0

SC FEPA SA

BÂRLAD

API SPEC 6D

CE 1370-PED-H-FEP-001-09-ROM 6D-1123

INSTALLATION,OPERATION&MAINTENANCE

By-P By-Pass Style Pig Valve

SC FEPA SA

Str.REPUBLICII nr.316, Cod postal 731120, Bârlad-România Tel.+40 0235 411812 Fax +40 0235 421 618/0235 413729 e-mail: fepa@fepa.ro / marketing@fepa.ro

FIRE SAFE ! API 607 API 6FA

1

1.INTRODUCTION

The manual is designed to give the user complete information regarding installation, operation, adjustment, perform periodic inspections and maintenance of valves RSD-PIG type whose producer is FEPA Birlad.

READ THE INSTRUCTIONS CAREFULLY BEFORE INSTALLING AND

USING THE PRODUCT!

For any further information it is recommended to contact the manufacturer. User's responsibility to know all the information presented in this manual and the specific application for which it was purchased valve. It is also the responsibility of the user to use for installation, operation and maintenance only qualified and trained On request the valve manufacturer can provide training to its headquarters or beneficiary. The user is obliged to ensure all measures for safe operation, the health of staff, environment and function of the equipment. Before delivery valves are tested by the manufacturer. If the instructions are not clear, please contact us address SCFEPA SA str.Republicii nr.316cod 731120BÂRLAD, or fepa@fepa.ro. At www.fepa.ro can find other information about the products FEPA.

2.Applications and technical characteristics

By-Pass Pigging Valves are a special top entry pig valve designed to launch and receive pigs so pipelines remain clean and serviceable for the transportation of gas or liquid products. Periodic use of the pig ball valves leads to trouble-free scraping and eliminates the additional expense of hot oil treatments and extended downtime.

The By-Pass style pig ball valve provides continuous flow capability in all valve positions by isolating the pig chamber from the flow line, thereby not closing in the

flow line. It is utilized where pumps or flow cannot be interrupted during the pigging

operation. The By-Pass is built integrally into the valve body and provides 35% or

more flow capacity to minimize pressure drops during the pigging operation.

Large Size range available from 2" up to 40" . One Piece Body/Flange design to

ensure complete integrity throughout the valve body and flanges. By-Pass Pig Valves are field repairable and serviceable without the need for special tools.

2

3. Features include:

-One Piece Body/Flange design- In terms of constructive RSD-PIG valve is designed on the basic structure of a valve type RSD-BB (block and bleed ball valve product FEPA), keep all functional advantages offered by RSD-BB. The basic construction of a valve is 3/2, provided with a manhole additional side (the place where the insert / discharge scraper, and a grid on one output (with a role in stopping the pig)

-Blow-Out proof stem

-ANSI Class: 150 – 1500(PN 16-240 bar), contact us for higher pressures - The design according to-API 6D and EN1983 -Large Size range 2" up to 40",(DN50-DN1000)

-By-Pass Style eliminates the possibility of line over-pressurization when operating the valve

-Two bleed fittings are provided for venting pressure in the pig chamber before removing bonnet cap

-Virtually any material combination to suit most applications

-By-Pass Pig Valves are feld repairable and serviceable without the need for special tools -Working temperature:-60C ..80oC -Working environment: gas, petroleum products and derivatives. - Working environment specified in the recipient's request.

VALVES FOR USE A WORKING FLUID OTHER THAN THAT FOR WHICH IT WAS DESIGNED EXONERATE THE MANUFACTURER FROM ALL OBLIGATIONS AND LEADS TO WARRANTY LOSS! VALVES FOR USE A WORKING FLUID OTHER THAN THAT FOR WHICH IT WAS DESIGNED EXONERATE THE MANUFACTURER FROM ALL OBLIGATIONS AND LEADS TO WARRANTY LOSS! -Sphere "full bore" -Mounting trunnion -Double block and bleed in opened and closed position -antistatic device -Fire safe construction -Purge and vent fitted with ball valves -Exchange-pressure shaft seal -Paste-injection system to obturator and shaft seal -The manhole (for launch and receipt Pig) with a lid (equipped with vent valve) -Pig stopping-sieve (catcher)

3

4. Operating Procedures

Our By-Pass pig valves may be converted from launcher to receiver or vice versa simply by rotating the valve 180 degrees from vertical. Please follow the guidelines for installing valves contained in the IOM

Launching

The launching valve is installed in the flow line with the pig chamber facing vertically upward within a maximum of 20 degrees vertical.(fig.1)

Fig.1 1. Turn off the valve. 2. It will relieve pressure vent valve located on the lid.

ATTENTION! -Check performed a full cavity depressurization valve then closes the vent valve.If decompression was not performed cooerect will resume operation from Step 1. 3. Slowly opens the lid. 4. Insert Pig-WARNING!-Pig launches downstream. 5. Close the lid, check that the vent valve is closed. 6.Opens the pressure equalization valve in Pig´s chamber 7. Open the valve

Open vent fitting to Remove cap and Replace cap and Rotate ball as Close equalizing valve vent pig chamber. load pig into cham- open equalizing shown so the pig and rotate ball as Close vent fitting. ber. valve. drops into the ball. shown. Pig is launched

downstream.

4

Receiving The receiving valve is installed in the flow line with the pig chamber facing vertically downward within a maximum of 20 degrees vertical.(Fig.2)

Fig.2 The valve will be prepared for extraction after Pig was stopped

1. Turn off the valve. 2.

2Should be made depressurization vent valve located on lid

.

ATTENTION! -Check performed a full cavity depressurization valve then closes the vent valve.If decompression was not performed cooerect will resume operation from Step 1. 3. Slowly opens the lid. 4. Remove Pig and make a careful cleaning of the valve cavity. 5. Close the lid, check that the vent valve is closed. 6. Open the valve

LOCAL OPERATING INSTRUCTIONS PIG -ALLOWED ACCESS For this position: Stopper (retainer) in LEFT Rotate the handwheel in clockwise Stopper in RIGT Rotate the handwheel in counterclockwise

Turn only the equalization valve open ! Turn only the venting valve close !

After pig is received open equalizing valve.

Rotate ball as shown. Pig drops into cap. Close equalizing Valve.

Rotate ball as shown. Open vent fitting and vent chamber. Close vent fitting.

Remove cap care-fully and remove pig and debris.

Replace cap. Valve is ready to receive the next pig.

5

PIG- DENIED ACCESS For this position: Stopper (retainer) in LEFT Rotate the handwheel in counterclockwise Stopper in RIGT Rotate the handwheel in clockwise

Turn only the equalization valve open ! Turn only the venting valve close ! OPEN PROCEDURE 1.Close the equalization valve(1) 2. Open the venting valve(2) 3.Turn the wrench(3)counterclockwise

6

4.Turn the handwheel counterclokwise (pull off the lid) 5.Pull off the lock bolt 6.Open the PIG lid. Free acces to PIG

CLOSING PROCEDURE 1.Close the cover and secure locking pin (5)

7

2Turn the handwhell clockwise(4) for insert the lid.

3.Turn the wrench (3)clockwise for close the lid

4.Close the venting valve(2) and lock the lid rotation

8

5.Open the equalization valve(1) CAUTION ! The valve operates only the equalization valve OPEN ! The valves operates only the venting valve CLOSE! Every opening the lid lubricating the seal and the metal surfaces with Molycote33(extreme low temperature) or other similarly product ! 5. Corrosion protection - high-strength epoxy.

6. Actuation - manual lever including up to NPS4”(DN100) / NPS4”(DN 100) with gear over

7.. Tests - Products are tested by the manufacturer - Test pressure and loss rates are allowable according to SR EN12266 (without losses) / API598/API6D

8. Identification

Each valve is provided with label (identification card) that includes: Depending on the requirements of the technical specification of the beneficiary may appear on the nameplate - CE, API 6D no. License / marking fire test API607 or API 6FA

9. Codification -Coding PIG VALVE type is presented in the general product specification 840/2009

10. Packing, transport, storage, Packing Each valve must be drained of fluid test. The ends of the body must be covered to prevent foreign bodies and moisture-protective covers are removed only when installing.

9

The valves are delivered with the obturator in the open position.! Products are delivered on a support of timber. Storage. Valve must be stored packed in closed rooms free of dust or corrosive agents, fungi or mold.

11. INSTALLATION INSTRUCTIONS Handling

Because of physical dimensions and heavy equipment will be used properly and lifting methods for transport, storage and installation. -valve are furnished in open position ,in order to minimize the effect of mechanical loads and impurities on seats,gaskets,and other pressure parts. Before handling the valve,verify it is open position.lift valve with sling suitable for its weight. Never use lever,actuatoror gear operator to lift the valve.

Installation

ALL OPERATIONS OF ASSEMBLY SHALL BE WITH QUALIFIED PERSONNEL AND OPERATION CHECKS WILL BE DONE BY SPECIALISTS

- After being removed from the container in which they were transported and stored, valves protections are removed from the connection ends. - Check that the product coincides with the inscriptions on the label and control - Check valve is not defective., impurities inside. - Assembly is only fully open valve - check that there are no foreign bodies pipes before installation will be clean, prepare piping. - Check that the seat-seal both good safety work permit upstream downstream. -Install the valve in the system using the proper size and type mating flanges and Ring Type Gaskets. The Launch/Receive direction and Catcher Side is noted on the Cover of the Pig chamber. The valve orientation is dependent on whether the valve will be used as a Receiver or a Launcher.

10

Never hold or lift the valve by the Gear Operator. Use the flange bolt holes or put straps between the flanges and the bonnet around the valve body. The valve is not balanced and care should be taken when lifting to prevent the valve from shifting or spinning around. Use proper lifting equipment and techniques.

After the valve is installed, ensure it is in proper working condition. The gear operator is set at the factory. Before applying pressure to the valve verify that the ball is in the open position .Verify that the Equalization valve is closed. Verify that the bleed fittings are closed. Verify that the Closure is screwed down tight ( a few light knocks on the closure lugs with a striking hammer should be sufficient). Rotate the ball by turning the Gear hand wheel. Counterclockwise to accept or discharge a pig and clockwise to launch or Receive. - make sure that the conditions of: a. Lateral alignment-misalignment: max 2mm flange ptr.NPS 4”(DN100) including - 3mm misalignment flange ptr: max. Rob. higherNPS 4” (DN100) b. Alignment angle-difference max. Measured between flanges max 2.5mm c. Max total misalignment. ptr allowable holes. org. assembly -2mm flange misalignment: max ptr.NPS 4”(DN100) including - 3mm misalignment flange ptr: max. Rob. higherNPS4”( DN100) - grease the bolt and nuts to get a correct bolt load. - Tighten the screws criss-cross (to avoid uneven loading gaskets and flanges)

12. INSTRUCTIONS FOR USE AND MAINTENANCE

Reconditioning Valve Checking and changing the shaft seal Fig3. after observing the above caution, disassembly may begin.: Step 1: Before removing the gear, rotate the ball so the flow bore is inline with the pipeline. Remove the gear assembly. Step 2: Remove the gland (stem) bolts (10) and slide the gland(stem) (11) off the Step 3: clean,checking and changing and grease the shaft seal (grafoil gasket -14 and Chevron seal-16)

To rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it on all seals. Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions. Step 1: Place the spring(6) first,than the plate(17). Step 2: Place the Chevron seal(16),than the stainless steel ring(15) Step 3: Place the grafoil gasket (14),than slide the gland(11) and fixed with bolts(10) Step 4: Install the gear assembly as requierd the gear installation instructions.

Make sure all bolts and nuts are tightened securely. Make sure all bleed fittings and the equalizer valve are installed properly. Rotate the ball to verify its operation. Because of construction anti blow-out proof stem shaft seal can be changed when the valve is under pressure.

11

Fig.3

By-Pass Style Pig Valves may be rebuilt to new condition without removing the valve from the pipeline. We recommend removing valves from the piping if they are upside down and used for receiving. Standard shop tools and lifting equipment required. FEPA SA is not responsible for improper assembly or disassembly including injury, wrong materials, bad repair practices or other unforeseen actions. Consult the factory prior to working on any valve. Caution! Prior to disassembly, valve must first be isolated from system pressure and flow. Also, with the valve ball at approximately half open, internal pressure must be bled to 0 bari. Finally, as a safety precaution open bleed fittings and equalizer valve . Use proper lifting equipment and tools when disassembling the valve. Valve components are heavy and care must be exercised when handling components Checking and changing the seat seal Fig4 after observing the above caution, disassembly may begin.:

.

Step 1: Remove the cover of pig chamber

Step 2: Remove the body nuts (33) and lift the bonnet/closure (32) off the body (30) caution the seat (25)/seat carrier (26) is in the bottom of the bonnet and may slip out.

12

Step 3: Before removing the gear, rotate the ball (1) so the flow bore is inline with the pipeline. Remove the gear assembly following the gear removal instructions Step 4: Remove the bonnet (stem) bolts (10) and slide the bonnet (stem) (11) off the stem (12). Slide the stem out of the bonnet. Step 5: The ball (1) may now be removed. Use a heavy duty nylon type strap through the ball port to lift the ball carefully out of the body cavity. Be careful not to bang the ball as you remove it.

Step 6: Remove the bottom seat (25) and seat carrier (26) from the bottom of the valve body. Remove the spring (22) from the bottom of the body. Clean all surfaces and inspect for damage.

If the equalizer valve or fittings need to be replaced, they may be removed at any time during the procedure.

At this point, all seals are readily accessible on the various components. Make sure all seals are removed and inspected prior to re-building the valve. Replace any seals that are damaged or worn

Rebuilding Valve

To rebuild the valve, first make sure all seals are in good working condition. Have grease lubricant handy and use it on all seals. Caution: Make sure any lubricant is compatible with the Seals and the intended valve service conditions. To rebuild the valve just reverse the instructions above. Install all o-rings and seals on the various components according to the assembly drawing.

Step 1: Place the spring first then the seat carrier (no O-ring required on OD) then seat then ball in the body cavity. Align the ball stem slot with the bonnet/stem bore to aid in inserting the stem.

Step 2: Put the other seat carrier in the bonnet/closure (this seat carrier uses the o-ring on the OD). The o-ring will hold the seat carrier in the bonnet. Install the seat

in the seat carrier (applying grease to the seat usually holds the seat in the carrier).

Step 3: Slide the bonnet/closure over the body studs and down onto the body. Make sure to align the bleed fittings and equalizer valve according to the assembly drawing. Install the nuts and tighten to bring the bonnet down onto the body.

Step 4: Push the stem and bonnet/stem as a group into the body and into the ball

slot. Use the bonnet bolts to bring the bonnet down onto the body. Step 5: Install the closure.

Step 6: Install the gear assembly as required using the gear installation instructions.

Make sure all bolts and nuts are tightened securely. Make sure all bleed fittings and the equalizer valve are installed properly. Rotate the ball to verify its operation. Unscrew the closure and lift the davit to verify they are in proper working condition (see launching and receiving instructions for this). Test the valve prior to using in service.

13

Fig.4

IS FORBIDDEN MAKING ACTUATION BEFORE CLEANING VALVES THAT ROUTE! Working fluid temperature must not exceed the minimum / maximum inscribed on the body or on its label. Working with the valves do not require specially qualified personnel. Where it is installed must meet environmental conditions imposed by the materials in valves

14

During venting flammable gases can be released! -make sure that it is removing any source of fire. Make sure the drain valve does not affect the operator.

Never attempt to open the PURGE AND / OR vent VALVE WHILE valve is in the partially open!. Valves are equipped with sealant injection system and the shaft sealing area, it provide additional emergency cases with damaged sealing surfaces. The use of a suitable injection device and only in emergencies! Valve position works in close / open operation is permitted in a position partially open / closed. The manually operated valves: -closure is done by turning clockwise 90 ˚. Do not use bars, pipes, keys or other devices for amplifying lever or wheel torque-handling can cause injury and damage to the valve. It will regularly check valve operation. The manufacturer is not responsible if the valve is not used and maintained properly!

Any violation of instructions will void the warranty 13. HEALTH, SAFETY, ENVIRONMENT

- products are designed, manufactured, tested and equipped in the system if necessary, so as to guarantee safety of the user and the environment. - the installation shall comply with all applicable law labor protection - will wear all required personal protective equipment - do not usethe valve than the designed parameters -beneficiary will not make changes without consulting the manufacturer / or if the manufacturer recommends - please check before installation if there reglementaride environmental, safety or other restricting use of the product. - Please firstly return to repair products that have circulated hazardous fluids decontaminated them .. Also any faucet returned must be accompanied by minimal information regarding the conditions of use, changes in the product, operations decontamination and / or cleaning fluid and safety data sheet - used packaging and waste from the retirement harness the special without regulatory requirements. Totusi please consider conditions of use of the product and to indicate the applicable legislation and packaging equipment.

15

14. MATERIAL The material will be chosen according to the conditions imposed by the data sheet (needs beneficiary) in compliance with the essential requirements European Directive (EC)-harmonized standard and / or requirements As the American Petroleum Institute (API6D)

SPARE PARTS for PIG VALVE

16

Nr pcs DN200 DN250 DN300 DN350 1 1 O-ringØ307x7 O-ringØ387x7 O-ringØ456.06x7 O-ringØ494.16x7

2 1 Ø352x Ø328

#3,2

Ø424.5xØ406.5#3,2 Ø501x Ø484

#3,2

Ø541x Ø524#3,2

3 1 OringØ230x3.55 OringØ290x3.55 OringØ354.97x5.33 OringØ380.37x5.33

4 2 OringØ215,27x5.33 OringØ266.07x5.33 OringØ304.17x5.33 OringØ329.57x5.33

5 2 O-ringØ224x7 O-ringØ278,77x7 O-ringØ329,57x7 O-ringØ367,67x7

6 2 9520DU Ø100xØ95

9020DU Ø95xØ90

12025DU 3825.3213

17025DU 3825.3208

7 1 WC102DU Ø118xØ104

WC194DU Ø120xØ96

WC133DU 3825.3212

WC183DU 3825.3209

8 2 OringØ118x5.33 OringØ128x5.33 OringØ148.59x7 OringØ196.22x7

9 1 Ø148x Ø135

#3,2

Ø157.6x Ø145

#3,2

Ø191x Ø176

#3,2

Ø241x Ø226 #3,2

10 2 5520DU Ø60xØ55

6020DU Ø65xØ60

7525DU 3825.3214

8520DU 3825.3210

11 1 WC60DU Ø90xØ62

WC60DU Ø90xØ62

WC73DU 3825.3215

WC83DU 3825.3211

12 1 Pack CHEVRON Pack CHEVRON Pack CHEVRON Pack CHEVRON 13 1 3825.3175 3825.3252 3825.3171 3825.3164 14 1 3825.3218 3825.3373 3825.3220 3825.3221 15 2 Ø324x Ø225

#3,2

Ø388x Ø279 #3,2 Ø458x Ø330

#3,2

Ø520.7xØ356.6#3,2

Manufacturer recommends to replace ,every intervention the next parts- 2;4;5;9;12; 14; 15.

SC FEPA SA Str.REPUBLICII nr.316, Cod postal 731120, Bârlad-România

17

Tel.+40 0235 411812 Fax +40 0235 421 618/0235 413729 e-mail: fepa@fepa.ro / marketing@fepa.ro