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HV 215
Installation Instructions 818480-01
Contents
Page
Important Notes
Usage for the intended purpose................................................................................................................................... 8
Safety notes................................................................................................................................................................ 8
Danger........................................................................................................................................................................ 8
Legal regulations......................................................................................................................................................... 9
Explanatory Notes
Scope of supply......................................................................................................................................................... 10
Description................................................................................................................................................................ 10
Function.................................................................................................................................................................... 11
Technical data..................................................................................................................................................... 11, 12
Fluid list............................................................................................................................................................... 13, 14
Installation
Hydraulic loading & unloading system HV 215........................................................................................................... 15
Mounting flange................................................................................................................................................... 15, 16
Bottom valve HWV 205/1 - DN 80.......................................................................................................................17 - 19
Bottom valve HWV 215/1 - DN 80.......................................................................................................................20 - 23
Cable routing............................................................................................................................................................. 24
Operating device BV 110........................................................................................................................................... 25
Connecting lines.................................................................................................................................................. 26, 28
Attaching operating plates HV 215............................................................................................................................. 29
Attaching list indicating fluids.................................................................................................................................... 29
Filling and venting of hydraulic system....................................................................................................................... 30
Filling and venting of hydraulic actuating system....................................................................................................... 30
Filling and venting of hydraulic indicating system...................................................................................................... 31
Performance test....................................................................................................................................................... 31
Operation
Service...................................................................................................................................................................... 32
Emergency operation................................................................................................................................................. 33
Maintenance
Bottom valves HWV 205/1 - DN 80 / HWV 215/1 - DN 80........................................................................................... 34
Operating device BV 110............................................................................................................................................ 35
Connecting lines........................................................................................................................................................ 35
Contents
continued
Page
Servicing
Hydraulic loading & unloading system HV 215........................................................................................................... 36
Replacing valve plug seal....................................................................................................................................36 - 38
Reworking seat flange............................................................................................................................................... 39
Replacing gaskets of actuacting cylinder............................................................................................................. 40, 41
Replacing control unit of bottom valve....................................................................................................................... 42
Components
HWV 205/1
HWV 215/1
BV 110
G
Y
Y
P
E
W
V
F
F
L G RP
K
K
F
B
closed
U
K
N
O
Q
S
S
Key
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
Shut-off valves
Actuating cylinder
Rail hook
Ring
Operating devices
Pump lever of hydraulic hand pump
Line leading to the indicating cylinder of the gas phase
Indicating cylinder
Filling connection
Sealing plug
Screw for sealing off opening for emergency unloading
Line leading to the indicating cylinder of the liquid phase
Bolt for operating device
Plate showing valve position of indicating pistons
Indicating pistons
Pressure line
Screw-in plug for venting facility
Return line
Screw for oil filling connection (with dip stick)
Hydraulic hand pump
Non-return valve
Transverse pipe-run
Frame
Control unit
Guide bushing
Fluid list
Valve head
Body
1
2
3
4
5
6
7
8
f
e
31
ji
hg
d
c
b
a
=
)
(
/
Actuating cylinder
0
!
"
$
% &
Key
1
2
3
4
5
6
7
8
9
0
!
"
$
%
&
/
(
)
=
a
b
c
d
e
f
g
h
i
j
31
Important Notes
Usage for the intended purpose
The hydraulically operated loading and unloading system HV 215 is intended solely for filling and draining stationary
and mobile tanks containing pressure liquefied gases.
Its use is permissible only within the allowable pressure and temperature ratings and only if the chemical and
corrosive influences on the equipment are taken into account. Before installing the equipment make sure that the
loading & unloading system is suitable for the intended application and the fluid to be used (corrosion resistance
and chemical suitability).
Modifications to the design may only be made if the manufacturers written permission is obtained.
Any type of use differing from the usage described above must be considered as improper. The resulting risk will
have to be borne by the user alone. The manufacturer hereby expressly rejects any claims for any resulting damage.
The use of external pumps for opening or closing the bottom valves is not permitted.
Safety notes
The loading and unloading system must not be installed or commissioned by anyone other than qualified staff.
Maintenance and service work must only be performed by adequately trained persons who have a recognised
level of competence.
For installation, removal, commissioning, operation and maintenance, every person who works with the loading and
unloading system must have read and understood the complete installation manual. Furthermore, responsibilities
must have been defined clearly and unambiguously and must be adhered to.
The operating company must ensure that, whenever the loading and unloading system is being operated, it is in
perfect condition.
Attention
Working methods that jeopardise safety must not be used!
Danger
If the loading and unloading system is used in an inexpert or improper manner by unqualified staff, it can cause
danger to life and limb for the user or for third parties, possibly resulting in death.
During operation, the bottom valves of the loaded and unloaded tanks are under pressure. During the loading and
unloading procedure all other components are also under pressure. In this condition, screws as well as nuts and
bolts of the loading and unloading system must not be slackened. Liquid or vaporizing fluids might escape and
could cause severe cases of poisoning and environmental pollution.
During the loading and unloading procedure do not leave the installation unattended.
The shut-off valves might be cold during the loading and unloading procedure. Make sure that the operator wears
protective gloves when operating the handwheels.
Any installation or removal work may only be performed when the tank is at zero pressure and completely free of gas.
When carrying out installation and maintenance work, make sure that the tank cannot be operated accidentally.
Important Notes
continued
Warning
Any use of naked flames is expressly forbidden!
Before perfomring any service work inside the tank make sure that the tank is sufficiently ventilated
and all gases have been completely vented. The rules concerning MAC (= maximum allowable
concentration) values at place of work must be strictly applied!
Legal regulations
The configuration of the loading and unloading system HV 215 mounted to the tank car carrying pressurized
gas meets the requirements of DIN 26026 or of EN 12561-3.
The bottom valves HWV 205/1- DN 80 and HWV 215/1- DN 80 fulfill the legal requirements of the RID / GGVSE section 6, constituting the first inner shut-off as defined in these regulations.
Explanatory Notes
Scope of supply
1 Bottom valve HWV 205/1 - DN 80
1 Bottom valve HWV 215/1 - DN 80 with tension rope
2 Hydraulic operating devices BV 110
2 Operating plates HV 215
2 Plates indicating fluids (only for bottom valves with valve plug seal made of CR)
1 Installation manual for loading & unloading system HV 215
1 Set of acceptance certificates
The following items are not scope of the supply but can be ordered separately:
1 Set of connecting lines as accessory kit
4 Shut-off valves DN 80
2 Valve mounting flanges
Description
The hydraulically operated loading and unloading system HV 215 is designed for filling and draining stationary
and mobile tanks containing pressure liquefied gases.
It is mainly used in tank cars carrying pressurized gases. These tank cars (TC) require a high degree of reliability,
ease of operation and maintenance and a long service life of the associated valves.
The loading and unloading system consists of the two rapid-action bottom valves, the two operating devices, the
shut-off valves, the rail hook and the tension rope. The connecting lines required for operating the loading and
unloading system are either made of hydraulic tubes and hydraulic hoses or entirely of hydraulic hoses.
The bottom valves type HWV 205/1 - DN 80 and type HWV 215/1 - DN 80 (with control unit) are designed for
installation in the valve-mounting flanges located at the bottom of the vessel. Both bottom valves are always
opened or closed together. A manifold connects the bottom valves directly with the shut-off valves. Both valves
can either be used for the liquid phase or the gas phase.
The operating devices consist of a hydraulic hand pump and one indicating piston for the liquid phase and one
for the gas phase. They are attached to the left and right hand side of the tank car, which means that the bottom
valves can be opened from either side of the tank car by actuating the respective operating device.
During the loading/unloading process the rail hook connected to the tension rope keeps the bottom valves in the
open position. In the event of an emergency, e. g. emergency shut-off or inadvertent moving of the tank car, the
rail hook is disengaged from the rail and the bottom valves close instantaneously (rapid-action closing).
10
Explanatory Notes
continued
Function
The loading and unloading system HV 215 is designed for filling and draining tanks that contain pressure-
liquefied gases.
One bottom valve opens for the liquid phase and the other opens for the gas phase. Both opening processes
always take place simultaneously.
The operating device of the tension rope (e. g. rail hook VZ 10) engaged to one of the rails provides the required
tension of the rope. This tension keeps the ball valve of the control unit of the hydraulic system closed.
The hydraulic hand pump of the operating device BV 110 can then be used to apply pressure to the hydraulic
system. The pressure acts on the actuating cylinders of the bottom valves, forcing the piston to go up and thereby
causing the bottom valves to open.
The current lift position of both bottom valves is indicated separately by the indicating cylinders of the operating
device BV 110.
When the rail hook is disengaged, i. e. when the load on the tension rope is reduced, the hydraulic system opens,
leading to the rapid-action closing of the bottom valves within less than 1 second.
The non-return valve integrated in the operating device BV 110 prevents the premature closing of the bottom
valves caused by leaking fluids in the hydraulic hand pump and the pressure-reducing valve.
Technical data
Attention
For pressure / temperature ratings of the bottom valves see name plate.
Name plate drawing
GESTRA HWV
T. AGG.
Type approval
Manu.-no.:
Ptest : 37.5bar
T min. : - 50C valve plug seal PTFE
Test pressure
MADE BY GESTRA
11
Explanatory Notes
Technical data
continued
continued
37.5
40 to + 50
50 to + 50
322 30
> 21.2
Drag coefficient
Item no.
b
$
7
e
f
3
4
0
68!
31
c
()
5
Weight [kg]
12
Loading
Unloading
3.3
2.8
Component
Material
Body
1.0566
A2-70 or A4-70
A2-70
Seat flange
1.4571
Valve plug
1.4571
Compression spring
1.4310
Spring plate
1.4301
Stay bolt
1.4301
Bellows, complete
Gasket
PTFE
PTFE or CR
A2-70
O-ring
NBR 70 Shore
Sleeve
1.4313
HWV 205/1
HWV 215/1
BV 110
Body
20
20
Valve head
Hydraulic actuator
Control unit
Total
36
39
2 x 16
Explanatory Notes
continued
Fluid list
Class
Classification
code
UN No.
Valve plug
seal CR down
to
Propane
2F
1978
Butane
2F
1011
Propene
2F
1077
Butene-1
2F
1012
Butadiene-1.3
2F
1010
Ammonia
2TC
1005
Ethyl chloride
2F
1037
Methyl chloride
2F
1063
Vinyl chloride
2F
1086
Gas R12
2A
1028
Gas R21
2A
1029
Gas R22
2A
1018
Gas R114
2A
1958
Gas R115
2A
1020
Gas R12 B1
2A
1974
Methyl bromide
2T
1062
2F
1061
2F
1032
2F
1083
2F
1036
Hexafluoropropylene R1216
2A
1858
Dimethyl ether
2F
1033
Chlorotrifluoroethane R133a
2A
1983
2TF
1040
2TF
1040
Mixture F1
2A
1078
Mixture F2
2A
1078
Mixture P1
2F
1060
Media
13
Explanatory Notes
Fluid list
continued
continued
UN No.
Valve plug
seal CR down
to
2F
1965
2F
1965
Mixture A1
2F
1965
Mixture B
2F
1965
2F
1965
2F
1010
Iso butane
2F
1969
Iso butene
2F
1055
Cis -2-butene
2F
1012
Trans -2-butene
2F
1012
Cyclopropane
2F
1027
2A
2602
2A
1973
Carbon dioxide
3A
2187
Ethylene
3F
1038
Class
Classification
code
Media
14
Installation
Hydraulic loading & unloading system HV 215
We highly recommend that only qualified staff should carry out installation work in accordance with these
installation instructions. The manufacturer expressly rejects any claims for damage caused by improper installation.
All parts to be fitted must meet the technical requirements specified by the manufacturer. All genuine parts are
guaranteed to comply with these requirements.
For installation work choose lifting devices that are specified for the respective weights. Use only suitable and
proper lifting devices.
When welding observe legal regulations and in-house guidelines concerning welded connections. Before welding
clean all spots to be welded.
Make sure that the gaskets of the flanged connections are exactly placed between the flanges. Clean all seating
surfaces before installing the equipment.
Before installing the valves remove the transport packing and all transit protection plugs for end connections.
Install the equipment in the following order:
n Mounting flanges
n Bottom valve HWV 205/1 - DN 80
n Bottom valve HWV 215/1 - DN 80
n Cable routing
n Operating devices BV 110
n Connecting lines
n Attaching operating plates HV 215
n Attaching plates indicating fluids
Mounting flange
The mounting flanges for bottom valves type HWV 205/1 - DN 80 and HWV 215/1 - DN 80 have the same
form and can be installed in the same way.
They are not scope of supply of the loading & unloading system HV 215 but can be ordered from Gestra.
Valve mounting flanges made from the following materials are available:
n P355NL1 (1.0566, old: TStE 355)
n S420NL (1.8912, old: TStE 420)
n P460NL1 (1.8915, old: TStE 460)
Further materials are available on request.
Gestra supplies valve mounting flanges with a standard diameter of 430+6 mm. To avoid a wall thickness
misalignment between the valve mounting flange and the tank wall, adjust the outside diameter D to the
thickness S of the tank car (see drawing on page 16). Make sure that the weld joint produced is in compliance
with the specifications of the tank manufacturer.
The valve mounting flanges are welded into the bottom of the vessel according to the specifications of the
local welding authority.
To calculate the dimensions of the pressure vessel to AD-B1/ B9, refer to the drawing ( see page 16) in which
the dimensions of the reinforcement are indicated.
15
Installation
Mounting flange
continued
continued
Attention
After the annealing process check the seating surfaces and, if necessary, clean, rework or cut them.
The reference dimension S varies as a function of the drop forging tolerance and must be
compensated for by the diameter D of the valve mounting flange.
Reference dimension varies as a function of the drop forging tolerance
430 +6
+4.3
-1.6
10
32
16
35
+4.3
-1.6
D
365
155
Installation
continued
17
Installation
continued
continued
After the valve head install the body with the actuating cylinder.
The assembly parts of the valve body comprise:
n 1 Gasket 125
n 6 Hexagon head cap screws M16 x 140
n 1 Gasket (spare part for replacement)
The body is supplied together with the actuating cylinder as a complete component part.
See drawings on page 4 and page 19
1. First weld the manifold to the body, taking the specifications of the local welding authority into account. The body
end is sized for a pipe having an outside diameter of 88.9 mm. To weld the manifold it might be necessary to
remove the actuating cylinder B from the body. For this purpose unscrew the hexagon head cap screws $ and
carefully push the actuating cylinder B downwards. Remove the gasket !. Do not re-use this gasket! Insert the
supplied spare gasket !.
2. Check the torque (50 Nm) required for tightening the hexagon head cap screws $. If the actuating cylinder B
has been removed, tighten the hexagon head cap screws $ with a torque of 50 Nm. Apply a commerically
available lubricant to the screws and tighten them in several steps in diagonally opposite pairs.
3. Then check the lift of the push rod 9 in the body with actuating cylinder B. For this purpose measure the
reference dimension 2 and 3 (see page 19) from the upper edge of the push rod 9 to the sealing surface of the
unloaded bellows 0 and to the lower stop of the bellows 0. If the distance exceeds the admissible tolerance,
check the push rod 9 for smooth operation. If the push rod is jammed, first eliminate the cause and then gently
knock with your hand against the push rod 9 until it can move freely. If you cannot find a fault please contact our
Technical Services in your country, stating the GESTRA manufacturing number.
4. Insert the supplied gasket 8 in the bottom of the valve head and use the hexagon head cap screws b to screw
the body to the mounting flange, applying a torque of 120 Nm. Apply a commerically available lubricant to the
screws and tighten them in several steps in diagonally opposite pairs.
Attention
Make sure that welding and, if necessary, annealing work does not damage the seals and gaskets!
Check and, if necessary, clean sealing surfaces.
Always replace gasket when removing the actuating cylinder.
The specified torques must be strictly observed.
Note: Do not use the push rod 9 as handle!
18
Installation
continued
continued
210 / 12 x M16
146
M12
116.5
,
78
e
6
6
31
c Torque 120 Nm
turned through 15
292
0
!
Manifold
88.9
b Torque 120 Nm
turned
through 90
32 turned through 90
$ Torque 50 Nm
112
turned through 45
Reference dimension 2
on body with actuating cylinder
(bellows unloaded)
Reference dimension 3
on body with actuating cylinder
(bellows at lower stop)
16 +9
71
11
Reference dimension 1
on valve head
19
Installation
continued
20
Installation
continued
continued
After the valve head install the body with the actuating cylinder.
The assembly parts of the valve body comprise:
n 1 Gasket 125
n 6 Hexagon head cap screws M16 x 140
n 1 Gasket (spare part for replacement)
The body is supplied together with the actuating cylinder as a complete component part.
See drawings on page 4 and page 23
1. First weld the manifold to the body, taking the specifications of the local welding authority into account. The body
end is sized for a pipe having an outside diameter of 88.9 mm. To weld the manifold it might be necessary to
remove the actuating cylinder B from the body. For this purpose unscrew the hexagon head cap screws $ and
carefully push the actuating cylinder B downwards. Remove the gasket !. Do not re-use this gasket! Insert the
supplied spare gasket !.
2. Check the torque (50 Nm) required for tightening the hexagon head cap screws $. If the actuating cylinder B
has been removed, tighten the hexagon head cap screws $ with a torque of 50 Nm. Apply a commerically
available lubricant to the screws and tighten them in several steps in diagonally opposite pairs.
3. Then check the lift of the push rod 9 in the body with actuating cylinder B. For this purpose measure the
reference dimension 2 and 3 (see page 23) from the upper edge of the push rod 9 to the sealing surface of the
unloaded bellows 0 and to the lower stop of the bellows 0. If the distance exceeds the admissible tolerance,
check the push rod 9 for smooth operation. If the push rod is jammed, first eliminate the cause and then gently
knock with your hand against the push rod 9 until it can move freely. If you cannot find a fault please contact our
Technical Services in your country, stating the GESTRA manufacturing number.
4. Insert the supplied gasket 8 in the bottom of the valve head and use the hexagon head cap screws b to screw
the body to the mounting flange, applying a torque of 120 Nm. Apply a commerically available lubricant to the
screws and tighten them in several steps in diagonally opposite pairs.
42
5. Engage the loop of the tension spring of
the control unit X to the hexagon head cap screw b.
Attention
Make sure that welding and, if necessary, annealing work does not damage the seals and gaskets!
Check and, if necessary, clean sealing surfaces.
Always replace gasket when removing the actuating cylinder.
The specified torques must be strictly observed.
21
Installation
continued
continued
22
Installation
continued
continued
210 / 12 x M16
146
M12
c Torque 120 Nm
116.5
78
e
6
6
turned through 15
31
42 41
8
292
! 0
Manifold
88.9
33
b Torque 120 Nm
35 36 37 38 39 40
34 Torque 120 Nm
32 turned through 90
112
turned through 90
$ Torque 50 Nm
turned through 45
Reference dimension 2 on
body with actuating cylinder
(bellows unloaded)
Reference dimension 3 on
body with actuating cylinder
(bellows at lower stop)
16 9
71
11
Reference dimension 1
on valve head
23
Installation
continued
Cable routing
Provide tank car with a guide sleeve Y for the tension rope.
The position of the guide sleeve Y must enable the tension rope to leave the control unit X of the bottom valve
at an angle of 45.
See drawing on page 4
1. The tension rope supplied by the manufacturer is 1500 mm long and must be cut to the required length.
2. To connect the tension rope with the rail hook C or the tension rope operating device, provide the tension
rope with a ring D according to DIN 26026.
Note that this ring D is not scope of the GESTRA supply!
Use the supplied wire clamp to attach the ring D. Fasten the screws of the wire clamp with a torque of 2 Nm.
520
270
Attention
Do not pass the tension rope over sharp edges.
The lay-out of the tension rope, the guide sleeve Y and the ring D for attaching the tension rope
operating device must comply with DIN 26026 and EN 12561-3.
24
Installation
continued
32
270
200
25
13
384
260
Attention
The hand lever supplied by Gestra protrudes approx. 300 mm out of the rear wall of the body
when the flap is closed.
If necessary you can shorten the hand level by max.150 mm.
If the welding process has affected the coat of paint, make sure that the damaged paintwork
is repaired.
25
Installation
continued
Connecting lines
The connecting lines have different lengths due to the different dimensions of the vessels or tanks. Use the table on
page 28 to ascertain the required lengths.
Hydraulic tubes in combination with hydraulic hoses or only hydraulic hoses can be used as connecting lines.
The specific lay-out of the connecting lines depends on the design of the tank car.
See drawings on page 4 and page 28
1. For one possible arrangement weld a transverse pipe-run V (sectional steel, e. g. L-type steel to EN 10056 -1
with dimensions 100 x 50 x 6 mm) between the two frames W of the operating device E.
In this case you can provide a recess at the left side of the transverse support V for the installation of the
hydraulic lines without any kinks.
The requirements and specifications of the local welding authority must be observed.
2. The length and form of the hydraulic tubes have to be matched to the transverse pipe-run V. Install the hydraulic
tubes at the inside (the side facing the bottom valves) of the transverse pipe-run V. The transverse pipe-run V
can then also protect the tubes.
g
3. Use pipe clamps to
fix the hydraulic tubes to the tansverse pipe-run V.
4. To connect the lines to the longitudinal pipe-run use T-type screw joints a .
5. For a flexible connection between the hydraulic tubes and the operating devices E use prefabricated hydraulic
hoses c with a length of approx. 280 mm.
At the side for connecting the operating device E they are provided with a 90 bend and a union nut M16 x1.5
and at the side for connecting the hydraulic tubes they have a stub M16 x1.5 for connecting the hydraulic tubes.
6. Several connecting lines from the transverse pipe-run V to the bottom valves can be made by using the
p q , r , s .
hydraulic tubes ,
d e , f to the
7. Use flexible hydraulic hoses with screwed end connections M16 x1.5 as connecting lines ,
control unit.
g
8. If necessary use pipe clamps to
connect the connecting lines. Recommended distance between pipe clamps:
r s will therefore require these clamps.
approx. 500 mm. Due to the length of the line most connecting lines ,
If only hydraulic hoses are used adapt the lengths accordingly and use suitable end connections.
26
Installation
continued
Connecting lines
continued
If the design of the installation makes it difficult or impossible to run the connecting lines to the end attachments
of the actuating cylinders of the bottom valves HWV 205/1 - DN 80 or HWV 215/1 - DN 80, you can swop the end
connections of the actuating cylinders with the filling connections.
For this purpose use a spanner 19 mm A. F. Apply a torque of 40 Nm to fasten the connections (see below).
Socket-weld end
for manifold
Connection for
indicating cylinder
Filling
connection
P
HWV 205/1
Standard arrangement when supplied
Filling
connection
P
HWV 215/1
Standard arrangement when supplied
Attention
The hydraulic tubes must meet the requirements of DIN 2391 and must be made of St 37.4 NBK
with a wall thickness of 10 x 1 mm.
The hydraulic hoses must be in accordance with EN 853 - 1SN 8.
When installing the connecting lines make sure that the lines have a slight inclination towards the
middle such that the hydraulic system can be vented.
If necessary take additional precautions to prevent the transverse pipe-run from swinging.
The hydraulic tubes leading to the actuating cylinders must be provided with expansion loops in
order to absorb vibrations.
Check the soft seals of the connections for damage. Only soft seals that are not damaged can be
used again. Replace damaged gaskets and seals.
27
Installation
continued
BV 110
P
R
LG
h
h i
pp
a
cc
l m
n o
Reference
P
R
R
Designation
Qty.
Adjustable
T-type screw joint
d e f
Length [mm]
Item
i
j
n
o
p
l
m
r
s
28
8
1 each
e.g. Company Stauff
Length [mm]
Item
10
Length [mm]
d
e
f
Items h-s: Permanent piping with
O. D. of pipe = 10 mm possible.
The tubes supplied by GESTRA
are not bent.
Installation
continued
GESTRA
29
Installation
continued
30
Installation
continued
31
Operation
Service
During the loading process the following actions will take place:
n Opening of bottom valve
n Closing of bottom valve
To open / close the bottom valves operate one of the operating devices E at either side of the tank.
See drawing on page 4
When opening the operating device E remove - if necessary - the customs lead seal from the bolt M.
1. To open the operating device E push the bolt M upwards and then turn it by 90 to one side.
You can now swing down the lid.
2. Make sure that the pump lever of the hydraulic pump F is completely extended towards the front.
3. Connect the rail hook C (e. g. rail hook VZ 10) to the tension rope and engage it in the rail.
The ball valve of the control unit X of the bottom vale will close and the hydraulic system is ready for operation.
4. The up-strokes and down-strokes of the lever of the hydraulic hand pump F in the operating device E
build up pressure in the hydraulic system, causing the two bottom valves to open simultaneously.
After approx. six strokes of the pump lever both bottom valves will be completely open. Check position
of bottom valves: The opening position of the bottom valves is indicated by the two completely extended
indicating pistons O of the indicating cylinders H (lift of indicating pistons approx. 46 mm).
5. Open the lateral shut-off valves A to start the loading/unloading process.
6. The pump lever of the hydraulic pump F is no longer required and must be returned to its original position.
Attention
If only one operating device for the loading system was opened, the lid of the other operating device
cannot be opened when the bottom valves are open.
Close bottom valves immediately after loading or unloading the tank.
See drawing on page 4
7. To close the bottom valves disengage the the rail hook C from the rail. This will loosen the tension rope.
The ball valve of the control unit X opens the hydraulic system and both rapid-action bottom valves will be
closed instantaneously. Be sure that both bottom valves are closed by checking the indicating pistons O
of the indicating cylinders H. Both indicating pistons must be retracted.
8. Then close and latch the operating device E.
9. To finish the loading/unloading process close the shut-off valves A and attach the sealing plugs to the
shut-off valves.
Attention
Note: If the lid cannot be closed, one or both bottom valves are still open!
The inside of the lid of the operating device features a bracket. This bracket prevents the closing
of the lid when one or both bottom valves are open. The lid can only be closed when the indicating
pistons are retracted. The cause of this malfunction must be ascertained and eliminated!
If only one operating device for the loading system was opened, the lid of the other operating device
cannot be opened when the bottom valves are open.
32
Operation
continued
Emergency operation
During emergency unloading the following actions will take place:
n Opening of bottom valve
n Closing of bottom valve
If both bottom valves are to be opened, open first the bottom valve for the gas phase and then the one for
the liquid phase.
See drawing on page 4
1. Unscrew the sealing plug J of the bottom valve located in the bottom of the actuating cylinder B.
A small amount of oil might escape. Put the sealing plug J in the operating device E.
2. Unscrew one or two of the required screws for sealing off the opening for emergency unloading K from
one of the two operating devices E and apply a smear of commercially available lubricant to them.
They are screwed one below the other at the back of the operating device E.
4. Screw the sealing-off screw K into the thread at the bottom of the actuating cylinder B in order to open
the bottom valve.
5. Open the lateral shut-off valves A to start the loading / unloading process.
Warning
Use the emergency operation of the bottom valves only if both hydraulic hand pumps have
failed or, for any other reason, there is not enough pressure for opening one or both bottom valves.
In case of emergency operation a rapid-action closing of the bottom valve is not possible.
If both bottom valves are to be closed via emergency operation, first close the bottom valve for the liquid
phase and then the one for the gas phase.
See drawing on page 4
1. To close the bottom valve unscrew the sealing-off screw for emergency unloading K out of the bottom
of the actuating cylinder B. The spring in the bottom valve effects the closing.
2. Once the emergency loading/unloading process has been accomplished, screw the sealing-off screws K
back into the rear wall of the operating device E.
3. To finish the loading/unloading process, close the shut-off valves A and attach the sealing plugs to
the shut-off valves.
4. Defective bottom valves must be permanently marked in order to avoid inadvertent re-commissioning.
Do not screw sealing plugs J into defective bottom valves.
5. The cause of the malfunction must be ascertained and eliminated by qualified personnel!
Warning
In case of emergency operation a rapid-action closing of the bottom valve is not possible.
When the emergency operation of one or both bottom valves is finished, find and eliminate the
cause for the malfunction. Note that the repeated or continuous application of the emergency
operation is considered as improper usage. The resulting risk will have to be borne by the user alone.
The manufacturer hereby expressly rejects any claims for any resulting damage.
33
Maintenance
Bottom valves HWV 205/1 - DN 80/ HWV 215/1 - DN 80
Type of maintenance
34
Time interval
Activity
When necessary,
during main inspection
at the latest (every 4 yrs.)
Main inspection
(every 4 yrs.)
Check
actuating cylinder B
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
torque of 50 Nm $
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
torque of 120 Nm b 34
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
smoothness of operation
of ball valve shaft 36
When necessary,
during main inspection
at the latest (every 4 yrs.)
Replace
piston seal (
When necessary,
every 8 years at the latest
Check
valve plug seal
31
Replace
valve plug seal
31
Maintenance
continued
Time interval
Activity
Check
oil level
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
tightness
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
valve lift
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
holding pressure
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
rapid-action closing
When necessary,
during main inspection
at the latest (every 4 yrs.)
Check
completeness
When necessary,
Both operating devices must have two emergency operating
during main inspection
screws each. These emergency operating screws must be
at the latest (every 4 yrs.)
screwed in the rear wall.
Connecting lines
Type of maintenance
Check
tightness
Time interval
Activity
When necessary,
during main inspection
at the latest (every 4 yrs.)
35
Servicing
Hydraulic loading & unloading system HV 215
Observe the following servicing instructions whenever carrying out:
n Visual examinations as part of the main inspection
n Repair work due to leaks or other malfunctions
The bottom valves HWV 205/1 - DN 80 and HWV 215/1 - DN 80 require maintenance and servicing. The operating
device BV 110 is maintenance free.
We recommend removing the bottom valves HWV 205/1 - DN 80 and HWV 215/1 - DN 80 and checking them for
wear and damage when performing visual inspections.
Do not re-use parts subject to wear, such as gaskets and seals. Worn or damaged parts must be replaced after ascertaining and eliminating the cause of the damage. Use only genuine GESTRA parts.
GESTRA supplies the following seal kits:
1. Stock code 049387
n 1 Valve plug seal PTFE 31
n 2 Gaskets 125 68
2. Stock code 049395
n 1 Valve plug seal CR 31
n 2 Gaskets 125 68
3. Stock code 049563
n 1 Piston seal
n 1 Seal ring a
n 2 O-rings ()
n 1 Gasket !
n 1 Gasket &
Modifications to the design may only be made if the manufacturers written permission is obtained.
Replacing valve plug seal
The valve head can be removed directly inside the tank. This option is highly recommended since in this case the
bottom valves, the connecting lines and the hydraulic system do not require any additional preparation.
If, however, the valve head can only be removed from the outside, please proceed as follows:
See drawings on page 4, page 6 and page 38
1. First disconnect all connections of the actuating cylinder B. A small amount of oil might escape.
Collect the oil and dispose of it correctly.
2. If possible separate the manifold from the body.
3. To remove the body and the actuating cylinder B unscrew the six hexagon-head cap screws b of the body
and remove the body and the associated actuating cylinder together. Remove gasket 8.
4. Undo the 12 socket-head cap screws c and take the valve head from the mounting flange. For this purpose
you can screw two hexagon-head cap screws M 10 into the two through threads of the seat flange.
Note that these screws are not scope of the supply.
36
Servicing
continued
continued
37
Servicing
continued
continued
1
2
3
4
5
6
7
f
e
31
38
ji
hg
d
c
Servicing
continued
85
39
Servicing
continued
40
Servicing
continued
continued
a
)
!
32
/
"
32
%&
41
Servicing
continued
41
36 37
42
38 39 40
43
www.gestra.de
Espaa
Polska
Great Britain
Portugal
Italia
USA
Flowserve S.p.A.
Flow Control Division
Via Prealpi, 30
l-20032 Cormano (MI)
Tel.
00 39 02 / 66 32 51
Fax
00 39 02 / 66 32 55 60
E-mail: infoitaly@flowserve.com
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Mnchener Str. 77, D-28215 Bremen
Telephone +49 (0) 421 35 03 - 0
Fax
+49 (0) 421 35 03 - 393
E-Mail
gestra.ag@flowserve.com
Internet www.gestra.de
818480-01/1005cm 2003 GESTRA AG Bremen Printed in Germany
44