installation/operationmanual piglauncher - schuck … · molchschleuse pig trap typ / type pn / cl...

Franz Schuck GmbH

Installation/operation manualPig launcher

Translation of the original Operation ManualKeep for future use!

IntroductionThis manual is written for installation, operating, maintenance and supervisorypersonnel.

This manual also describes components and auxiliary units that are not includedor are only partially included in the scope of supply.

The manual must be read, understood and observed by the user. We emphasizethat Franz Schuck GmbH assumes no liability for damage or malfunctions arisingfrom non-compliance with this manual.

With regard to the illustrations and information in thismanual, we reserve the rightto make technical modifications.

CopyrightThe copyright for this manual remains with Franz Schuck GmbH.

The instructions and drawings contained hereinmay not be reproduced or dissem-inated either fully or in part, nor used for competitive purposes or communicatedto other parties without authorization.

Contact addressFranz Schuck GmbHDaimlerstraße 5 – 789555 SteinheimGERMANYPhone +49 (7329) 950-0Fax +49 (7329) 950-161

[email protected]

2013-02-09 I

Table of Contents

Table of Contents

Chapter 1 1-1Preliminary remarks

1.1 1-1Legal notes

1.2 1-1Application range

Chapter 2 2-1Safety

2.1 2-1Fundamental safety instructions

2.1.1 2-1General

2.1.2 2-2Intended use

2.1.3 2-3Organizational measures

2.1.3.1 2-3Special hazard points

2.1.3.2 2-4Workplace and personal protective gear

Chapter 3 3-1Description

3.1 3-1System overview

3.1.1 3-2Identification plate

3.1.2 3-3Closure

Chapter 4 4-1Assembly

4.1 4-2Preparation

4.1.1 4-2As-delivered condition

4.1.2 4-2Transport

4.1.3 4-3Inspection

4.1.4 4-3Storage

4.2 4-4Installation

4.2.1 4-4General installation instructions

4.2.2 4-4Pig launchers with weld ends

4.2.3 4-4Pig launchers with flanges

4.2.4 4-5Installing pig launchers

4.3 4-6Testing

4.3.1 4-6Function test

4.3.2 4-6Pressure/leak tightness test

2013-02-09 II

Table of Contents

Chapter 5 5-1Operation

5.1 5-1Safety instructions for operation

5.2 5-2Operation

5.2.1 5-2Inserting the pig into the pipeline

5.2.2 5-2Removing the pig from the pipeline

Chapter 6 6-1Maintenance

6.1 6-2Inspection

6.1.1 6-2Regular maintenance

6.1.1.1 6-2Closure

6.1.1.2 6-2Ball valve

6.2 6-3Repairs

Chapter 7 7-1Appendix

7.1 7-1Tightening sequence for flange bolts

7.2 7-2Conversion factors

7.3 7-3Calculation formula to determine the carbon equivalent (CEV)

7.3.1 7-3Calculation formula (standard)

7.3.2 7-3Calculation formula for steels with different consistencies

7.4 7-4Marking of packages

7.4.1 7-4Marking of packages according to DIN 55402 and ISO R 780

7.4.2 7-5Schuck symbols – transporting and unpacking packages

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Preliminary remarks

1 Preliminary remarks

CAUTION

Danger of consequential damage due to incorrect operation, maintenance and/or handling!

We explicitly emphasize that we assume no liability for damage ormalfunctionsarising from non-compliance with this manual.

Therefore it is important to comply with all instructions in this manual!

This manual is to provide technicians and users with the necessary informationfor assembly and adjustment work and to help in performing work quickly andcorrectly.

For your own safety, read this manual carefully and pay particular attention to thehighlighted tips. In any case, keep this manual to hand.

Pay special attention to all safety instructions in this manual. You will find thesafety instructions in Chapter 2, in the introductions to chapters and before prac-tical instructions. The General Terms and Conditions of the company apply exclu-sively to all deliveries and performances made by Franz Schuck GmbH, includingany future transactions.

1.1 Legal notes

The component may only be installed and operated by skilled personnel.

Please check parts upon receipt for any possible damage that may have occurredduring transport. Only undamaged parts may be fitted or used.

No warranty can be claimed if maintenance work is neglected or carried out incor-rectly. Only original spare parts guarantee quality, reliability and exchangeability.

Any modification(s) of the component are in general prohibited by Franz SchuckGmbH. The manufacturer guarantee becomes void if this prohibition is not com-plied with!

1.2 Application range

This operationmanual applies to the Franz Schuck GmbH product described in thismanual.

The appropriate operation manuals for optional accessories must also be ob-served.

These operation manuals are included in the overall documentation if the acces-sories belong to the scope of supply from Franz Schuck GmbH.

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Safety

2 Safety

CAUTION

Dangers to the health and safety of operating and maintenance staff as wellas to the functioning capacity of the valve. Dangers to the environment due toescaping gaseous or liquid media.

Escaping sour gas or sulphinic lye might cause life danger hazard!

Non-compliance with these instructions jeopardizes the obligation by FranzSchuck GmbH to follow through on the warranty/guarantee.

The instructions in the “Safety” Chapter must be unconditionally observed!

2.1 Fundamental safety instructions

2.1.1 General

Modifications on valves and attachments which could affect safety may not becarried out without written permission from the manufacturer.

The guarantee becomes void if this prohibition is not complied with!i

• This product has been manufactured according to the recognized rules oftechnology and according to internal Schuck quality standards; the product isshipped from the factory in a perfect technical condition

• Nevertheless, valves can cause hazards to people, material goods and the en-vironment if operating personnel use them improperly or in a manner that iscontrary to their intended use

• Any person dealing with assembly, commissioning, operation and/or mainte-nance of the valvemust have read and understand this entiremanual, andmustbe able to prove they possess professional qualifications for implementing thework

• Please observe the valid accident prevention regulations when installing thecomponent

• Suitable protective gear must be worn when carrying out the works

• The manual must be kept safe and accessible at all times at the place wherethe valve is in use

• If malfunctions occur, notify Franz Schuck GmbH immediately and take appro-priate measures

• Work on ball valves (such as inspection, servicing and/or maintenance work)may only be carried out in a depressurized state and with the energy supplysecured and switched off

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Safety / Fundamental safety instructions

• Valvesmust be effectively covered and/or protected whenwork is being carriedout that could lead to contamination or damage to the valve, the assembledparts and/or the anti-corrosion protection

2.1.2 Intended use

Any other media and/or applications outside the permissible pressure and temper-ature range can lead to damage and/or leaks.

Intended use includes observing the instructions in this operating manual and ad-hering to the operating conditions on the identification plate, the final inspectioncertification and drawings, as well as observing the locally applicable accident pre-vention guidelines and regulations for protecting the environment.

Any operating conditions or applications which differ from those prescribed areonly valid with the agreement of Franz Schuck GmbH!

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2.1.3 Organizational measures

2.1.3.1 Special hazard points

There is no immediate danger from a pig launcher that is installed and servicedaccording to instructions.

Life hazard in the case of escaping sour gas or sulphinic lye!

i• Danger from escaping media

– depending on theworkingmedium, fire or explosion hazards can arise fromelectrical contact, naked flames, light and/or smoking

– there is a risk of poisoning, chemical burns, scolding and environmentalpollution

– hazardous materials must be collected or sucked up, if necessary, and dis-posed of properly

• Danger from opening under pressure

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2.1.3.2 Workplace and personal protective gear

Sufficient space is required for carrying out assembly and maintenance worksafely. The operator must ensure that the workplace is clean and clearly arranged.

If media (including residues) can escape in case the ball valve or the actuator sys-tem experiences operational faults or malfunctions, then the endangered personsmust use suitable personal protective gear, as far as this is necessary.

Only use components in a technically perfect condition; use them according tospecifications in a safety and risk-conscious manner while complying with the op-eration manual! Remedy faults in particular that could impair safety (or have themremedied)!

The operating manual must be supplemented by instructions which take into ac-count supervisory and reporting duties with regard to work related particularities,e.g. in respect of how work is organized, working procedures and the personnelemployed.

Technically trained staff commissioned to work on a component must have readthe chapter on safety in this operating manual before starting work. Staff mustalready be aware of potential hazard sources when working to be in a position toreact quickly and correctly. This applies in particular to staff who are only employedoccasionally to work on a component, e.g. when setting up or servicing.

Observe all safety and hazard instructions for the equipment/the component!

Make sure all safety and hazard signs are complete and legible!

No modifications, attachments or conversions which could impair safety may beimplemented without authorization from Franz Schuck GmbH! This also applies tothe assembly and the adjustment of safety devices and safety valves as well as forwelding on load-bearing parts.

Lubricants and sealing compounds as well as spare parts should conform to thetechnical specifications. This is always guaranteed when using original spareparts.

Replace hydraulic and pneumatic hose lines in specified or appropriate intervals,even if no security-relevant defects are evident.

Adhere to the prescribed deadlines, or the deadlines stated in the operation man-ual, for recurring tests/inspections!

Appropriate workshop equipment is essential for carrying out maintenance work.

Make sure the location or fire extinguishers is clearly indicated and operating in-structions are available!

Make sure to observe the fire alarm and fire fighting instructions!

DANGER

Risk of injury from bursting components/system parts!

If the permissible limit values are exceeded, thecomponent/system can be destroyed, and as aconsequence of this persons can be injured or killed!

Always operate components/system parts within thepermissible limit values!

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Description

3 Description

3.1 System overview

Task

Pigs are fittings used to clean and check pipelines. The pig launcher is used toinsert the pig into the pipeline and to ensure safe removal of the pig. Differenttypes of sending and receiving stations are available.

Function

The closure that consists of a bayonet lock and pressure warning arrangement forthe opening process (depending on type) ensures safe insertion or removal of thepig. In addition, a bypass is installed that ensures that the pig is transported alongwith the operating medium of the pipeline that is to be checked or cleaned. Thisbypass is also required when draining the pig launcher. It allows to remove thepig while preventing the operating medium from escaping.

Components

Delivery on customer request. It is also possible to integrate a pig launcher sig-nalling unit.

1 2 3 4 5 6 7 8

9

1011121314

130nn004

Fig. 3-1 Pig launcher

1 Quick-action closure2 Pressure gauge connection3 Expansion tube4 Kicker Line5 Name plate (identification plate)6 Pressure gauge connection7 Pig launcher signalling unit (optional)

8 Expansion tube9 Line connection10 Drainage11 Seat support leg12 Pig launcher body13 Drainage14 Seat support leg

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Description / System overview

3.1.1 Identification plate

Components

SCHUCKFranz Schuck GmbH Daimlerstraße 4—7 D — 89555 Steinheim

Molchschleuse — Pig trap

Typ / Type PN / CL Ident-Nr. / Ident. nº.

DN / NPS

TS min. / max.

PSV Rating for

TAG-Nr. / Tag nº. Herstelljahr / Year built Gewicht / Weight

Einbauten / Trim identification Auftrags-Nr. / W.o. nº.

PS max. PT / Test pressure

Baulänge / Face to face dim.

3

4

1010

7

1 2

9

1111

8

5 6

1414

[mm / inch] [mm]

[°C] [bar] [bar]

Pos.

Bestell-Nr. / Ident. nº.

1212 1313

130nn003

Fig. 3-2 Information on the identification plate

1 Type2 Nominal pressure PN/ANSI class3 Ident no.4 Nominal diameter DN/NPS5 Face-to-face dimension6 Order no.7 Design temperature TS

8 Max. design pressure PS9 Test pressure PT10 Built-in components11 Order no.12 TAG no.13 Year built14 Weight

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Description / System overview

3.1.2 Closure

Closures are bought-in parts , observe the operation manual of the manufac-turer! i

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Assembly

4 AssemblyFor questions regarding assembly, please contact:

Franz Schuck GmbHDaimlerstraße 5 – 789555 SteinheimGERMANYPhone +49 (7329) 950-0Fax +49 (7329) 950-161

[email protected]

DANGER




CAUTION

Danger of hardness increase of the steel when welding without pre-heating theweld junction at temperatures exceeding 80 °C!

Pre-heat the weld-on ends depending on the carbon equivalent (CEV) beforestarting the welding process.

Observe the instructions concerning the CEV ( Page 7-3, Chapter 7.3).

Make sure to monitor the temperature when pre-heating and welding!Suitable measures (such as cooling, extending the weld-on ends withoutcoating, dismantling, etc.) must be taken to avoid elevated temperatures inareas with coated surfaces.Temperatures of up to 100 °C are permissible for a short time.

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Assembly / Preparation

4.1 Preparation

DANGER

LIFE HAZARD from suspended loads or shifting of loads!

Proceed cautiously when transporting the pig launcher!

To lift the pig launcher only use appropriate liftingdevices as well as the designated lifting points.

Never hang or raise the pig launcher on drive parts orpiping systems!

4.1.1 As-delivered condition

If no other contractual agreements have beenmade, the pig launchers are suppliedfor transport under the following conditions:

• weld-on ends andmounted flange sides are coatedwith an anti-corrosive prod-uct

• the ball valves of the additional connections are in “OPEN” position

• valve ends are sealed with PE protective caps or wooden caps to prevent thepenetration of dirt and moisture

• the pig launchers are packed on wooden pallets or boxes

4.1.2 Transport

Procedure

1. Only use the original packaging for transporting the pig launcher to its placeof installation.The pig launcher can be damaged by incorrect handling.

2. Only use lifting devices that are appropriate to the weight being moved.

3. Use appropriate protectivematerials when using steel cables or chains in orderto protect the outer coating.

4. Ensure the load does not tip sideways.

5. Never attach and remove the pig launcher to lines that are welded on or toadditional attachments.

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Assembly / Preparation

4.1.3 Inspection

Procedure

1. Check the delivery notes to make sure that the delivery is complete.

2. If there are any discrepancies, contact Franz Schuck GmbH immediately.

3. Check the delivery immediately on receipt for damage incurred during trans-port.In the event of damage, observe the stipulations of the insurance companywhich, among other things, prescribe that evidence of damage is confirmedimmediately by the forwarding agent.

4. If applicable, photograph damage to proof evidence.

4.1.4 Storage

If possible store the pig launcher in its original packaging.

Take suitable measures to protect the pig launcher against external influences, dirtand moisture.

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Assembly / Installation

4.2 Installation

4.2.1 General installation instructions

CAUTION

Risk of damage to the seat support legs due to overload! Support legs of thepig launcher are designed to support the dead load only.

No transmission/support structure of pipeline forces (no fixed point)!

The valve must be installed in the pipeline free from mechanical stress.

If necessary, position the pig launcher on a suitable foundation (seat support legs)in order to avoid any bending, torsion, pushing or tractive strain.

4.2.2 Pig launchers with weld ends

For delivery, the weld ends have been providedwith anti-corrosion protection. Theweld ends must be carefully cleaned before being welded into the pipeline.

Welding must be carried out using an appropriate process and must be in accor-dance with all requisite instructions and requirements (test procedure, weldingtest, welding plan, test plan, etc.).

Apply an appropriate anti-corrosion protection as soon as possible after finishingthe weld seams.

4.2.3 Pig launchers with flanges

For delivery, the flange sealing surfaces have been provided with anti-corrosionprotection. The flange sealing surfaces must be carefully cleaned before beinginstalled in the pipeline.

The flange seals and bolts must be suited for sealing strip shape, pressure, tem-perature and medium.

The pipeline counter flanges must be aligned plane-parallel and concentrically.

Retighten the screw connections crosswise and evenly with the appropriate tight-ening torque.

Recommended tightening sequence ( Page 7-1, Fig. 7-1)

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Assembly / Installation

4.2.4 Installing pig launchers

Prerequisite

• The mechanical components of the system have been tested

• All damage has been reported and remedied

• General safety instructions have been observed prior to assembly/disassembly

• Preparatory measures (tabular, with tool overview) have been met

• Direct hazard sources (electric/temperature/mechanical/crush, etc.) areexcluded

Procedure

1. Do not remove the packaging of the pig launcher and the protective caps untilinstalling the pig launcher.

2. Carefully remove the anti-corrosion protection on the flange sealing surfacesor the weld-on ends using appropriate means.

3. Examine the pipelines for contamination and foreign particles before installa-tion, and clean if necessary.

4. Ensure that no contamination or foreign body can enter the pipeline or thevalve during assembly work.

5. Install all existing ball valve into the pipeline with the ball position “OPEN”.

6. Install the pig launcher into the pipeline as stress-free as possible.External tractive, compressive or bending forcesmust be avoided or reduced toaminimum using suitablemeasures (such as erecting a foundation), Page 4-4, Chapter 4.2.1.

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Assembly / Testing

4.3 Testing

4.3.1 Function test

Before applying pressure to the pig launcher for the first time, a function test mustbe carried out when it is de-pressurized.

Procedure

1. Properly clean the interior of the ball valve and the closure.

2. Fully close the ball valves and the closure and open again.The ball valves must run through the entire stroke trouble-free.

4.3.2 Pressure/leak tightness test

Only use mechanically clean water with an admixture of anti-corrosive agent as atest medium.

If no anti-corrosive agent is used, the pig launcher must be drained and dried asquickly as possible after the pressure test in order to avoid corrosion.

CAUTION

Risk of damage to pig launcher and ball valve!

Make sure to carry out the hydraulic pressure test with the ball valve closedand only with the maximum permissible internal design pressure PS!

The ball valve must be open when testing the system with test pressure PT!

Prerequisite

Close all installed ball valves before running the pressure/leak tightness test.

Procedure

1. Provide the pressure gauge connections with a manometer.

2. Close all drainage and venting connections.

3. Close the main connection ball valve for pressure relief ( Page 3-1, Fig. 3-1,item 9).

4. Use an expansion tube to fill the pig launcher with water and vent it via theventing connection.

5. Carry out the hydraulic pressure test. Drain the pig launcher subsequently.

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Operation

5 Operation

5.1 Safety instructions for operation

Comply with the safety instructions and protective measures specified in chapter2 as well as the applicable legal regulations. i

DANGER




CAUTION

Incorrect operation of the component can lead to damages or function changes!

Carry out all operational steps carefully.

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Operation / Operation

5.2 Operation

5.2.1 Inserting the pig into the pipeline

Procedure

1. Depressurize the pig launcher

2. Open the closure , observe the operation manual of the manufacturer!

3. Insert the pig.

4. Close the closure , observe the operationmanual of themanufacturer! Makesure the closure is actually closed!

5. Pressurize the pig launcher.

6. Move the pig into the pipeline.

5.2.2 Removing the pig from the pipeline

Procedure

1. Depressurize the pig launcher

2. Open the closure , observe the operation manual of the manufacturer!

3. Remove the pig.

4. Close the closure , observe the operationmanual of themanufacturer! Makesure the closure is actually closed!

5. Pressurize the pig launcher.

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Maintenance

6 Maintenance

CAUTION

Dangers to health and safety of operating andmaintenance personnel. Dangersto the environment.

Personnel can be harmed by external energy or stored energy. Escapinggaseous or liquid media can be harmful to personnel and the environment.

Life hazard in the case of escaping sour gas or sulphinic lye!

The safety instructions must be unconditionally observed!

For support in maintenance and optimization work, we recommend you contactthe Franz Schuck GmbH service department.

Franz Schuck GmbHDaimlerstraße 5 – 789555 SteinheimGERMANYPhone +49 (7329) 950-0Fax +49 (7329) 950-161

[email protected]

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Maintenance / Inspection

6.1 Inspection

6.1.1 Regular maintenance

6.1.1.1 Closure

please refer to the operation manual of the closure.

6.1.1.2 Ball valve

please refer to the operation manual of the ball valve.

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Maintenance / Repairs

6.2 Repairs

In principle, repair workmay only be carried out by the Franz Schuck GmbH serviceteam or by personnel trained by Franz Schuck GmbH.

This is the only way to ensure that repairs are carried out correctly using originalspare parts. This will maintain the validity of the warranty.

i

Observe the following instructions:

• If faults occur, immediately notify the Schuck service personnel in charge andtake appropriate measures

• Do not carry out work on pressurized systems, do not open the equipment

– De-pressurize system before starting work

• Do not remove any components during operation

– Turn off control pressure, control voltage and electricity

• Display warning signs that refer to the risks involved if the system is started upunintentionally or if the electricity or line pressure is switched on

• If there is damage or a defect, switch off the affected equipment and systems

• In the case of damage of any kind, stop work on the affected equipment andsystems

• After completion of work, check for correct function and if appropriate fulfilland comply with all technical guidelines

• Check that the optionally mounted accessories are functioning correctly

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Appendix

7 Appendix

7.1 Tightening sequence for flange bolts

The bolt numbers represent the order in which they should be tightened.

1

2

3

4

1

4

2

3

5

6

7

8

26

7

3

1

9

5

8

4

11 10

12

26

7

3

1 95

8

4 11

10

12

13

14

15

16

26

7

3

1

9

5

8

4

1110

12

13

14

15

16

17

18

19

20

26

7

3

1

9

5

8

4

11

10

12

13

14

15

16

17

18

19

20 21

22

23

24

25

26

27

28

2

6

7

3

1 9

5

8

4 11

10

12

13

14

15

16 17

18

19

20

21

22

23

24

4-HoleFlange

8-HoleFlange

12-HoleFlange

16-HoleFlange

20-HoleFlange

28-HoleFlange

24-HoleFlange

110nn010_en

Fig. 7-1 Tightening sequence for flange bolts

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Appendix / Conversion factors

7.2 Conversion factors

Value Unit Conversion unit Factor

mm in 0.03934

in mm 25.4

m ft 3.28084

Length

ft m 0.3048

kg lb 2.204622Weight

lb kg 0.453592

bar psi 14.5035

psi bar 0.06895

MPa psi 145.035

psi MPa 0.006895

bar MPa 0.1

Pressure

MPa bar 10

°C °F 1.8 °C + 32Temperature

°F °C (°F – 32) × 0.5556

cm3 in3 (cubic inch) 0.06102Volume

in3 (cubic inch) cm3 16.387

Nm Lbf-ft 0.737562Torque

Lbf-ft Nm 1.35582

Tab. 7-1 Conversion factors

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Appendix / Calculation formula to determine the carbon equivalent (CEV)

7.3 Calculation formula to determine the carbon equivalent (CEV)

To avoid an increased hardness in the weld junctions during welding, it is requiredto pre-heat the weld-on ends depending among others on the carbon equivalent.

7.3.1 Calculation formula (standard)

The calculation formula applies for steels of the following consistency:

• Carbon C: up to 0.22%

• ManganeseMn: up to 1.6%

• Chromium Cr: up to 1.0%

• Nickel Ni: up to 3.5%

• MolybdenumMo: up to 0.6%

• Copper Cu: up to 1.0%

The calculation formula for steels of the above-mentioned consistency is:

CEV = C +% Mo

4+

% Cr5

+% Mn

6+

% Ni15

+

% P

2+

% Si4

+% V

5+

% Cu13

%

Carbon Equivalent

Fig. 7-2 Steel consistency and the resulting calculation formula

Adjust the pre-heat temperature on an individual basis depending on carbon equiv-alent, welding consumable, product gauge, hydrogen content and heat input incompliance with the welding supervisor. iThe following temperature is recommended after determining the CEV value:

CEV [%] Recommended temperature for pre-heating [°C]

≤ 0.45 up to 100 °C

0.45 – 0.60 150 – 250 °CTab. 7-2 Recommended temperature for pre-heating

7.3.2 Calculation formula for steels with different consistencies

When using steels outside the above-mentioned consistency, adjust the heat inputin compliance with the welding supervisor on an individual basis.

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Appendix / Marking of packages

7.4 Marking of packages

7.4.1 Marking of packages according to DIN 55402 and ISO R 780

Overview

Marking of packages according to DIN 55402 and ISO R 780

Electrostatic sen-sitive device

Do NOT use forklift truck here

Sling here Tear off here

Use no hooks Clamp here This way up Centre of gravity

Do not destroybarrier

NO hand truckhere

Protect from heatand radioactivesources

Keep dry

Keep away fromheat

Fragile, Handlewith care

Stacking limita-tion

Temperature limi-tations

Tab. 7-3 Marking of packages according to DIN 55402 and ISO R 780

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Author:Fran

zSchuck

GmbH


Asof:2013-01-07

Revision:2013/01

Appendix / Marking of packages

7.4.2 Schuck symbols – transporting and unpacking packages

Overview

Schuck symbols – transporting and unpacking packages

Use edge protec-tors

Do not use chains Do not destroypipes

–

Tab. 7-4 Schuck symbols – transporting and unpacking packages

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