class).

Fig. 1

2. General product information

IM-P184-09 CMGT Issue 4

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0 100 200 300

400 500 600 700

0 10 20 30 40 51

425

300

200

100

-29

700

500

300

100

-21

0 100 200 300 400 500

0 5 10 15 20 25 30 35 40

400

300

200

100

700

600

500

400

300

200

100

Pressure psi g

Temperature °F

ANSI 300

PN40

Temperature °C

Pressure bar g

Steam

saturation

curve

Temperature °C

Pressure bar g

Body design conditions PN40

PMA Maximum allowable pressure 40 bar g @ 0 °C (580 psi g @ 32 °F)

TMA Maximum allowable temperature 400 °C @ 24 bar g (752 °F @ 348 psi g)

Minimum allowable temperature -10 °C (14 °F)

PMO Maximum operating pressure for saturated steam service 30.4 bar g 441 (523 °F)

TMO Maximum operating temperature 400 °C @ 24 bar g (752 °F @ 348 psi g)

Minimum operating temperature

(Note: For lower operating temperatures consult Spirax Sarco)

-10 °C (14 °F)

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

Body design conditions ANSI 300

PMA Maximum allowable pressure 51 bar g @ 37.7 °C (739 psi g @ 100 °F)

TMA Maximum allowable temperature 425 °C @ 28 bar g (797 °F @ 406 psi g)

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

PMO Maximum operating pressure for saturated steam service 41.6 bar g (603 psi g)

TMO Maximum operating temperature 425 °C @ 28 bar g (797 °F @ 406 psi g)

Minimum operating temperature

(Note: For lower operating temperatures consult Spirax Sarco)

-29 °C (-20 °F)

Designed for a maximum cold hydraulic test pressure of: 77 bar g (1 117 psi g)

2.3 Pressure/temperature limits (ISO 6552)

Steam

saturation

curve

The product must not

be used in this region.

Temperature °F

Pressure psi g

The product must not

be used in this region.

IM-P184-09 CMGT Issue 4 7

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 protective covers from all

connections, threaded blanking plug

from the bleed port (screwed and socket

weld version only) and the protective film

from all name-plates, where appropriate,

before installation on steam or other high

temperature applications. A suitable form

of isolation must be fitted to the bleed port

before commissioning of the line.

3.3 The valve can be installed in the horizontal

or vertical plane. When installed in the

horizontal plane the bleed port should

ideally be positioned at the bottom (see

Figure 2). Isolation of the bleed port should

be positioned as close to the valve as

possible to avoid back-up of condensate

in the isolated bleed line. The bleed port

connection must be piped to a safe visible

atmospheric place as close to the valve

as possible.

Please note there is no flow direction arrow

on the valve as it can be installed with flow

from right to left or left to right.

3.4 When installed on steam systems a suitable

steam trap should be fitted immediately

upstream of the isolation valve to drain

condensate. This will ensure drainage of

the pipe when the valve is closed, and

will prevent damage of the valve due to

waterhammer. The drain trap should be

either a ball float (FT) or thermodynamic

(TD) type. Correct condensate drainage of

all upstream pipework is also vital.

Fig. 2

Incorrect Installation

Correct Installation

Bleed point

3. Installation

IM-P184-09 CMGT Issue 4

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

or protective devices.

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 handwheels. Special care must be taken to ensure that the

movement is made in the correct direction.

To open the valves fully, it is recommended to turn the handwheels until the shafts are raised to the

maximum position, indicated by the (+) on the bonnet, then turn the handwheel clockwise 1/8 to ¼

turn to remove any backlash. This action prevents any force being applied to open a valve, which is

already fully open, resulting in damage to the stem, bellows unit or other components. Spirax Sarco

bellows sealed isolation valves are fitted with a position indicator, which can be found on the stem,

and should align with the (+) or (-) on the bonnet support pillars. (+ = fully open and - = fully closed).

5.3 If valve ‘keys’ are used care must be taken not to use excessive force when opening or closing the

valve.

5.4 A Valve Integrity Test must be undertaken prior to each double isolation of the system. Refer to

Figure 3 and the Table below for correct sequence of operation.

Flow from Left to Right (L-R) Flow Right to Left (R-L)

1. All valves closed 1. All valves closed.

2. Open bleed/drain valve C.2. Open bleed/drain valve C.

3. Open downstream valve B.3. Open downstream valve A.

4. Upstream valve Ashould remain closed. 4. Upstream valve Bshould remain closed.

5. After initial discharge of downstream

depressurisation from the bleed valve C,

no further steam/fluid should be observed

(integrity proved).

If fluid is observed check valve A is fully closed,

if fluid is still evident contact Spirax Sarco and

Do Not Use.

5. After initial discharge of downstream

depressurisation from the bleed valve C,

no further steam/fluid should be observed

(integrity proved).

If fluid is observed check valve B is fully closed,

if fluid is still evident contact Spirax Sarco and

Do Not Use.

It is advisable to place a copy of the above table in close proximity of the Spirax SafeBlocTM valve.

4. Commissioning

5. Operation

IM-P184-09 CMGT Issue 4 9

Flow L - R

Fig. 3

Flow R - L

5.5 Before undertaking any maintenance of plant downstream of the valve both handwheels should be

isolated. Refer to Figure 3 and the Table below for the correct sequence of handwheel operation.

When handwheels Aand Bare closed and drain port Cis opened there will be an initial discharge

as the valve depressurises. If there should be any visible discharge after a short period, consult

Spirax Sarco Service Department.

Note: Handwheels should always be opened slowly to avoid system shocks.

Operation sequence

for the Spirax SafeBlocTM

Flow Left to Right (L-R)

Operation sequence

for the Spirax SafeBlocTM

Right to Left (R-L)

Isolation Opening Isolation Opening

Close AClose CClose BClose C

Open COpen BOpen COpen A

Close BOpen AClose AOpen B

For illustrative purposes refer to Steps 1 to 5 on pages 10 and 11.

Note: Name-plates are fitted to the valve to identify which handwheel operates which port. If the valve is

insulated, ensure the name-plates remain visible.

IM-P184-09 CMGT Issue 4

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TRANSLATION RUN OVER

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

Warning

The body/bonnet gaskets (11a and 11b) contain a thin stainless steel support ring which may cause

physical injury if not handled and disposed of carefully.

6.1 General information

Before undertaking any maintenance on the valve, ensure 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.

Ensure that the correct tools and necessary protective equipment are used at all times. When maintenance

is complete open isolation valves slowly and check for leaks.

Note: The bonnet bush and threads of the stem are packed with a high quality grease on assembly. It is

recommended to re-grease these items whenever maintenance is undertaken on the valve.

6.2 Sequence of operation for safe maintenance of plant

Please note: that all the drawings in Steps 1 to 5 are illustrated with the ow direction from left to right.

Key

= Valve open

= Valve closed

Step 1

=Normal operation

position

Step 2

=Full isolation position

6. Maintenance

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