Fast Loop Module, FLM, User`s Manual
Contents
1. FA El E fe a RG D A W mw HH vos a a mm ough authorized e ind service representative Contents Fast Loop Module System Manual 0085 3 Introduction s ss s e A 4 Configurations noa oaoa oa a a a a a 5 MOUMURG s s sam e a a a E DEE a a e aaa 10 BS s e e eree deco Al e te a R a 12 System Startup aoo a a 13 OPANG e ps pd e we SD 2 ee a ee 15 Maintenance 2 a A 16 Troubleshooting 1 ee 20 System Component User Instructions 24 Swagelok Instructions Swagelok Tube Fitting Instructions for 1 in 25 mm and smaller fittings MS 12 01 24 Swagelok VCO Fittings Installation Instructions MS CRD VCO 1 a a a 25 Packing Adjustment for 40 Series Ball Valves MS INS 40 2 0 0 2 000 0 ee ee ee 21 Packing Adjustment for 40G Series Ball Valves MS INS 40G 2 2 ee 28 R3A Series Externally Adjustable Relief Valve Maintenance Instructions MS CRD 0013 29 R4 Series Relief Valve Maintenance Instructions MS CRD 0048 0 0 0 000002 ee eee 36 Plug Valve Subassembly Replacement and O Ring Rebuild Instructions MS CRD 0012 38 Repacking Instructions for N and HN Series Valves MS INS N ge es ea a eR a ee ew ee ew eS So 39 CH Series Check Valve Service Instructions MS CRD 0025 2 2 a a 41 Tornado Instructions Tornado Model 601 Element R2. 3 Clean body bore and lubricate lightly with a silicone based lubricant Also lubricate entire surface of new O rings with a silicone based lubricant Install O rings on plug with the larger two around the top and bottom of the plug the smaller one on the side 4 Insert plug straight down into body See Fig 3 Note Do not pinch O rings between body and plug 5 Install snap ring with snap ring pliers or similar tool See Fig 4 6 Test the valve for proper operation Repacking Instructions for N and HN Series Valves Kit Contents PTFE Packing UHMWPE Packing Packing 1 Packing support 2 Grafoil Packing PEEK Packing Packing 2 Packing support 2 Lubricant 1 Instruction sheet 1 MSDS 1 Packing 1 Lubricant 1 Instruction sheet 1 MSDS 1 Lubricant 1 Instruction sheet 1 MSDS 1 Lubricant 2 Instruction sheet 1 MSDS 2 1Number of packings will vary according to valve series A WARNING BEFORE SERVICING ANY INSTALLED VALVE YOU MUST depressurize system Reassembly 9a PTFE Packing Lubricate the stem threads with MS LT NNS 1 and re insert the stem through the bottom cycle the valve purge the valve Disassembly 1 Loosen the lock nut and packing bolt of the bonnet Lubricate the valve body threads and the body to bonnet sealing area with MS LT NNS 1 and place the bonnet assembly onto the body Tighten the union nut onto the body 2 Remov
3. if pressure increases there may be an upstream flow restriction Check the pressure at the probe or regulator outlet if the system is losing pressure replace with a wider bore probe or different regulator Replace the fast loop supply and return lines with larger tubing Reduce the pressure in the process pipe near the sampling nozzle Turn the needle valve handle counter clockwise to increase flow and release pressure Check the pressure indicator PI and replace if necessary Check that the process isolation valve and all valves in the return line are fully open Then check for possible blockage Only available through authorized Swagelok sales and service representatives Troubleshooting The needle valve NV1 is closed Turn needle valve counter clockwise to increase too much the flow Configuration 3 and 4 the plug Close the plug valve PV valve PV may be open If zero flow indicated the 1 4 in FLM close the metering valve and wait for flowmeter pointer is not one minute Slowly open the metering valve and following float position adjust flow to desired rate 1 2 in FLM close the needle valve and wait for one minute Slowly open the needle valve and adjust flow to desired rate Adjust the flow rate with the needle valve NV1 and observe whether the flowmeter indicates the changes The flowmeter float is stuck in Flush the system with solvent to remove oil and the tube solid deposits
4. 3 16 in max Torque wrench capable of Spring Kit Identification Initial Spring Set Cap Designator Pressure Position and Range number Color psig bar of turns Spring Kit Basic Ordering Number 177 R3A K1 50 to 350 gaan 350 to 750 24 1 to 51 7 750 to 1500 51 7 to 103 3000 to 4000 White 206 to 275 E 4000 to 5000 275 to 344 Only available through authorized e owagelok sales and service representatives 30 R3A Series Externally Adjustable Definition of Symbols Relief Valves Maintenance A Instructions Discard Lubricate N WARNING 4 Before servicing any installed valve Existi xisting you must spring e depressurize system e cycle valve e purge the valve Existing WARNING peor Residual material may be left in the valve and system CAUTION Do not scratch any sealing surfaces while following these instructions Valve performance could be affected 5 Make sure all components are clean Spring Installation 6 1 New E spring Ba p spring Lock nut suppor Loosen 2 7 Existing label Cap 8 Loosen New label 9 initial position indicated in Spring Kit Identification table 3 a Cap Cap o Thread to owagelok sales and service representatives R3A Series Externally Adjustable Relief Valves Maintenance Instructions 10 Manual Override Conversion Manual Override Kit Red handle 7 P 1 Follow steps 1
5. O5 05mimn 2 2micon 10 10 micron 25 25 micron 50 50micron _ Kit quantity Blank Kitof 5 1 Kit of 1 Mounting bracket accessory Part 602 509 SS sold separately How to build the model number How to build the replacement element kit number so r Iss 62 a a Element rating 0 5 is pourous metal All others are screens 0 5 is pourous metal All others are screens Kit quantity Bie cannot recommend specific sealing materials due io the complex nature of sample stream compositions Temperature and pressure also may be factors i Unless specified otherwise the product will ship with our standard sealing materials and materials of consiruction stated in the technical specifications section of the comesponding Product Sheet Please refer io werw duponielasiomers com for sealing material recommendations and advice itis the user s responsibility io specify the sealing materials and other materials of construction for their application Gene GUT SM and Tomado are trademarks or registered trademarks of A Corporation LLC All other referenced trademarks are the property of their respective owners Only available through authorized owagelok sales and service representatives Only available through authorized owagelok sales and service representatives A Swagelok Pre Engineered Subsystem Fast Loop Module Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a cop
6. wrench 28 2 Nm retainer espe ao Bonnet nut 67 8 N m Bonnet nut Loosen Seal Kit Bonnet Seat Quad O ring Retainer O ring seal OOO a oe A WARNING Before removing any installed valve you must e depressurize system e cycle valve Bonnet e purge valve A WARNING Residual material may be left in the valve on system Do pese Only avaraiotetyredgh author Swag tek sates ind service representatives 34 R3A Series Externally Adjustable Relief Valves Maintenance Instructions 6 11 Seat retainer 2 Insert assembly Bonnet O ring Stem T 12 Quad seal Retainer Seat retainer h 8 G Tighten to 250 in lb 28 2 N m 13 Seat retainer SAN Seat O ring Insert Quad seal lt gt Retainer Teeth facing away from quad seal 14 9 Make sure all components are clean 6 o 10 Stem Seat O ring Lubricate top of stem Insert Only available through authorized owagelok sales and service representatives R3A Series Externally Adjustable Relief Valves Maintenance Instructions 15 a Bonnet O ring 16 Bonnet Body 17 Bonnet Tighten to 600 in Ib 67 8 N m 18 To adjust set pressure see steps 10 through 13 in the Spring Installation section 19 Install valve in system Grip valve on wrench pad during installation R3A Series Cutaway Cap Spring Label Lock wire hole Lock
7. 77 Purge in Drain vent 13 8 35 1 Fast loop inlet Out to analyzer Relief outlet option Drain vent na o Only avail bt through authorized 65 to 75 Ib 29 5 to 34 0 Swagelok sales and service representatives Relief outlet Installation 1 4 inch and 1 2 inch systems have fractional Swagelok tube fittings or metric Swagelok tube fittings for the system connections Note For 1 4 in systems all inlet and outlet connections are 1 4 in or 6 mm with the exception of the sample to analyzer connection which is 1 8 in or 3 mm Note For 1 2 in systems the fast loop out fast loop in relief outlet oily drain bottom right and grab sample outlet connections are 1 2 in or 12 mm return from analyzer purge in and oily drain center right connections are 1 4 in or 6 mm sample to analyzer connection is 1 8 in or 3 mm Note All internal fittings non system connections are fractional fittings Install Swagelok tube fitting according to the Swagelok Tube Fitting Instructions for 1 in 25 mm and smaller fittings page 24 Inlet Connections 1 Fast Loop In connect to the sample transport line to be analyzed Fast loop out Fast loop in ara F Am F Only available th oug 1 2 in Fast Loop Modul 2 Sample to Analyzer connect to the remainder of the sample conditioning system prior to the analyzer 3 Return from Analyzer option connect to the outl
8. Remove the flowmeter and clean the inside of the The loop pressure flow tube is acceptable but there is little or no Replace the flowmeter flow Move the black handle to the right and verify the One of the bypass valves is not two ball valves BV1 BV2 are fully closed fully closed Release set screws reposition handle and retighten set screws l Check the rotation speed of the fast loop pump Fast loop pump if used is damaged Check the flow rate from pump repair or replace pump as necessary The fast loop return line or Check that all valves in fast loop system external process return nozzle is partially to FLM are fully open or fully blocked The process return pressure is Find a lower pressure point for return to process too high During initial startup the flow is Replace the fast loop supply and return lines with too low the fast loop supply line larger tubing may be too small or too long Only available through authorized owagelok sales and service representatives Troubleshooting The filter element is obstructed Replace the filter element If possible increase the fast loop flow and check for improvement If the additional time delay is acceptable decrease the filtered sample flow consider reducing analyzer bypass flow Filter element is becoming frequently obstructed e g daily replacement needed Change the element to one with a larger pore size if analyzer can accept
9. body Service Instructions CH Series Check Valve Outlet Body Reassembly 3 Remove the spring Outlet Body 1 Place the backup ring on the outlet body soy Lubric e ing with a compatible lubric Side the O ting ov er the threads against the backu me OY Se Inlet Body NO oo A gt Insert the spring into the body EAN 5 ox system compati He bod SD a ae cae reasse 7 Remove the poppet ennieiok sales and service representatives Service Instructions CH Series Check Valve Inlet Body 9 Look into the valve outlet port to verify that the spring is aligned in the center 6 Insert the poppet bonded side first of the poppet stop into the body Poppet Stop 7 Insert the poppet stop prongs first 10 Tighten the valve bodies into the body E DES NN 8 Thread the outlet and inlet bodies Tighten the body together halves to approximately 200 in lb 22 N m EM gt Body Hex Socket Y EA V O 11 Refer to the Installation and Testing sections A Note Do not pinch the O ring and backup ring between the outlet and inlet bodies during assembly The O ring must fit tightly into the inlet body Only available through authorized owagelok sales and service representatives Service Instructions CH Series Check Valve Troubleshooting Reference Symptom Possible Causes to Pg 46 Corrective Action Poppet elastomer was chemically 9 Replace poppet w
10. sample fluid is passing through the upstream of the FLM probe and isolation valves There is no process pressure Check that the process line is pressurized Pressure indicator PI shows low pressure Pressure indicator PI shows high pressure Configuration 3 and 4 the plug valve PV may be open The needle valve NV1 is fully open The relief valve RV is relieving pressure and flowing to the vent Pressure indicator PI is damaged There is low process pressure If flow rate is acceptable there may be a partial blockage in probe or sample transport lines to the FLM There is a flow restriction external to the FLM ex process probe or regulator not properly sized for the system During initial startup the flow is too low the fast loop supply line may be too narrow or too long There is high process pressure The needle valve NV1 is restricting flow Pressure indicator PI is damaged If using a liquid fast loop pump the return line or process isolation valve may be blocked Close the plug valve PV Turn the needle valve handle clockwise to restrict flow and increase pressure Check the set pressure on the relief valve and increase if necessary Check the pressure indicator PI and replace if necessary Check the pressure in the process pipe near the sampling nozzle Partially close the needle valve NV1 and check for pressure increase on the pressure indicator PI
11. the additional particle load Restrict the fast loop flow to increase sample pressure by turning needle valve NV1 handle clockwise being careful not to reduce flow too If the analyzed sample returns much to the FLM there may not be enough pressure drop in the Check that the sample return valve BV3 is fully ac FLM to drive the sample flow open release set screws reposition handle and there is little or ah if noton Go te through the analyzer retighten set screws if necessary analyzer Consider changing the method of disposing of the analyzed sample The check valve CV1 is not Maintain or replace the check valve cracking Fast loop pressure and flow are acceptable but If the sample is returned via fast loop return to process reduce the return line pressure drop by is too high return line to process Consider changing the method of disposing of the analyzed sample There is high flow resistance in Check all sample conditioning equipment analyzer the sample path to the analyzer flow path and analyzer vent for a closed valve or external to the FLM obstruction l The needle valve NV2 is Open the needle valve by turning the handle There is no flowin closed counter clockwise the grab sample SE Ta outlet Pressure indicator PI shows See cause and remedy for Pressure indicator PI zero or low pressure shows no or low pressure The needle valve NV3 is Open the needle valve by turning the han
12. Element Replacement Kit Instructions Element Kit Part 601 5TX Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 5TX Teflon Element Gacket Assemblies Only available through authorized owagelok sales and service representatives 48 Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 5TX the body and press the cover on the body to complete the assembly installation Only available through authorized owagelok sales and service representatives Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 6XX Tornado Model 601 Flow Screen Replacement Kit Instructions Flow Screen Kit Part 601 6XX Carefully remove a new flow screen from one of the clear plastic azs m the replacement kit Only available through authorized Swagelok sales and service representatives 50 Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 6XX Use the i torque each bolt to 120in lbs Tighten the bolt m am until all bolts are torqued to 120 m bs If the Tornado does mot have a Reorder Kit 2 label remove the protective backing from SEE OUR WEESITE FOR OTHER PRODUCTS amp LITERATURE AVAILABLE FROM A CORPORATION www geniefilters com a ee Ce Pica Leet Regina Brochure ACC Analyzer Application Notes Consult 44 Corporation technical support for speeifie Only available through authorized owagelok sales and servic
13. FL NV1 Liquid Fl Fast NVI Loop Gas Out Fast Loop CV In From Analyzer ey Pl SN Liquid To Analyzer FFL Only available through authorized owagelok sales and service representatives Configurations Configuration 3 Return from Analyzer Switch Drain Ball valve Grab sample BV3 BV4 needle valve NV2 Flow indicator E F a Relief valve RV no Needle valve PR NV1 Filter Pressure Plug valve FFL indicator PV Pl NV1 Liquid Fast Loop Out Oily Drain Fast ne Loop e From Analyzer PI SN Pt To O Analyzer FFL Oily Drain Vent Only available through authorized owagelok sales and service representatives Configurations Configuration 4 Gas or Liquid Purge Manual Drain Ball valve Grab sample BV3 BV4 needle valve NV2 Flow indicator Fl Ball valve MA BV1 BV2 Purge needle valve NV3 Relief valve Needle valve RV NV1 Filter Pressure Plug valve FFL indicator PV PI NV1 n Liquid AN FI Fast NV1 Loop Gas Oily Out Drain Vent Fast Purge Loop In From Analyzer SN Liquid To Analyzer lt FFL Oily RV Drain Vent Only available through authorized Swagelok sales and service representatives Mounting The FLM must be mounted to a vertical The FLM is designed to flow with fast loop face or wall for function of the flowmeter process connections on t
14. acking bolt clockwise in 1 16 turn increments until leak tight performance is achieved Always verify proper operation upon installation Only available through authorized owagelok sales and service representatives 40G Series Valve Packing Adjustment IMPORTANT This valve is factory tested with nitrogen at 1000 psig 69 bar or the rated pressure if lower than 1000 psig 69 bar Periodic maintenance Packing adjustments may be required during the service life of the valve to prevent leakage Adjusting the Packing 1 Adjust the packing by turning the packing bolt clockwise in 1 16 turn increments until leak tight performance is achieved 2 Test valve for proper function and operation A Before removing any installed valve from the system you must e depressurize the system e cycle the valve e purge the valve Only available through authorized owagelok sales and service representatives R3A Series Externally Adjustable Relief Valves Maintenance Instructions R3A Series Exploded View Plug Cap Label Lock wire hole Lock nut Spring gt Spring support Bonnet Bonnet O ri Quad seal ring E Retainer Stem Seat retainer Seat O ring S Insert Lock wire hole Spring Kit Lockwire Spring Spring Lead support seal ua at Label Tools Required 3 4 in Thin head Open end 3 16 in max wrench 3 4 in Crow s foot Thin head Lock nut
15. aintenance VCO Fitting Maintenance When required maintain the VCO fittings within the system according to VCO Fittings Installation Instructions page 25 Verify that the O ring is in place when reassembling the fitting The locations of the VCO fittings within a Configuration 4 FLM are indicated in the drawing below Note The VCO fitting locations may vary slightly between configurations Configuration 4 1 2 in Liquid System with Optional Grab Sample and Relief Outlets Shown Only available through authorized owagelok sales and service representatives A Swagelok Pre Engineered Subsystem Fast Loop Module Maintenance System Component Reference for Replacement Ordering Information Proportional relief valve 1 4 in FLM R3A series 1 2 in FLM R4 series 1 4 in die es eras Plug Valves P4T and P6T Series 1 2 in FLM P6T series mete VCOS fitting VCO O Ring Face Seal Fittings MS 01 28 Needle valve Variable Area Flowmeters G Series and flow indicator M Series 1 4 in systems M1 series MS 02 346 Needle valve flow indicator 1 2 in systems 12N series Proportional Relief Valves R Series MS 01 141 Needle valve Severe Service Union Bonnet Needle optional grab sample outlet Valves N Series and HN Series 1 4 in systems 3N series MS 01 164 1 2 in systems 12N series Needle valve optional purge outlet 3N series Flow indicator Variabl
16. bonnet 11 Lubricate the top 2 or 3 threads on the bonnet and screw lock nut onto the bonnet 12 Place the handle on the stem Be certain that the set screw hole is aligned with the indentation in the stem before tightening the set screw 13 Back stem out of the bonnet 2 or 3 turns to prevent galling during the torquing procedure 14 Torque union nut to body according to torque chart 15 Tighten packing bolt to seal packing against given system pressures 16 Hold packing bolt in place and tighten the lock nut against the packing bolt Torque Chart 360 40 9 1080 122 gh Handle Set a qm Coy Handle Locknut pin Panel nut a gt lt Union nut J a Packing bolt it Gland 11 PTFE packing Lower 42 supports E i PEEK packing Grafoil UHMWPE packing packing SOMAN aa PRI stem Soft seat Regulating regulating stem stem A Fa Body k a 1 Number of packings will vary according to valve series authorized Service Instructions CH Series Check Valve Contents EH Component Identification Tool Requirements Installation Testin i Ai Q Kit Contents Maintenance Troubleshooting The valve in this procedure is shown with Swagelok Tube Fitting end connections These instructions also apply to check valves with pipe ends and check valves with VCR and VCO ends Component Identification End Connection Backup Ring ute oS Pop
17. connections for clarity Black handle Interlock flange Lower coupling Only available through authppizegpe move onnections for clarity Swagelok sales and service representatives Maintenance To access the valve packing you must remove the black handle subassembly 1 Turn the black handle to the left to place the system in bypass mode Fig 1 2 Configurations 3 and 4 Remove the interlock flange Fig 2 3 Remove the black handle shaft by turning it counterclockwise Fig 2 4 Loosen the two set screws on the upper coupling Fig 2 5 Loosen the set screw on the lower coupling Fig 2 6 Slide the couplings toward the center Fig 3 Fig 3 7 Lift out the black handle subassembly Fig 4 Fig 4 Only available through WARAKI Gace the handle subassemblies Swagelok sales and service representatives 8 Adjust the valve packing according to 1 4 in Packing Adjustment Card for 40G Series Ball Valves page 28 1 2 in Packing Adjustment Card for 40 Series Ball Valves page 27 9 Configurations 3 and 4 To adjust the valve packing on the 40G valves M Loosen the interlock set screws Fig 5 E Remove the interlock gears Interlock set screws Fig 5 Note Configuration 3 only the lower gear must be removed mM Adjust the valve packing according to Packing Adjustment Card for 40G Series Ball Valves page 28 Fig 6 to valve packing M
18. de Install valve in system Grip valve on wrench pad during installation 10 11 12 Spring Kit Identification Nominal Cracking Pressure psig bar Spring Kit Ordering Number Cap Bonded Stem Body Stem and O Ring Replacement 1 2 3 4 10 Remove valve from system Loosen cap to relieve spring pressure Remove bonnet from body Remove stem from bonnet Make sure all parts are clean before reassembly Place new stem into bonnet Remove and replace bonnet O ring Lubricate with system compatible lubricant Thread bonnet into body and torque to 400 in lb 45 N m Adjust desired set pressure as described in steps 7 through 10 in the Spring Installation section on reverse side Install valve in system Grip valve on wrench pad during installation Initial Cap Position number of turns 50 to 350 Sa 3 4 to 24 1 350 to 750 avauqiale Quo aut owagelok sales and service representatives R4 Series Relief Valve Maintenance Instructions Spring Installation A Warning Relieve system pressure before installing spring Spring Support Bearing TT Bomet g Lock Wire Hole Body 1 Loosen lock nut and remove the cap from bonnet 2 Remove existing spring if necessary 3 Make sure all components are clean 4 Place spring support bearing in valve with bearing side UP 5 Install proper spring for desired set pressure range 6 Replace existing lab
19. dle closed counter clockwise There is insufficient purge fluid Check that the purge fluid is supplied to the FLM There is no purge pressure at a sufficient pressure The drain is blocked external to the FLM Ear Serra is not fully in bypass retighten set screws into system during purge Ball valves BV1 or BV2 need Tighten the packing according to Maintenance packing adjusted page 16 Only available through authorized Swagelok sales and service representatives Troubleshooting There is excess process See cause and remedy for Pressure indicator PI ressure shows high pressure The relief valve is p JAR open Increase the set pressure if necessary The set pressure is too low Replace valve spring with the next higher range There is backflow Check valve CV1 is stuck open Maintain or replace the check valve Verify into the analyzer orientation when the check valve is reinstalled Pressure indicator Fast loop pressure is pulsating Consider replacing PI with a liquid filled gauge E co The snubber is incorrect for the Replace the snubber with a more restrictive SUS na sample viscosity range excessively Only available through authorized Swagelok sales and service representatives Swagelok Tube Fitting Instructions for 1 in 25 mm and smaller fittings Installation These instructions apply to both traditional fittings and to fittings with the advanced back p ferrule geometry 1 Full
20. e Area Flowmeters G Series and 1 4 in FLM M1 series M Series 1 2 in FLM M3 series MS 02 346 Ball valve One Piece Instrumentation Ball Valves 40G or 40 series 40G Series and 40 Series MS 02 331 Pressure indicator Pressure Gauges Industrial and Process PGI series B model PGI Series MS 02 170 Check valve Check Valves C CA CH CP and CH series CPA Series MS 01 176 Snubber fitting Pressure Gauges Industrial and Process PGI Series MS 02 170 Filter Kit Information Element Size Module 2 micron 10 micron 25 micron Size Filter Type Kit Type Ordering Number Gasket Element Kit 601 5T2 601 5T10 601 5125 1 4 in FLM 601 Filter Flow Screen Kit 601 62SS 601 610SS 601 625SS 602 5T2 1 602 5T10 1 602 5T25 1 1 2 in FLM 602 Filter ma res la A LA Piece Elementkit 602 572 602 50 602 5725 Y TUTO aU O O O J am a a gt owagelok sales and service representatives Troubleshooting Place the FLM into sample mode by moving the black handle to the right FLM is in bypass mode Check that both ball valves are turning when black handle is moved if not tighten set screws with valve in correct orientation Pressure indicator Fast loop is shut off Open all valves in fast loop line external to the Pl shows no FLM pressure The sample supply line is Check that there is pressure in sample supply line obstructed There is an obstruction Check that
21. e representatives Tornado Model 602 Maintenance Instructions Tornado Model 602 Maintenance Instructions Manufacturing Contact Information A Corporation LLC Coll for expert product application assistance 4104 Hack LERET Ral Phone 22S AAA Weale ewweercnichiliencom Gonzala LA TTT Paw AR T E mail alsa gentefihera com Safety Warnings O 4 Failure to abade by any of the safety wammes below will result m release of had at full pipeline pressure and could resali in serous inpury or death Tools Required Foot Pouri Torque Wrench wath 5 8 socket Wrench GO A Comoro LLC Allright reserved SOC 607 57 ds Mola 1409 Only available through authorized owagelok sales and service representatives 2 Tornado Model 602 Maintenance Instructions E aaa E Ha 23 H a w E E Rn E HUHH il EMEA mt J E mm il t li a S i ef 7 E E F EE Only available through authorized owagelok sales and service representatives A Swagelok Pre Engineered Subsystem Fast Loop Module Tornado Model 602 Maintenance Instructions o p Maintenance Instructions Remove ali icare of pressore from the Tornado Use the wrench to remove the four 7 16 bode and the Tomado cover Lay Ge couve dowi elemni ode up Remove and disenrd the old element end peri Remise a new elect mul gate fren the replacement brit Place the new element in the cover cavify with the finer smallest miron screen facing op The ele
22. e the bonnet assembly from the finger tight Place one of the packing valve body Do not remove the union supports into the bonnet Place the nut from the bonnet packing into the bonnet by carefully 3 Turn the stem into the bonnet until the pushing down with a blunt instrument handle slightly touches the packing Be careful not to damage any stem bolt or bonnet threads Put the second 4 Loosen set screw and remove handle packing SPPON into te penne omon l of the packing Place the gland into the 5 Remove packing bolt and lock nut bonnet Proceed to step 10 6 Remove the stem from the bonnet Turn the bonnet upside down to remove the packing s packing supports in PTFE and PEEK packed valves and the gland NOTE Be very careful when removing packing so as not to damage the inside of the bonnet 9b UHMWPE Packing Lubricate the stem threads with MS LT NNS 1 and re insert the stem through the bottom of the bonnet Lubricate the valve body threads and the body to bonnet sealing area with MS LT NNS 1 and place the bonnet assembly onto the body Tighten the union nut onto the body 7 Discard the packing s and packing finger tight Place the packing into the supports in PTFE and PEEK packed bonnet with a blunt instrument Be valves DO NOT discard the gland careful not to damage any threads 8 Clean all reusable parts thoroughly in Place the gland into the bonnet solvent and dry all parts 9c Proceed to st
23. el with new label Check this label against spring identification table for proper set pressure range 7 Thread cap onto bonnet to initial position indicated in Spring Kit Identification Table Tighten lock nut against cap and test for set pressure 8 Relieve system pressure unthread cap as needed and retest Repeat procedure as necessary to obtain desired set pressure 10 Lock wire the cap and body together to maintain relief setting Manual Override Conversion A Warning Relieve system pressure before installing manual override handle Spring Support 1 Loosen lock nut and remove the cap from bonnet 2 Remove the plug from the cap 3 Remove existing spring and spring support bearing 4 Place new bearing and thrust wash ers over pull rod resting them on the spring support 5 Install pull rod into bonnet 6 Place blue A spring over pull rod resting it on the thrust washer 7 Place the cap over pull rod resting it on bonnet 8 Thread handle onto pull rod Tighten set screw on handle to 20 in lb 2 2 N m with a 5 64 in hex wrench 9 Engage the cap threads To adjust the set pressure refer to steps 7 through 10 in the Spring Installation section 9 Ti nat ck nut against the cap to Only availabte through authorized owagelok sales and service representatives 38 Plug Valve Subassembly Replacement and O Ring Rebuild Instructions It is recommended that a replacemen
24. ep 10 Grafoil Packing Lubricate the stem threads stem shank and each individual piece of grafoil packing with MS LT NNS 1 Re insert the stem through the bottom of the bonnet Lubricate the valve body threads and the body to bonnet sealing area with MS LT NNS 1 and place the bonnet assembly onto the valve body Tighten the union nut onto the body finger tight Only available through a thgrizEda os vse ar or Swagelok sales and service representatives 40 Only Swagelok s sales one service representatives Repacking Instructions for N and HN Series Valves the packings included in the kit Be careful not to damage any threads Place the gland into the bonnet Proceed to step 10 9d PEEK Packing Lubricate the stem threads stem shank and the packings with MS LT WL7 Re insert the stem through the bonnet Lubricate the valve body threads and the body to bonnet sealing area with MS LT NNS and place the bonnet assembly onto the body Tighten the union nut onto the body finger tight Place one packing support inside the bonnet and press it down with a blunt instrument Be careful not to damage any stem or bonnet threads Insert the lubricated bottom packing and then the top packing Press down into the bonnet Insert the second packing support press down Insert the gland and press down into the bonnet Proceed to step 10 All Assemblies 10 Lubricate the outer threads on the packing bolt and screw into the
25. eplacement Kit Instructions Element Kit Part H601 DTX aaa a a a a a a a a a 47 Tornado Model 601 Flow Screen Replacement Instructions Flow Screen Kit Part 601 6XX 2 49 Tornado Model 602 Maintenance Instructions 51 Only available through authorized owagelok sales and service representatives Fast Loop Module ONA FLM System Manual Configuration 4 1 2 in Liquid System with Optional Grab Sample and Relief Outlets Shown Only available through authorized owagelok sales and service representatives Introduction Fast Loop Systems are designed to handle high flows in sample transport lines to reduce time delays for online analyzer systems Located at the analyzer and offering a bypass the Swagelok Fast Loop Module FLM can isolate the sample system and introduce a purge gas for system cleaning The FLM extracts a sample through a filter while using the high flow rate of the fast loop to keep the filter element clean All FLM subsystems feature dual interlocked ball valves which enable the fast loop to be bypassed when the analyzer is not in service This feature maintains flow through the fast loop system and improves overall system performance once the analyzer is back online Only available through authorized owagelok sales and service representatives Configurations The FLM is available in four main configurations See the Fast Loop Module Application Guide MS 02 361 for additio
26. er to flush the sample return lines Configurations 3 and 4 verify the plug valve PV is closed Red handle BV3 BV4 Black handle BV1 BV2 Place the FLM in sample mode by moving the black handle to the right Pressure will be shown on the pressure gauge PI Adjust the flow to the desired rate 1 4 in systems use the metering valve that is integral to the flowmeter 1 2 in systems E Gas systems use the needle valve NV1 that is upstream of the flowmeter E Liquid systems use the needle valve NV1 downstream of the flowmeter Needle valve NV 1 Pressure Plug valve PV indicator PI 1 2 in Fast Loop Module Liquid System Configuration 4 Only available through authorized owagelok sales and service representatives System Startup 6 Verify that flow is reaching the sample conditioning system downstream of the FLM 7 Adjust the relief valve set pressure if desired according to the appropriate instructions Note The relief valve is pre set at the factory as specified in the ordering information 1 4 in R3A Series Externally Adjustable Relief Valve Maintenance Instructions page 29 1 2 in R4 Series Relief Valve Maintenance Instructions page 36 Note 1 2 in systems with perfluorcarbon FFKM seals will contain R3A series relief valves Red handle BV3 BV4 Black handle BV1 BV2 Relief valve RV Needle valve NV 1 Pressure Plu
27. erating pressures close to the cracking nee pressure Valve size exceeds system require ments Consider using a spring with a lower cracking pressure Consider using a smaller valve Consider adding a flow restriction downstream of the valve Valve chatter or noise at high flow rates Consider using a spring with a higher or lower cracking pressure Consider using a larger or smaller valve Poppet and spring unstable in the flow stream Consider using an appropriate positive shutoff valve Check valves cannot isolate incompatible fluids O N yaah able ta Q LIGA aLwinonzead for assistance owagelok sales and service representatives Check valve used to Fluid mixing separate incompatible fluids 46 Service Instructions CH Series Check Valve O ring OC Good Contaminated Swollen Damaged Good Contaminated Damaged Ref 1 Ref 2 Ref 3 Ref 4 Ref 5 Installation Using a Backup Wrench O ring Permeation During Helium Leak Testing Vacuum Ref 7 Safe Product Selection When selecting a product the total system design must be considered to ensure safe trouble free performance Function material compatibility adequate ratings proper installation operation and maintenance are the responsibilities of the system designer and user Only available throug iibi kio iens pars wit those of other manufacturers owagelok sales and service representatives Tornado Model 601
28. errule seats against the fitting body Fig 6 3 While holding the fitting body steady rotate the nut with a wrench to the previously pulled up position as indicated by the marks on the tube and the flats at this point you will feel a significant increase in resistance Fig 7 4 Tighten the nut slightly A Caution Do not use the gap inspection gauge with reassembled fittings ao A Caution ES Do not mix or interchange parts with those of other manufacturers iW d a N ough sestineriatncie ces MS 01 140 owagelok sales and service representatives Swagelok vco Fittings Installation Instructions Bodies without weld fittings 1 16 1 8 3 16in 2 3 4 mm 6 Finger tight Only available through authori d 7 Swagelok sales and service representatives 2O Swagelok vco Fittings Installation Instructions Bodies with weld fittings owagelok sales and service representatives 40 Series Valve Packing Adjustment IMPORTANT This valve is adjusted for factory testing with nitrogen at 1000 psig 69 bar or the rated pressure if lower than 1000 psig 69 bar Packing must be readjusted for service at higher than test pressure AA Warning Packing adjustment may be required during the service life of the valve to prevent leakage Before servicing any installed valve you must depressurize the system cycle the valve and purge the valve Adjust the packing by turning the p
29. et line from the analyzer There must be sufficient pressure to create flow back into the FLM return 4 Purge In option connect to a purge line It will be used to purge the sample side of the system prior to servicing Configuration 4 The purge media may be either a liquid or a gas Outlet Connections 5 Fast Loop Out connect to the return transport line This line must be at lower pressure than the process supply line and is typically downstream from the sample point 6 Relief Outlet option connect to a sample disposal This line will open if an overpressure event activates the relief valve 7 Grab Sample Outlet option connect to a grab sample unit to collect samples for analysis 8 Oily Drain x 2 Vent option connect to an oily drain or sample disposal suitable for the system media Grab sample outlet Return from analyzer Purge in Oily drain vent Sample to analyzer Oily drain vent h authorized as System Configuration 4 owagelok sales and service representatives System Startup 1 Place the FLM in bypass mode by moving the black handle BV1 BV2 to the left 2 Configurations 3 and 4 Close the sample return valve by moving the red handle BV3 BV4 to the up position 3 Open flow to the FLM by opening all fast loop in fast loop out and process return lines Since the FLM is in bypass mode allow your system to run for a minimum of five minutes in ord
30. g valve indicator PV PI 1 2 in Fast Loop Module Gas System Configuration 4 Only available through authorized owagelok sales and service representatives Operation 1 To place the FLM in sample mode move 3 Configuration 4 To adjust purge flow the black handle BV1 BV2 to the right turn the handle of the purge needle This will switch the flow to the sample valve NV3 clockwise for less flow or side of the FLM counterclockwise for more flow 2 To place the FLM in bypass mode move 6 To collect a sample from the grab the black handle to the left This allows sample outlet open the needle valve all FLM flow to bypass the sample side NV2 of the loop 7 To return the FLM to sample mode 3 Configurations 3 and 4 To drain the reverse steps 1 through 3 system while in bypass open the plug valve PV Configuration 3 systems may not drain completely If more effective N draining is required Configuration 4 Failure to periodically inspect and would be more appropriate maintain valve packing may result 4 Configurations 3 and 4 To place the in leakage system in drain purge mode move the N black handle to the left to put the FLM Swagelok ball valves are in bypass mode Then move the red designed to be used in the fully handle to the down position to switch open or fully closed position the analyzer return line to drain mode and opens the purge lines Purge lines are in Configuration 4 only Grab sa
31. he left and the and to allow for gravity to assist in draining outputs to the analyzer on the right System the system Mount the FLM as close to operation is not recommended in any other the analyzer inlet system or analyzer as orientation possible The mounting holes are designed to fit over the bolt heads and assist in mounting Attach with 1 4 in fasteners with a maximum head size of 1 2 in not provided in the four mounting holes on the plate Dimensions in inches centimeters are for reference only and are subject to change 1 4 in Fast Loop Module Top 4 mounting holes for 1 4 in 6 mm socket 0 40 1 02 head cap screw or gt lt 0 35 0 89 nr hex head bolt Left Side Grab sample 1 71 43 4 ng ia Fast loop outlet outlet option Return from analyzer 0 69 1 75 Purge in Fast loop inlet 9 90 11 9 251 Relief outlet 302 Out to option analyzer Drain vent Drain vent Only avaitaBte hrough sathorized 22 to 27 Ib 10 0 to 12 2 kg owagelok sales and service representatives Mounting 1 2 in Fast Loop Module Top 0 75 1 90 RE 4 mounting holes for 1 4 in 6 mm gt lt 0 50 1 27 socket head cap screw or hex head bolt 2 66 6 76 15 0 38 1 Left Side Right Side 1 81 4 81 4 60 Grab sample 0 88 2 24 mint a PesEisop UNE outlet option e A Return from 1 09 analyzer 2
32. ith a material that is compatible attacked with the system fluid Poppet elastomer was Poppet contamination Clean poppet and valve inside surfaces Seal leakage Fluid deposits buildup on seat SS Consider using two check valves in series Upstream pressure is greater than the cracking pressure when valve is not expected to be open Age or wear Downstream pressure is less than the reseal pressure when back pressure is required for sealing lower cracking pressure springs Reverse flow and upstream pressure has dropped to 0 Spring not centered on the poppet stop Incorrect reassembly of valve Incorrect installation of valve Consider using a spring with a higher cracking pressure Service during preventive maintenance Clean and replace internal components as needed Consider using a spring with a higher cracking pressure Install spring per service instructions Reassemble valve according to service instructions Use a backup wrench Inspet end connection for damage replace if damaged Leakage to the End connection leakage Reinstall the fitting to the valve end connection atmosphere o Clean O ring and reassemble valve per service Replace O ring Reassemble valve according to Check valve not compatible with helium leak test specifications Helium leak test leakage Consider using a positive shutoff valve Cracking pressure of spring is too Valve chatter or high INg pressi pring i noise at op
33. ment bos 2 Teflon tunada to bold the Jnr emgann br rimi arany bareh The Tifi beile alr irha h i brep Ehr ccenpenbe rinami pmol m tia coral emp testa lation The orginal saidile steel bolts were nbncmed H necenary apply small aguas of lhe jo the bower half of each bolt t dinee they m huhrirated Remove any reer lobe fore the bolts hefeer ieainiiiag ibe Held the cove verticalby wiih at lean to of the fener bales irvialiad to te palm of your hand insili the new gases over the bolita vo dini i m agent the mew element Figure 1 7 Plar fhe cow ath fhe erw elit ol gnaket me fhe benle aoe oral Br Priima taatia mni ibe ane Lier ibe ans qual limpa wrench wih the 8 socket to tighten each bolt to 50 Fitba Tighten the bolti m as alterations pattern mal all bolts ere torqued tp 20 TE fhe Restore the melo flew ic the Tamada NOTE The garbei choad te reptaced each time the Tornado 602 a duagsembled Canis A erporntias Lido AD npghes reserved 3 ECC AOS DIDO 1 In Mairsen rico 00H Only available through authorized S k q t t WagelOK Sales ana service representatives Qu analnk Pra Enninaarad Qrheyetam Fact nonon Mad ile aAUCIUR FIC ETUINICE CU OUUSVoOLG HH Faol LUUD IVIQUUIE J J 54 Tornado Model 602 Maintenance Instructions VORNADO K An ISO 9001 2008 certified company Model Numbering amp Additional Part Numbers Your model number is determined by your specific needs Choose options below Element rating
34. mple Red handle needle valve BV3 BV4 NV2 Black handle BV1 BV2 Purge needle valve NV3 Needle valve NV 1 Pressure Plug valve indicator PV P1 Only available care macas Ore owagelok sales and service representatives Maintenance A Warning Before servicing any installed system component you must E depressurize the system E purge the system when possible Follow these steps to depressurize your FLM 1 Place the FLM in bypass mode by moving the black handle BV1 BV2 to the left Fig 1 2 Configurations 1 and 2 There is no direct method within the FLM to fully depressurize the system Use external means to depressurize these configurations 3 Configurations 3 and 4 Place the system in drain purge mode by moving the red handle BV3 BV4 to the down position 4 Configurations 3 and 4 Open the purge valve PV 5 Configurations 4 After a suggested minimum of five minutes close the purge line by moving the red handle to the up position 6 Verify that the FLM is depressurized by checking the pressure on the pressure gauge PI Ball Valve Packing Adjustment If a packing adjustment is needed on the 40 series ball valves BV1 BV2 and BV3 BV4 it is not necessary to shut down or remove the system from service Upper coupling A Interlock Black flange handle Lower coupling Fig 1 System shown in Bypass mode Shown without tubing or system
35. nal information Configuration Symbols BV Ball valve NV Needle valve flow indicator L CV Check valve PI Pressure indicator FI Flow indicator O 2 FFL Filter fast loop PV Plug valve RV Relief valve optional Y w O z7 bid NV Needle valve grab sample or NV purge outlet SN Snubber fitting gauge protector SN standard for liquid service Configuration 1 Base Module Bypass Only Needle valve NV Flow indicator Fl Ball valve BV1 BV2 Pressure r 2 indicator Filter PI FFL NV Liquid Fast Loop Out Fast Loop In Only available Pazed Analyzer owagelok sales and servic representatives Configurations Configuration 1 Base Module Bypass Only with Grab Sample and Relief Outlets Shown Grab sample needle valve NV2 Flow indicator FI Ball valve BV1 BV2 Relief valve Needle valve RV NV1 Filter Pressure FFL indicator Pl Grab Sample Outlet NVI Liquid NV1 Gas Fast Loop Out Fast Loop In NH SN Liquid To Analyzer Relief FFL Outlet RV Only available through authorized owagelok sales and service representatives Configurations Configuration 2 Return from Analyzer To Process Grab sample needle valve NV2 Flow indicator FI Ball valve BV1 BV2 Relief valve RV Needle valve NV1 Pressure indicator Ria PI F
36. nut Spring support Bonnet Bonnet O ring Stem Lock wire hole Quad seal Retainer Seat retainer Seat O ring A Swagelok proportional relief valves should never be used as code safety relief valves A Some system applications require relief valves to meet specific safety codes The system designer and user must determine when such codes apply and whether these relief valves conform to them A Swagelok proportional relief valves are not Safety Accessories as defined in the Pressure Equipment Directive 97 23 EC Only availabe Swagelok sales and service representatives R4 Series Relief Valve Maintenance Instructions Seal and Stem Replacement Instructions Contents e 1 quad seal e1 O ring e 1 bonded stem Quad Seal and O Ring Replacement 1 Remove valve from system 2 Loosen cap to relieve spring pres sure 3 Remove bonnet from body 4 Remove stem and retainer from bonnet 5 Remove quad seal from bonnet 6 Make sure all parts are clean before reassembly 7 Install new quad seal into bonnet Lubricate with system compatible lubricant 8 Place retainer in bonnet then insert stem into bonnet through retainer and quad seal 9 Remove and replace bonnet O ring Lubricate with system compatible lubricant Thread bonnet into body and torque to 400 in lb 45 N m Adjust desired set pressure as described in steps 7 through 10 in the Spring Installation section on reverse si
37. pet Stop Poppet N W Body Hex Inlet Body Poppet Seal End Connection Only available through authorized owagelok sales and service representatives Service Instructions CH Series Check Valve Tool Requirements Tool size depends on the nominal end connection size and style See the chart below Tool Size and Quantity for body for End for body Hex Connection Qty 2 Qty 1 Nominal End Connection Size 1 8 in 1 4 in 6mm 3 8 in 1 2 in 1 2 in FNPT 1 2 in BSP ISO 8mm 11 16 in 7 16 in 11 16 in 9 16 in 11 16 in 14 mm i 1 1 16 in 1 1 16 in 1 1 16 in 1 1 16 in 1 1 16 in 12mm 22mm 3 4 in 1 1 8 in 1 in 1 1 2 in 22 mm 1 1 2 in Torque wrench to read 200 in Ib 22 N m 10 mm 25 mm Spring Kit Contents f Installation 1 Refer to the flow direction arrow on the check valve and install the valve in the correct orientation Outlet Flow Direction Arrow 2 Follow the fitting assembly instructions for Swagelok VCR and VCO fittings 3 When installing a valve with pipe fittings or straight thread fittings follow standard industry practices Testing 1 Test the valve to ensure there is no leakage to the atmosphere 2 Check for correct cracking pressure 3 Test the valve to ensure it stops reverse flow Maintenance Disassembly 1 Remove the check valve from the system 2 Separate the inlet body from the outlet
38. t kit be used rather than a rebuild kit Insufficient lubrication twisting of seals etc can adversely affect performance Kit Contents Replacement Kit O ring Kit Handle O rings 8 total Roll pin 2 sizes Plug O rings 3 Snap ring Note Brass plugs have green PTFE coating 316 SS plugs have gray PTFE coating Procedure A Before servicing any installed valve you must depressurize system cycle valve purge the valve Replacement Kit Instructions 1 Remove snap ring using snap ring pliers or similar tool and discard See Fig 4 Turn handle to the open position 2 Lift up handle to remove old plug and discard entire subassembly 3 Clean body bore and lubricate lightly with a silicone based lubricant 4 Remove protective sleeve from new plug Insert plug straight down into body See Fig 3 Note Do not pinch O rings between body and plug 5 Install snap ring with snap ring pliers or similar tool See Fig 4 6 Test the valve for proper operation Only available through Swagelok sales and servic representatives i In Handle O rings 3 total 2 Sizes gt Snap ring Fig 1 Small Large O ring O rings Fig 2 O Ring Kit Instructions 1 Remove snap ring using snap ring pliers or similar tool See Fig 4 Set aside Turn handle to the open position 2 Lift up handle to remove plug remove the O rings from the plug and discard O rings See Fig 3
39. through 4 in the Spring Installation section Springs A B or C can be reused in step 3 Tighten against cap 11 Test for set pressure 12 To adjust set pressure relieve system 2 pressure and loosen lock nut To increase set pressure tighten cap as needed To decrease set pressure loosen cap as needed 13 Repeat steps 10 through 12 as necessary to obtain desired set 2 pressure 14 Lock nut Tighten to 100 in Ib 11 3 N m 15 4 Cap Rest on bonnet Cap Bonnet a Lockwire Lead seal Body Only av ugh authorized owagelok sales and service representatives 32 R3A Series Externally Adjustable Relief Valves Maintenance Instructions pull rod Pull rod 6 Set screw Tighten to 10 in Ib 1 1 Nm T Cap Thread to initial position indicated in Spring Kit Identification table 8 To adjust set pressure see steps 10 through 13 in the Spring Installation section Only available through authorized Swagelok sales and service representatives R3A Series Externally Adjustable Relief Valves Maintenance Definition of Symbols Instructions Seat Replacement Tools Required Discard Lubricate With system compatible lubricant 3 4 in Thin head Lock nut 1 R f t 3 16 in max Remove valve trom system Open end Ca Bonnet nut Body wrench retainer Hex bit 5 16 in Seat socket retainer Torque 250 in lb Seat
40. y visit swagelok com or contact your authorized Swagelok representative Swagelok veo VCR TM Swagelok Company Tornado TM ahah tion LLC snay available through authorized owagelok sales and service represer PASSES MS 13 219
41. y insert the tube into the fitting and 3 against the shoulder rotate the nut finger tight Fig 1 High Pressure Applications and High Safety Factor Systems Further tighten the nut until the tube will not turn by hand or move axially in the fitting 2 Mark the nut at the 6 o clock position Fig 2 3 While holding the fitting body steady tighten the nut one and one quarter turns to the 9 o clock position Fig 3 Note For 1 16 1 8 and 3 16 in 2 3 and 4 mm tube fittings tighten the nut three quarters turn to the 3 o clock position Gaugeability On initial installation the Swagelok gap inspection gauge assures the installer or inspector that a fitting has been sufficiently tightened Fig 1 Position the Swagelok gap inspection gauge next to the gap between the nut and body Fig 4 e f the gauge will not enter the gap the fitting is sufficiently tightened e If the gauge will enter the gap additional tightening is required Reassembly Instructions You may disassemble and reassemble Swagelok tube fittings many times A Warning Always depressurize the system before disassembling a Swagelok tube fitting 1 Prior to disassembly mark the tube at the back of the nut mark a line along the nut and fitting body flats Fig 5 Use these marks to ensure you return the nut to the previously pulled up position 2 Insert the tube with preswaged ferrules into the fitting body until the front f
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