User Manual - Rev 10 Mar 15
Contents
1. Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc Page 19 of 192. Branch 35 ene So 1 74 ranch 40 InstrumentTee 760 2 Branch 50 InstrumentTee 89 0 3 Branch Ca nn Tee 15 0 au 40 50 s10 WPCV WPCV WPCV WPCV WPCV 30 0 35 0 45 0 56 0 71 0 4 100 WPCV jan 100 stev 5o je 150 _ stcv 560 js 200 stcv 600 680 780 80 0 10 68 0 78 0 Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc Page 5 of 19 3 1 8 3 Bellows Data Nominal Bore Half Joint Total Merle Thickness 1 25 14 5 1 4 32 14 5 1 4 40 18 5 2 50 18 5 2 65 18 5 3 80 18 5 4 100 20 5 125 24 6 150 25 8 200 27 5 10 250 26 12 300 26 14 350 28 5 16 400 27 18 450 29 5 20 500 33 24 600 33 5 28 700 36 5 30 750 40 5 32 800 40 5 36 900 40 5 Nb As standard bellows are supplied with threaded flange holes 3 1 8 2 Nut Stud Data Thread Nut Thickness mm UNC Thread Pitch mm Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc Thread Pitch Nut Thickness mm mm Metric Thread Assuming nuts are faced on one side Example To work out the length of a stud for a joint add together the total length for each half of the joint e g a 1 1 2 fitting to a 1 1 2 rotating flange spool 21mm 32 5mm 53 5mm To this value add on two off nut thicknesses clear threads if using studs or one nut thickness cl
3. Flange Material Types BS1501 161 430A ASTM A216 Grade WCB ASTM A240 Gr 304 BS970 1991 Gr 304515 230M07 070M20 ASTM A240 Gr 316 BS970 1991 Gr 316531 ASTM A240 Gr 304L 316L BS970 1991 Gr 304811 316511 Further with the BFSG Range of products the floating ball is the limiting pressure factor For 1 2 NB the maximum pressure is 6 bar g For the larger sizes the maximum pressure is 4 bar g These pressures apply across the entire temperature range 4 2 4 LGSG Tubular Sight Glasses These products are unsuitable for resisting torsional loads and the support system should ensure that these are not applied Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc 4 2 4 1 Maximum and Minimum Allowable Operating Pressures and Temperatures These are determined by the lowest of the allowable limits for the items comprising the sight glasses In most cases the PFA lining is the limiting factor see the graph below Recommended Maximum Internal Pressure bar 12 10 Pressure bar g O N A OD 0 25 50 75 100 125 150 175 Temperature C However in a few cases the flanges can be the limiting factor The tables below show the situations where this may be the case If the flange doesn t appear then this means that it can never be the pressure limiting factor for the sight glass Flange Temp Flange Material Type Class C Tn 220 304 56 7 10 to 50 10 0 10 0
4. Particular care should be taken to ensure the following e End boards must be kept in place until immediately prior to installation e Flare faces must be protected during preparation for painting and during painting e When the end boards of an item are removed the flare faces should be visually inspected If there is any surface contamination this should be removed using a soft clean cloth Page 2 of 19 3 1 3 System Pressure Testing In deciding upon the appropriate line test pressure this should be calculated to be 1 5 times the rated pressure of the lowest rated lined piping component in the system unless some other constraint from another item in the system requires a lower test pressure to be used In undertaking a pressure test care should be taken to ensure that pressure is applied from the upstream side of all non return valves and is released from the downstream side of all such valves to ensure a a pressure test of the complete system and b all of the test pressure has been removed from the system at the end of the test 3 1 4 Gaskets Gaskets are not normally required where PTFE lined items are being connected to similar products Where components are connecting to dissimilar materials such as glass ceramic or exotic metal then the use of a PTFE envelope gasket or similar device is recommended 3 1 5 Vent Holes The majority of lined products contain vent holes typically 5mm diameter These hol
5. 13 4 11 0 11 0 12 4 11 7 150 11 9 15 6 11 0 11 4 9 2 13 0 10 0 10 0 11 2 10 7 200 11 0 15 1 10 2 10 6 8 5 12 6 9 0 9 0 10 3 9 7 Flange Materials DIN 17100 R St 37 2 EN10025 235 JRG2 Werkstoff No 1 0038 C22 8 ASTM A105 ASTM A350 Gr LF2 ASTM A216 Gr WCB ASTM A182 Gr F304 ASTM A182 Gr F316 ASTM A182 Gr F304L 316L BS1501 161 430A ASTM A516 Gr 60 EN10028 2 P265GH ATIOAT VOIABOD Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc EN10222 5 Grade X5CrNi18 10 EN10213 4 Grade GX5CrNi19 10 and EN10028 7 Grade X5CrNi18 10 304 EN10222 5 Grade X2CrNi18 9 EN10213 4 Grade GX2CrNi19 11 and EN10028 7 Grade X2CrNi19 11 304L EN10222 5 Grade XSCrNiMo17 12 2 EN10213 4 Grade GX5CrNiMo19 11 2 and EN10028 7 Grade X5CrNiMo17 12 2 316 EN10222 5 Grade X2CrNiMo17 12 2 EN10213 4 Grade GX2CrNiMo19 11 2 and EN10028 7 Grade X2CrNiMo17 12 2 316L Page 12 of 19 BS10 Table D BS10 Table E IS01609 spool fitting on Temp Minimum Pressure Maximum Pressure 178 20 69 178 20 r8 29 200 However in a few cases the pipe can be the limiting factor The tables below show the situations where this may be the case If the pipe doesn t appear then this means that it can never be the pressure limiting factor for the MEI mm mm eNe 273 Max Allowable Pressure bar g at 250 N a N a 27 5 N a N a 7 N a 28 9
6. 24 M30 385 24 M36 435 36 900 44 7 8 M24 77 28 M30 365 28 M36 415 Note that for 28 and 32 ASME 150 torque for Series B flanges are quoted The torque values given above are a guide they may be exceeded by a value of 50 to effect a seal If once this torque level has been reached a seal has not been achieved it is likely that some other source of failure such as scratched flare faces is operating Note When bolting together dissimilar materials always tighten to the lowest recommended torque of the components in the joint Using higher torques may result in damage to the softer material in the joint 3 1 7 Disassembly The bolts on lined systems must not be loosened while the system temperature is above 60 C otherwise flare distortion or irrevocable damage may occur Always secure end covers on to the flanges of lined components which have been removed from a system this will prevent damage Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc the ingress of dirt and allow trouble free re assembly 3 1 8 Stud Bolt Length Calculator In order to calculate the length of stud bolt required for any joint it is necessary to calculate the half joint length for the two flanges that make up the joint and then add them together In addition allowance must be made for any wafer pattern item such as an instrument tee that is included in the joint The information below pr
7. fluid with the flange material These products are unsuitable for resisting torsional loads and the support system should ensure that these are not applied Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc Type 1 spacers are unsuitable for pressures greater than those of ASME B16 5 Class 150 Pressures are shown in bar g 4 2 3 1 Maximum and Minimum Allowable Operating Pressures and Temperatures In all cases these products can withstand full vacuum across their entire operating temperature range The one exception to this is if a PFA FEP liner has been added to the inside of the glass in which case the sight glass is not suitable for vacuum duties The maximum allowable operating pressures are determined by the lowest of the allowable limits for the items comprising the sight glasses In most cases the glass is the limiting factor see the table below data is for all temperatures from 29 C to 150 C Pressures are shown in bar g Page 14 of 19 Maximum Pressure However in a few cases the flanges can be the limiting factor The tables below show the situations where this may be the case If the flange doesn t appear then this means that it can never be the pressure limiting factor for the sight glass NB The pressures shown here given in bar g are applicable across the entire operating temperature range Flange Temp Flange Material Type Class C 10 to 50 9 1 Maximum Pressure
8. torques are checked at least 24 hours after commissioning or following the initial full process cycle and at least annually thereafter 3 2 2 LGSG Level Gauge The LGSG is lined with a PFA liner and is adequately protected in transit This packing must not be removed until installation as the liner can easily be damaged through the level gauge viewing slots 3 2 3 WPCV amp FPCV Wafer amp Flanged Poppet Check Valve In addition to the generic installation instructions for lined pipe products Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc e Check that the direction of flow arrow on the valve body points in the right direction e Ensure that the mounting flanges are parallel e Position the valve centrally between flange faces Ensure that there is sufficient contact between the flange faces and the sealing area of the check valve 3 2 4 SPCV Sight Glass Poppet Check Valve Follow generic installation instructions for lined pipe products and the additional instructions above for CTSG DTSG BFSG products Also particular care must be taken to ensure the product is installed the correct way up vis vis flow direction 3 2 5 Dip Legs amp Dip Pipes The Dip Pipe is internally and externally lined in PTFE and great care must be taken when handling this product to ensure that the liner is not damaged during transport storage or installation 3 2 6 Tee Piece amp Bulls Eye Sight Glasses Following installat
9. 10 0 10 0 9 1 9 1 7 ym 100 10 0 9 3 8 0 9 3 7 5 7 8 6 3 BOOM o 9 7 27 75 27 6a 7a 57 al aes Maximum Pressure BS10 17 8 to 200 Table D eam ss Flange Material Types 1 ASTM A105 ASTM A350 Gr LF2 ASTM A216 Gr WCB BS1501 161 430A DIN 17100 R St 37 2 DIN 2528 C22 8 ASTM A182 Gr F304 ASTM A182 Gr F316 ASTM A182 Gr F304L F316L Page 15 of 19 4 2 5 WPCV FPCV and SPCV Poppet Check Valves When considering draining and venting of systems containing check valves consideration must be given to the non return flow characteristics of the valves In assessing the suitability of SPCV valves for a particular service duty consideration must be given to the corrosion and erosion resistance of the borosilicate glass used in the sight glass element of the valves These are made from borosilicate glass 3 3 to ISO 3585 4 2 5 1 Maximum and Minimum Allowable Operating Pressures and Temperatures In all cases these products can withstand full vacuum across their entire operating temperature range Their maximum operating pressures are as detailed below Temperature range 29 C to 200 C WPCV Pressure range 1 to 19 6 bar g SPCV Temperature range 29 C to 150 C Pressure range 1 to 10 0 bar g FPCV See table below for details of the allowable pressure and temperature ranges for these valves These are determined by the lowest of the allowable l
10. 26 23 2 N a 300 323 9 3 2 L 30 9 29 3 25 5 22 8 N a M 28 9 26 9 24 2 21 5 19 5 N N a 30 9 N a N a N a P 30 2 29 2 26 9 N a N a 3 6 M N a 30 3 27 3 N a N a 350 355 6 3 6 L N a 30 26 2 23 4 N a M 29 6 27 6 24 8 22 20 P N a 29 9 27 6 N a N a 4 M N a 30 7 27 6 N a N a Pipe Materials EN10216 5 Seamless amp EN10217 7 Welded Grade X5CrNi18 10 304 EN10216 5 Seamless amp En10217 7 Welded Grade X2CrNi19 11 304L EN10216 5 Seamless amp En10217 7 Welded Grade X5CrNiMo17 12 2 316 EN10216 5 Seamless amp EN10217 7 Welded Grade X2CrNiMo17 12 2 316L v2 RT Room Temperature i Pipe NB EET ene Max Allowable Pressure bar g at Max Allowable Pressure bar g at Pipe Pipe NB Schedule Material 12 10 Pipe Eg ime 150 to 29 to 150 to 6 27 7 N a T 20 7 20 1 24 9 23 5 U 17 3 16 1 T 29 7 N a 20 R 28 9 N a 8 10 R 25 3 23 6 S 24 1 22 8 S 21 1 19 9 T 28 9 N a T 25 3 N a U 24 1 22 3 U 21 1 19 5 V 30 7 30 7 10 10 R 22 6 21 1 14 10 R 26 3 N a S 18 9 17 9 S 21 9 20 7 T 22 6 21 8 T 26 3 N a U 18 9 17 5 U 21 9 20 3 12 10 R 20 7 19 4 20 S 27 4 25 9 S 17 3 16 4 U 27 4 N a Pipe Materials R ASTM A312 TP304 U ASTM A312 TP316L S ASTM A312 TP304L V ASTM A333 Gr 6 T ASTM A312 TP316 Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc Page 13 of 19 The vacu
11. CRP crp EENE ENN ete el Todmorden Road Littleborough OL15 9EG United Kingdom Phone 44 0 1706 756400 Fax 44 0 1706 379567 Email enquiry crp co uk Web Issue Date 9 3 15 www crp co uk User Manual A guide to the specification storage installation operation and maintenance of CRP s range of lined pipes fittings and ancillary piping products Sections 1 3 contain practical information for those involved in storage and installation whilst section 4 is more relevant to those involved in specifying product Each section starts with generic information relevant to all products This is followed by product specific information An EC declaration of conformity is included in the guide If you have questions not answered by this guide CRP will be pleased to help our contact details can be found above User Manual Rev 10 Mar 15 doc Page 1 of 19 1 Introduction This document is intended to provide information to aid in the specification storage installation operation and maintenance of CRP s range of lined pipes fittings and ancillary piping products While the information contained here is based upon many years of experience test results and design calculations it is for general guidance only and is given without guarantee warranty or liability In the case of uncertainty on the part of the user please contact the manufacturer for advice on any of the contents of this document PTFE
12. PFA and FEP lined products cannot be treated in the same way as unlined steel products and personnel responsible for all aspects of them should be competent to undertake such work 2 Storage 2 1 Generic Instructions Lined products should ideally be stored indoors in cool dry conditions This is because neither the end boards nor the primer paint with which they are painted are intended for prolonged outdoor exposure PTFE and PFA are relatively soft materials Therefore to protect the lined surfaces they are supplied with end boards These boards should only be removed immediately prior to installation If they are removed for inspection purposes they should be replaced immediately or irrevocable damage and distortion may occur During removal of the end boards care should be taken to avoid damaging the flare faces of the products since this will likely result in leakage once the item has been installed During transport lined products should not be moved by having anything placed inside the bore as an aid to moving such as the forks of a fork lift truck since this may well damage the liner resulting in failure of the lined item 2 2 Product Specific Instructions 2 2 1 LGSG Level Gauges The LGSG is lined with a PFA liner and is packed in such a way as to protect this liner during transport and storage This packaging should not be removed until installation as the liner can easily be damaged through the level gauge viewing s
13. commodate should have been within the allowable ranges However in time if the process changes or there is any subsequent movement in the pipework this may result in the movements required of the bellows falling outside the acceptable limits If this is found to be the case steps should be taken immediately to remedy the situation PTFE Convolutions The PTFE convolutions of a bellows should be inspected regularly for signs of external and internal damage If any significant damage is found the bellows should be immediately removed from service 3 2 8 5 Allowable Bellows Movements Bellows are designed to allow axial lateral and angular movements and combinations of these movements Page 9 of 19 Axial Movement Lateral Movement It is not allowable to have the maximum amount of any one movement combined with any amount of the other possible movements The following is a useful rule of thumb in trying to assess situations where a combination of movements is required Let Dx axial movement Dy lateral movement Da angular movement Dx Dy Da lt 1 DXmax DY max Da max Nb Bellows are not designed to allow torsional rotation around their axis movements If torsional Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc movements occur this will compromise the integrity of the bellows and lead to immediate or premature failure 3 2 8 6 Genera
14. creased although if it is desired to limit the axial extension of the bellows they can be shortened The tie rods should never be removed It should be noted that the tie rods are not designed to be sufficiently strong to resist all possible axial loads that could be applied by a piping system Rather they are designed to resist any loads generated by pressure inside the bellows themselves Limit Sleeves The limit sleeves are supplied set to prevent the bellows from being over compressed These should never be removed Movement Range Setting Ideally a bellows should be fitted such that the movements it experiences results in the bellows being as near its neutral length as much as possible since this will ensure its life is maximised It may therefore be appropriate to install the bellows extended or compressed compared to its neutral length so that at its operating temperature it has returned to approximately its neutral length In a similar vein if a bellows is to cope with a movement say of 20 mm axially it would be better Page 8 of 19 to arrange the adjacent pipework such that the movement is 10mm about the neutral length rather than the neutral length 20 Omm Post Installation Inspection After installation and again after the first process cycle the bellows should be re inspected particularly to detect any increased misalignment compared to the design amounts If any increase has occurred appropriate acti
15. cted to ensure that no excessive erosion has occurred In designing the support structure the user must take into account the following factors in both operating and test conditions and the possibility of more than one of these loads occurring simultaneously Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc Internal pressure from the contained fluid The mass of the contained fluid Traffic wind and earthquake loading The potential to overstress the flanges Vibration Reaction forces and moments which result from the supports attachments thermal movement other piping etc e Fatigue etc In earthquake conditions CRP is unable to guarantee the integrity of its products and the user must take suitable precautions to guard against potential product failure and its consequences in these circumstances It is the responsibility of the user to ensure that suitable pressure relief and other appropriate safety devices have been included in the design of the entire pressure system and that discharges from such equipment have been considered including draining facilities to prevent liquid build up in gas lines which may give rise to water hammer If the products are to reach temperatures during operation or test which would be harmful to individuals should they come in contact with the products in these conditions it is the users responsibility to overcome this hazard The user is responsible for ensuring that suitable
16. ear threads if using bolts If using an item with threaded holes no nuts are required If the threaded holes are blind no clear threads need to be added for that side of the joint If the threaded holes are through holes clear threads may also be added if required Page 6 of 19 3 2 Product Specific Instructions If there is no mention of a particular product in this section there are no additional product specific instructions to follow 3 2 1 CTSG DTSG BFSG Tubular Sight Glass Following installation the tie rod torques must be checked This is achieved in the following manner Release the backing nuts at both ends of the sight glass Check the torques on the outer tie rod nuts with a torque wrench in pairs diagonally opposite see the table below for recommended torques Nb This is a safety critical step Failure to retighten the tie rods may lead to leakage between the end flanges and the glass Retighten all of the backing nuts NB This is a safety critical step Failure to retighten these nuts may lead to excessive compressive or torsional loads being applied to the glass resulting in damage to or failure of the glass The following table gives recommended torque levels for tie rod nuts Nominal Bore Torque imp Nm 1 25 10 1 1 2 40 15 2 50 20 3 80 30 4 100 37 6 150 44 8 200 44 10 250 44 12 300 44 It is strongly recommended that tie rod
17. es fulfil two critical purposes 1 In some circumstances depending on temperature pressure and the chemistry of the contained media a small amount of material may permeate through the liner As it reaches the outside of the PTFE it can form a pocket of trapped gas and if this permeant is not allowed to escape through the vent holes it can lead to the collapse of the liner in the lined component 2 They provide an early indication of liner failure Rather than a liner failure occur catastrophically the vent holes can indicate a problem possibly before it becomes serious Where vent holes exist the user is responsible for setting up a system to regularly check them If any product is leaking from the vent holes the item in question should be removed from service without delay since catastrophic failure is likely to occur if no action is taken It is therefore important not to block the vent holes with paint or any other substance This requirement applies equally to systems where vent extensions plugs are utilised Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc 3 1 6 Bolting Materials Bolting materials should be of good quality clean and well lubricated The use of washers is recommended to ensure correct even torque Bolts should be tightened by use of a torque wrench in strict sequence of diagonally opposite pairs This and all subsequent torqueing of bolts should be undertaken at ambient temperature It is stron
18. gly recommended that all bolts are re torqued a minimum of 24 hours after commissioning or following the initial full process cycle The torque of all bolted joints should then be rechecked at least annually thereafter The following table gives recommended torque levels for flange to flange connections Page 3 of 19 Torque and Bolting Details Nominal ASME 150 Meie Quantity Sorsat porstu Bho Quantity ae hes Quantity eae eee v 15 4 1 2 M12 7 4 M12 16 4 M12 16 1 20 4 1 2 M12 15 4 M12 32 4 M12 32 1 25 4 1 2 M12 19 4 M12 40 4 M12 40 1 4 32 4 1 2 M12 24 4 M16 55 4 M16 55 1 4 40 4 1 2 M12 27 4 M16 60 4 M16 60 2 50 4 5 8 M16 47 4 M16 66 4 M16 66 2 72 65 4 5 8 M16 53 8 M16 45 8 M16 45 3 80 4 5 8 M16 73 8 M16 50 8 M16 50 4 100 8 5 8 M16 54 8 M16 55 8 M16 55 5 125 8 3 4 M20 83 8 M16 74 8 M16 74 6 150 8 3 4 M20 108 8 M20 103 8 M20 103 8 200 8 3 4 M20 136 8 M20 137 12 M20 91 10 250 12 7 8 M24 127 12 M20 99 12 M24 118 12 300 12 7 8 M24 145 12 M20 104 12 M24 148 14 350 12 1 M27 182 16 M20 142 16 M24 191 16 400 16 1 M27 173 16 M24 197 16 M27 247 18 450 16 1 1 8 M30 262 20 M24 173 20 M27 245 20 500 20 1 1 8 M30 231 20 M24 197 20 M30 332 24 600 20 1 1 4 M30 331 20 M27 257 20 M33 494 28 700 40 3 4 M20 70 24 M27 295 24 M33 337 30 750 44 3 4 M20 51 Not applicable 32 800 48 3 4 M20 66
19. imits for the flanges on the ends of the valves Nb Pressures are in bar g Flange Class Temp C 1 2 3 4 5 29 to 38 19 6 19 0 19 0 15 9 16 3 50 19 2 18 3 18 4 15 3 16 0 100 17 7 15 7 16 2 13 3 14 9 150 15 8 14 2 14 8 12 0 14 4 200 13 8 13 2 13 7 11 2 13 8 10to50 10 0 9 1 9 1 7 6 10 0 100 10 0 7 5 7 8 6 3 9 3 150 9 7 6 8 7 1 5 7 8 7 200 9 4 6 3 6 6 5 3 7 8 10 to 50 16 0 14 7 14 7 12 3 16 0 100 16 0 12 1 12 5 10 2 14 9 150 15 6 11 0 11 4 9 2 13 9 200 15 1 10 2 10 6 8 5 12 4 BS10 17 8 to 6 9 LE m D 200 Maximum Pressure BS10 17 8 to 13 8 Table E 200 Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc Flange Material Types ASTM A105 ASTM A350 Grade LF2 ASTM A216 Grade WCB ASTM A182 Grade F304 ASTM A240 Grade 304 ASTM Grade F316 ASTM A240 Grade 316 ASTM A182 Grades F304L and F316L ASTM A240 Grades 304L and 316L BS1501 161 Grade 430A 4 2 6 Dip Legs and Dip Pipes 4 2 6 1 Maximum and Minimum Allowable Operating Pressures and Temperatures In all cases these products can withstand full vacuum across their entire operating temperature range Their maximum operating pressures are determined by the lowest of the allowable limits for the items comprising the dip legs pipes In most cases the fla
20. ion the tie rod torques must be checked with a torque wrench in pairs diagonally opposite The following table gives recommended torque levels for tie rod nuts Nominal Bore No of Tie Rods 1 25 4 11 15 1 1 2 40 4 18 24 2 50 4 31 42 3 80 4 44 59 4 100 6 51 69 6 150 8 39 53 It is strongly recommended that tie rod torques are checked at least 24 hours after commissioning or following the initial full process cycle and at least annually thereafter 3 2 7 STCV Swing Check Valve The valve can be universally mounted in both horizontal and vertical pipelines and some angled pipelines The angled sealing face is particularly beneficial in horizontal lines in providing a positive shutoff as even when the disc is closed against the seat gravity still exerts a noticeable closing force on the disc In horizontal lines the valve must be mounted correctly with the hinge part of the valve uppermost within the pipeline Page 7 of 19 In vertical or angled lines the flow must be upward through the valve allowing gravity to provide a valve closing force The valve body has a clear flow direction arrow cast into the side The valve must be fitted into the pipeline with the direction of this arrow pointing downstream The 8in DN200 and above sized valves have a threaded hole in the top of the body to allow a lifting eye to be fitted to allow easy handling and installation The valve is manufact
21. l Comments Due to the nature of PTFE bellows extra care must be taken when handling installing and using these products In particular the following issues must be addressed to ensure satisfactory operation of the bellows Bellows are not designed to accommodate incorrect pipework installation In fact they should be fitted with as much care as a pump and similar equipment In assessing the required movements from a bellows likely construction tolerances should be taken into account Do not use abrasives such as steel wool wire brushes or emery paper to clean bellows These can cause scratches on the PTFE leading to premature failure of the bellows If there is a possibility of temperature or pressure surges beyond the operating range of the bellows systems must be put in place to prevent such surges from occurring If a bellows is to be used with abrasive slurries or solids a smooth bore internal sleeve should be used to ensure smooth flow through the bellows and to minimise the risk to the PTFE convolutions from abrasion by the contained fluid 3 2 9 Atomac and Durco Valve Products Please refer to the appropriate Installation Operation and Maintenance Manuals on the website Page 10 of 19 4 User Instructions 4 1 Generic User Instructions It is the responsibility of the user to ensure that the products are suitable for conveying the intended chemical s and for the intended operating conditions Specificall
22. lots Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc 2 2 2 Sight Glasses By their very nature sight glasses contain glass which is brittle Care must be taken to avoid impacts with all glass parts of these products during transport and storage 2 2 3 Dip Legs Dip Pipes Since these products have an external lining of PTFE extra care must be taken when storing handling and transporting them since due to their mass fairly minor drops knocks or scrapes can result in the liner being damaged or broken 2 2 4 Bellows The PTFE convolutions of bellows are not protected by any metalwork Therefore during storage and handling particular care must be taken not to damage them Also the packaging that they are supplied in should be kept in place until immediately prior to installation 3 Installation Operation amp Maintenance 3 1 Generic Instructions 3 1 1 Overview PTFE amp PFA lined products cannot be treated in the same way as unlined steel products In order to ensure trouble free operation the following instructions should be followed carefully Note Welding brazing soldering or flame cutting must not be performed on lined products These processes may damage the liner and toxic gasses may also be produced 3 1 2 Flare Faces The flare face on any lined piping component forms the sealing face of the component to the next item in the line Therefore it is vital that this face is not damaged at any stage
23. m their position and route be recorded in the technical documentation to facilitate safe maintenance inspection and repair If lined equipment is to be used to for wet chlorine duty the maximum temperature must not exceed 150 C Above this temperature any chlorine that permeates the liner may react with the steel shell and cause a fire 4 2 Product Specific User Instructions 4 2 1 NB 14 NB Spools amp Lined Fittings 4 2 1 1 Maximum and Minimum Allowable Operating Pressures and Temperatures These are determined by the lowest of the allowable limits for the items comprising the spools fittings In most cases the flanges are the limiting factor see tables below Nb Pressures are shown in bar g For pressure ratings at intermediate temperatures in the tables below linear interpolation can be used to calculate allowable pressures Flange Material Types 1 ASTM A105 ASTM A350 Grade LF2 ASTM A216 Grade WCB ASTM A182 Grade F304 ASTM Grade F316 F100 27 8 ASTM A182 Grades F304L and F316L BS1501 161 Grade 430A Flange Materials Tempe car ree ae 10to 50 10 0 10 0 100 8 0 10 0 a S i 3 2 150 7 5 9 7 6 8 7 1 5 7 8 1 6 2 6 2 7 0 6 7 200 6 9 9 4 6 3 6 6 5 3 7 9 5 6 5 6 6 4 6 1 10 to 50 16 0 16 0 14 7 14 7 12 3 14 7 14 2 14 9 14 6 13 5 100 12 8 16 0 12 1 12 5 10 2
24. ng Flange 325 3 80 Heavy Duty Spool Rotating Flange 425 4 100 Heavy Duty Spool Rotating Flange 44o jee tee tesa ee O e Standard Duty Spool Rotating Flange 54 0 Standard Duty Spool Rotating Flange 370 t 300 Standard Duty Spool Rotating Flange 58 5 14 350 Standard Duty Spool Rotating Flange 8 200 Heavy Duty Spool Rotating Flange Heavy Duty Spool Rotating Flange 12 300 i F 3 1 8 2 Wafer Pattern Product Data Metric 2 Branch mer Tee Component Component Thickness 80 Fitting Rotating Flange 100 Fitting Rotating Flange 150 Fitting Rotating Flange 200 Fitting Rotating Flange 10 250 Fitting Rotating Flange 12 300 Fitting Rotating Flange 14 350 Fitting Rotating Flange 3 so crse rss 6 150 crse brss 8 200 ctse otsg_ 10 250 ctse otse_ eo Je sages 45 degree Elbow Fixed Flange 1 45 degree Elbow Rotating Flange 1 45 degree Elbow Rotating Flange 1 45 degree Elbow Rotating Flange 2 45 degree Elbow Rotating Flange 2 Notes 1 Bolt holes threaded UNC 2 Bolt holes threaded UNC Half Joint Total Thickness 12 5 15 0 17 0 21 0 23 0 28 5 29 5 31 5 36 5 39 5 41 0 43 5 22 5 27 0 29 0 EEN EYA e 45 5 49 5 56 5 61 5 63 0 67 5 34 0 38 0 38 0 38 0 43 0 46 0 46 0 45 0 49 0 52 0 14 5 23 9 27 5 28 5 34 5 1
25. nges are the limiting factor see tables below NB Pressures are shown in bar g Flange Material Type Class C 1 2 3 4 5 asme ERE B16 5 17 9 15 9 16 2 13 4 17 2 Class 149 15 9 14 1 14 8 12 1 15 9 150 13 8 13 1 13 4 11 0 13 8 OVJ 29 to 38 31 0 31 0 31 0 31 0 31 0 B16 5 27 8 27 8 27 8 27 8 27 8 Class 149 23 7 23 7 23 7 23 7 300 200 0 20 0 20 0 20 0 20 0 10 to 50 10 0 9 1 9 1 7 6 10 0 BS EN on EAEE PN10 200 9 4 6 3 6 6 5 3 7 8 10 to 50 16 0 AGEN 14 7 14 7 12 3 16 0 100 16 0 1092 1 12 1 12 5 10 2 14 9 Nee o se 15 1 Flange Temp Maximum Pressure BS10 Table E Flange Material Types 1 ASTM A105 ASTM A350 Gr LF2 ASTM A216 Gr WCB ASTM A182 Gr F304 ASTM A182 Gr F316 ASTM A182 Gr F304L F316L BS1501 161 Grade 430A Page 16 of 19 Adapter Flanges ee Max pressure bar g 400x25 25 0 400x40 25 5 400x50 26 0 400x80 27 0 400x100 29 0 NB While every effort is made to ensure that the products supplied are to specification the user should note that it is impossible to pressure test dip leg pipes and therefore as part of plant commissioning such a test should be undertaken 4 2 7 Blanking Spades Lined Spectacle Blinds and Solid PTFE Spectacle Blinds 4 2 7 1 Maximum and Minimum All
26. noted that the glass elements of these sight glasses are made from borosilicate glass to DIN 7080 and if the glass is unlined the user must confirm the suitability of this glass for conveying the intended chemicals 4 2 8 1 Maximum and Minimum Allowable Operating Pressures and Temperatures In all cases these products can withstand full vacuum across their entire operating temperature range Their maximum operating pressures are determined by the lowest of the allowable limits for the flanges on the sight glasses and are as detailed below NB All pressures are shown in bar g Cast Sight Glasses Temp Operating Pressures Bar g C 29 to 38 Page 17 of 19 Fabricated Sight Glasses Flange Temp Class 29 to 38 5 100 150 200 10 to 50 100 150 2 10 to 50 16 0 14 7 Maximum Pressure OORD 17 3t0200 69 BS10 Table E 17 8 to 200 13 8 Flange Material Type 2 16 3 16 0 14 9 14 4 13 8 9 1 8 3 8 1 Q n 19 6 19 2 17 7 15 8 13 8 10 0 10 0 9 7 Q o Q Q Q oO zx io Flange Material Types 1 ASTM A105 ASTM A350 Grade LF2 ASTM A216 Grade WCB 2 BS 1501 16 430A DIN 2528 C22 8 The glass discs on sight glasses must never be loosened or removed when the internal pressure in the sight glass is other than ambient nor when there is a contained fluid present whose leakage would be hazardous to personnel or equipment 4 2 9 STCV Swing Check Valves When c
27. ollowing standards as relevant ASME B31 3 ASTM F1545 Product Range Description Nominal Bore Size Range PTFE Lined Pipe Spools gt DN25 DN350 CTSG amp DTSG Tubular Sight Glasses gt DN25 DN300 BFSG Tubular Sight Glasses gt DN25 DN150 PTFE Lined Dip Pipes Dip Legs gt DN25 DN100 LGSG Tubular Sight Glasses gt DN25 DN50 PTFE PFA Lined Elbows all angles up to 180 gt DN25 DN350 PFA Lined Tees equal and reducing gt DN25 DN350 PFA Lined Lateral Tees equal and reducing gt DN25 DN350 PFA Lined Instrument Tees gt DN25 DN350 PFA Lined Short Stack Tees gt DN25 DN350 PFA Lined Crosses equal and reducing gt DN25 DN300 PTFE PFA Lined Concentric amp Eccentric Reducers gt DN25 DN300 large flange end PTFE PFA Lined Reducing Flanges PTFE PFA Lined Blank Flanges WPCV FPCV and SPCV PFA Lined Poppet Check Valves PTFE Type 1 Spacers PTFE Lined Type 2 amp 3 Spacers PTFE PFA Lined Blanking Spades PTFE PFA Lined Spectacle Blinds Solid PTFE Spectacle Blinds Tee Piece Sight Glasses Bulls Eye Sight Glasses Swing Check Valves Bellows gt D gt D gt D gt D gt D gt D gt D gt D gt D gt D DN gt D N25 DN600 large side N25 DN600 N25 DN100 N25 DN300 N25 DN300 N25 DN350 N25 DN300 N25 DN200 N25 DN100 N25 DN100 100 DN300 N25 DN900 ies e A E Lage wus David MacGregor Engineering Manager
28. on should be taken to remedy the situation Welding Weld spatter hitting the PTFE convolutions will cause bellows to fail prematurely It is therefore vital that welding is not allowed in the vicinity of bellows at any time Safety Shields For all PTFE bellows excluding those with a metallic outer there is only one layer of PTFE between the contained fluid and the outside world Therefore CRP recommends the use of safety shields on bellows for hazardous duties Pipe Supports Bellows should not be fitted and the system pressure tested until all of the supports on the adjacent pipework have been installed Failure to do this could lead to the bellows being forced to move beyond their allowable limits causing premature failure Almost all pipework systems are subject to a variety of forces such as thermal expansion vibration internal pressure etc which can give rise to unwanted pipework movements To ensure the longevity of the pipework system it is critical that these movements are considered and suitable measures including pipework supports are taken to accommodate them PTFE bellows can provide one part of the solution in accommodating such movements It is beyond the scope of this document to define suitable pipe supports however with regard to bellows the designer must take account of the following Pipework adjacent to bellows must be suitably supported to prevent inappropriate loads being transferred to the bell
29. onsidering draining and venting of systems containing check valves consideration must be given to the non return flow characteristics of the valves Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc 4 2 9 1 Maximum and Minimum Allowable Operating Pressures and Temperatures For these valves the maximum operating pressure is limited to that of an ASME B16 5 Class 150 flanged component of the same material as detailed in the table below pressures are shown in bar g Valve Material Temperature ASTM A216 ASTM A351 C Gr WCB Gr CF8M 29 38 19 7 19 0 93 17 9 16 2 149 15 9 14 8 200 13 8 13 4 4 2 10 Bellows 4 2 10 1 Maximum and Minimum Allowable Operating Pressure and Temperatures These are as detailed in the CRP bellows brochure Under no circumstances should these be exceeded Page 18 of 19 EC Declaration of Conformity hereby declare that the products listed below comply with the requirements of the relevant sections of the Pressure Equipment Regulations 1999 Pressure Equipment Directive 97 23 EC Manufactured by CRP Ltd Todmorden Road Littleborough OL15 9EG UK Assessed by the notified body Royal amp Sun Alliance Certification Services 17 York St Manchester M2 3RS Assessed against the requirements of the Conformity Assessment Procedure Module H Designed amp manufactured to meet the appropriate requirements of the f
30. ovides the data necessary to allow these calculations to be made Page 4 of 19 3 1 8 1 Lined Item Data Half Joint Total Thickness 40 Vanstone Spool o s 37 80 Vanstone spool f o s a7 100 Vanstone spool f o e 200 Vanstone Spool Heavy Duty iner a0 er 2o Vanstone spool tonoa Dune f ero yr Heavy Duty Spool Fixed Flange 13 5 4 76 Heavy Duty Spool Fixed Flange 14 5 1 25 Heavy Duty Spool Fixed Flange 17 5 Bas 40 Heavy Duty Spool Fixed Flange Component 50 f 10 100 Heavy Duty Spool Fixed Flange Heavy Duty Spool Fixed Flange Heavy Duty Spool Fixed Flange Heavy Duty Spool Fixed Flange 21 5 26 5 yxH0 31 0 20 5 Size Component y Fitting Fixed Flange Ma ain e a 25 ting Fixed Flange 3 s0 Fitting Fixed Flange e 150 FittingFixedFlange ES 200 300 350 15 20 75 40 50 Fitting Rotating Flange Fitting Rotating Flange Fitting Rotating Flange Fitting Rotating Flange Fitting Rotating Flange Pe a Standard Duty Spool Fixed Flange 10 250 Standard Duty Spool Fixed Flange eS Standard Duty Spool Fixed Flange TERRE Standard Duty Spool Fixed Flange Heavy Duty Spool Fixed Flange 35 0 Heavy Duty Spool Fixed Flange 38 0 12 300 Heavy Duty Spool Fixed Penge 40 0 e is heaw Duty Spool Rotating Fange 235 20 Heavy Duty Spool Rotating Flange 265 40 Heavy Duty Spool Rotati
31. owable Operating Pressures and Temperatures In all cases these products can withstand full vacuum across their entire operating temperature range Their maximum operating pressures are as detailed below Maximum Pressures bar g Blanking Spades PTFE PFA lined Solid PTFE Spectacle 29 C to 150 Cto Steel Pinas 149 C 200 C Spectacle 100 200 15 31 31 31 0 31 31 24 20 31 31 31 0 31 31 24 25 31 31 31 0 31 27 15 40 31 31 31 0 25 11 6 4 50 24 22 31 0 31 18 10 80 11 10 31 0 18 8 1 4 5 100 6 3 5 9 30 6 29 13 7 4 150 2 8 2 6 31 0 13 5 9 3 3 200 1 6 1 5 31 0 7 3 3 3 1 8 250 1 0 0 93 31 0 n a n a n a 300 0 68 0 64 31 0 n a n a n a 350 0 57 0 54 n a n a n a n a 400 0 43 0 41 n a n a n a n a NB For PTFE PFA lined items the operating temperature range is 29 C to 200 C For FEP lined items the range is 29 C to 150 C For solid PTFE spectacle blinds the limits are for blinds of the thicknesses detailed below For other thicknesses contact CRP for details of pressure limits All pressures are shown in bar g Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc DN DN Thickness 15 10 i310 16 p90 10 100 27 25 10 150 27 10 200 27 16 4 2 8 Tee Piece and Bulls Eye Sight Glasses In assessing the suitability of tee piece and bulls eye sight glasses for a particular service duty it should be
32. ows E g A vertically mounted bellows must not be relied upon to support the weight of the pipework mounted above or below it Bellows have significant spring rates and can exert significant loads on adjacent pipework as they are expanded or compressed Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc As bellows are pressurised this creates end loads on the adjacent pipework Nb For the above reasons vertically mounted bellows should not be attached directly to vessels on load cells 3 2 8 4 Maintenance and Routine Inspection Bellows are largely maintenance free items However regular inspections are required of them The following items should be checked on a regular basis Metallic Components Tie rods flanges and root rings These items should be inspected on a regular basis to look for any signs of damage or corrosion If any significant damage or corrosion is detected the bellows should be removed from service In addition it should be checked that the tie rods can move freely within the holes in the bellows flanges Leakage If any leakage around the bellows is detected or if any significant damage or discolouration of the PTFE convolutions is detected this should be investigated and appropriate action taken Appropriate precautions must be taken not to endanger personnel during any such investigations Movement When the pipework system was initially installed the movements that the bellows had to ac
33. provision is made to allow for any necessary draining and venting of the system The user is responsible for ensuring that suitable provision is made to allow for isolation of take off pipes if these are of a size to present a significant risk In addition the risk of inadvertent discharge must be minimised and the take off points must be clearly marked on the permanent side indicating the fluid contained While CRP applies a corrosion resistant undercoat paint to products or other customer specific paint prior to despatch unless specifically instructed not to do so by the customer or it is unnecessary due to the materials of construction the user is responsible for the maintenance of the exterior of the products to prevent corrosive attack Where under reasonably foreseeable conditions the allowable pressure limits of the products could be exceeded the user is responsible for the fitting of suitable protective devices and if appropriate adequate monitoring devices Page 11 of 19 By their nature PTFE PFA FEP lined products are not fire proof the PTFE PFA FEP lining will melt under extremes of heat Also the integrity of the glass elements of sight glasses cannot be guaranteed under such conditions Therefore if appropriate the user must consider how to meet any damage limitation requirements in the event of a fire If lined pipes or other products are to be placed underground it is recommended that as a minimu
34. s The specification of the bellows supplied should be checked against that ordered both in terms of its physical attributes size flange type number of convolutions etc and also any special elements such as root ring material The flare faces should be examined to ensure that they are free from Issue Date 9 3 15 User Manual Rev 10 Mar 15 doc scratches or other damage that would allow the joint to leak Also the convolutions should be examined to look for any abrasion nicks in the PTFE or any other damage Once the bellows have been examined the end caps and other protection should be refitted until the bellows is due to be installed 3 2 8 3 Installation Lifting If a bellows is to be lifted by crane or other mechanical lifting device it should be slung from one or more of the tie rods but ensuring that the sling does not press against the convolutions Never lift by slinging around or through the PTFE convolutions themselves End Caps All bellows are supplied with end caps covering both flare faces These should be kept in place until immediately prior to installation of the bellows After installation it is good practice to keep the end caps so that if the bellows are removed from service during maintenance or similar the end caps can be refitted to protect the flare faces Tie Rods Tie rods are supplied set to limit the axial extension of the bellows to the maximum allowable length These should never be in
35. um performance of spools and fittings are as detailed below T t Spools 1 2 8 NB full vacuum 29 C to 200 C Spools 10 amp 12 NB heavy duty liner full vacuum 29 C to 150 C Spools 14 NB standard duty liners full vacuum 29 C to 50 C Fittings 1 2 6 NB full vacuum 29 C to 200 C Fittings 8 14 NB consult factory 4 2 2 Spacers Types 1 2 amp 3 4 2 2 1 Maximum and Minimum Allowable Operating Pressures and Temperatures These are determined by the lowest of the allowable limits for the adjacent components See tables below Flange Temp Maximum Class C Pressure 29 to 38 19 6 ASME B16 5 Class 150 Agee amp Class 300 l o i 150 15 8 200 13 8 10 to 50 10 0 100 10 0 BS EN 1092 1 PN10 150 97 200 9 4 10 to 50 16 0 BS EN 1092 1 PN16 100 19 150 15 6 200 15 1 BS10 Table D 17 8 to 200 6 9 BS10 Table E 17 8 to 200 13 8 IS01609 29 200 1 5 4 2 3 CTSG DTSG and BFSG Tubular Sight Glasses In assessing the suitability of a CTSG DTSG BFSG for a particular service duty it should be noted that the tubular elements of these sight glasses are made from borosilicate glass 3 3 to ISO 3585 and the user must confirm the fitness of this glass for conveying the intended chemicals Further if an unlined tubular sight glass is being used the user must ensure the compatibility of the contained
36. ured to self centre between the boltholes Typically for instance in a horizontal line the two adjacent bottom bolts would be fitted first and the swing check valve rested on these bolts Then the remaining bolts can be fitted and all bolts correctly tightened to the specified torque There are no user serviceable items in the product although it is recommended that for critical services the valve should be inspected for wear at an interval to be determined by the user according to the severity of the duty 3 2 8 Bellows 3 2 8 1 Bolt Holes Bellows are supplied with threaded bolt holes as standard These should not be drilled out to create clearance holes due to the possibility of nuts studs hitting the PTFE convolutions leading to bellows failure or damage to the bellows during the drilling process In some circumstances there is no danger of nuts studs hitting the convolutions and so bellows flanges with clearance holes can be supplied Consult the factory if clearance holes are required When installed no more than 2 threads of the connecting studs should protrude beyond the back face of the bellows flanges 3 2 8 2 Initial Inspection Upon receipt from the manufacturer a bellows should be thoroughly inspected to ensure that it has not been damaged during transit from the factory If at all possible this inspection should be carried out in a clean dry covered area to avoid any potential damage during the inspection proces
37. y consideration must be given to the effects of corrosion erosion wear including potential effects from turbulence and vortices etc It should be noted that while PTFE PFA FEP have outstanding corrosion resistance they have limited erosion resistance and contained fluid velocities should be kept below 15m s In addition these products are not approved for conveying unstable fluids Solids or slurry handling can create erosion in addition to corrosion The following list provides general guidance on the handling of slurries However the degree of erosion is dependent on the nature of the solids being handled and therefore in cases of doubt it is recommended that testing be carried out to prove the suitability of lined piping The contained fluid and solids should be chemically compatible with the lining Ideally the flow velocity should be kept at 0 6 to 1 2 m sec but in any case should not be more than 2 1 m sec Consideration must be given to components where the flow path is convoluted since this may give rise to local flow velocities in excess of the general flow velocity To minimize erosion particle sizes should be less than 60 microns Particle sizes greater than 150 microns will likely result in unacceptable levels of erosion Intermediate particle sizes will likely result in acceptable levels of erosion Long radius elbows should be used Regular inspections of the insides of the lined piping system should be condu
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