Raimondi Test pressure caps device F6072-6075 IOM Owner's manual

Brand: Raimondi

Model: Test pressure caps device F6072-6075 IOM

Type: Owner's manual

Test pressure caps device – Figure 6072 to 6075

Installation and Maintenance Instructions

Emerson reserves the right to change the contents without notice RAIIC-0051-EN-1310

1. Safety notice

Proper installation, operation and maintenance are essential to the safe and reliable operation of

valve products.

The relevant procedures recommended by Raimondi are described in this manual, and effective

methods of performing the required tasks.

It is important to note that this manual contains various ‘safety messages’ which should be

carefully read in order to minimise the risk of personal injury, or the possibility that improper

procedures will be followed which may damage the involved

Raimondi product, or render it unsafe.

It is also important to understand that these ‘safety messages’ are not exhaustive. Raimondi cannot

possibly know, evaluate, and advise any customer of all the conceivable ways in which tasks might

be performed, or the possible hazardous consequences of each way. Consequently, Raimondi has

not undertaken any such broad evaluation and, thus, who uses a procedure and/or tool, which is

not by Raimondi, or deviates from Raimondi recommendations, must be thoroughly satisfied that

neither personal safety, nor valve safety, will be jeopardised by the method and/or tools selected. If

not so satisfied, contact Raimondi if there are any questions relative to tools/methods.

Some of the products manufactured by Raimondi may be used in radioactive environments.

Consequently, before starting any operation in a radioactive environment, the proper health physics

procedures should be consulted and followed, if applicable.

The installation, operation and maintenance of valves and/or valve products may involve proximity

to fluids at extremely high pressure and/or temperature. Consequently, every precaution should be

taken to prevent injury to personnel during the performance of any procedure.

These precautions should consist of, but not limited to, ear drum protection, eye protection and

the use of protective clothing (i.e. gloves etc.) when personnel are in or around a valve work area.

Due to the various circumstances and conditions in which these operations may be performed on

Raimondi products, and because of the hazardous consequences of each way, Raimondi can not

possibly evaluate all that might injure personnel or equipment. Nevertheless, Raimondi does offer

the safety precautions listed on page 4 for customer information only.

It is the responsibility of the purchaser or user of Raimondi valves/equipment to adequately train

all personnel who will be working with the involved valves/equipment. Further, prior to working

with the involved valves/equipment, personnel who are to perform such work should become

thoroughly familiar with

the contents of this manual. Accordingly, should any additional copies of this manual be required,

they can be purchased by contacting Raimondi

2. Introduction

This special isolator was developed to provide a simple means of isolating Test pressure cap

devices for hydrostatic test.

The product comprises a robust body in the appropriate grade of steel, having two parallel faces

inside the centre chamber.

Both of these faces, the furthest from the Test pressure cap device, is a sealing face, which is

cladded with stainless steel to prevent corrosion. The internal closure realizes a seal against this

face. During normal plant operation, the isolator acts as part of the pipe, featuring an unobstructed

flow (see Fig. 1b).

Fig. 1a

Index

1. Safety notice 1

2. Introduction 1

3. Design features 2

4. General arrangement 2

5. Parts list 3

6. Dismantling procedure 4

7. Assembly procedure 4

8. Inventory philosophy 5

9. Classification of spare parts 6

10. Factory refurbishment 7

11. Service warranty

12. Raimondi product repair by

unauthorized sources

Some of the products manufactured by Raimondi may be used in radioactive environments. Before

starting any operation in a radioactive environment, consult the proper health physics procedures

and follow them.

The installation, operation and maintenance of valves and/or valve products may involve proximity

to fluids at extremely high pressure and/or temperature. Precautions must be taken accordingly in

order to prevent injury to personnel and damage to property.

These precautions include, but are not limited to, ear drum protection, eye protection and the use

of protective clothing (gloves etc.) when personnel are in or near valve operation area. Due to the

variety of operating circumstances and conditions, Raimondi cannot possibly evaluate all situations

that might result in personal or property damage. Nevertheless, Raimondi does offer safety

precautions in page 4 for customer information only.

It is the responsibility of the purchaser or user of Raimondi valves/equipment to adequately train

all personnel who will be working with Raimondi valves/equipment. Prior to working with the

valves/equipment, personnel who are to perform such work should be familiar with the contents

of this manual. Accordingly, should any additional copies of this manual be required, these can be

purchased by contacting Raimondi.

Test closure

assembly

O-ring seal

Fig. 1b

RAIMONDI

www.valves.emerson.com

76228

3783717

124

17a

157a

157

105

28a

103

Test pressure caps device – Figure 6072 to 6075

Installation and Maintenance Instructions

Emerson reserves the right to change the contents without notice page 2

3. Design features

The bonnet seal in the Raimondi pressure seal test pressure cap device comprises a gasket ring in

reinforced graphite, compressed to a specific density.

The advantages of this type of seal are:

1. A normally machined sealing face is all that is required.

No lapping is involved.

2. Any minor damage to the sealing faces during maintenance only requires blending in into the

surface.

No expensive machining or lapping required.

3. The sealing ring surface does not require extremely careful handling during assembly.

4. The seal is made directly onto the body and bonnet.

There is no inlay or hard facing.

4. Internal test closure (See fig. 3)

1. This has been designed to be stored and assembled into the body as one unit.

2. Operation to realize the body/closure seal is by using a normal open ended spanner with

minimum of effort to produce the initial sealing force on the ‘O’ ring seal.

3. For safety during handling, lifting eye bolts are provided which DO NOT have to be removed at

any time during use.

5. Leakage detection (See fig. 2)

Provisions have been made in the body for leakage detection on both sides of the internal closure.

These connections are provided with a threaded plug and spiral wound stainless steel/CAF gasket.

Alternatively, by removing the plug and gasket, a pipe can be socket welded to the body without

further machining.

Fig. 2

Fig. 3

Table 1 - Partslist

Ref. No. Qty. Description Ref. No. Qty. Description

1 1 Body

2 1 Bonnet

3 1 Cover

17 1 Pressure seal gasket

17a 2 Gasket

28 * Cover stud

28a 1 Dome stud nut

37 1 Distance piece

51 1 Disk

63 2 Eyebolt

76 1 Segment ring

78 * Cover nut

78a 1 Dome nut

103 1 O-Ring

105 1 Locking plate

110 1 Name plate

124 2 Screwed plug

157 2 Shoulder screw

157a 1 Jacking screw

* Quantity depending on valve

size

Test pressure caps device – Figure 6072 to 6075

Installation and Maintenance Instructions

Emerson reserves the right to change the contents without notice page 3

6. Dismantling procedure (see Fig. 2 and Fig. 3)

6.1 To remove top cover and bonnet

1. Remove all cover nuts (78)

2. Using lifting equipment and eyebolt (63), lift the cover (3).

3. Tap down the bonnet (2), using a soft-faced hammer. This will relieve any pressure on the

segment ring (76).

4. Remove the segment ring (76) as described in section “Removal/Replacement of Segment Ring”.

5. Replace the cover (3) upside down, then using four equi-spaced cover nuts (78), “jack-up”

bonnet (2) until it comes into contact with the underside of cover (3).

6. Using lifting equipment, lift the cover (3) and bonnet (2) assembly completely, and lower to a

safe place.

7. Remove the four cover nuts (78), cover (3), distance piece (37) and pressure seal ring (17) from

the bonnet (2).

8. Inspect all cover studs (28) for wear or damage, replace with new ones as necessary

6.2 To remove internal closure

1. Unscrew hexagon-head jacking screw (157a) until locking plate (105) is approximately parallel

with the disc (51).

2. Using lifting equipment and the two eyebolts (63a), lift the closure assembly completely from the

body, taking care not to damage seat face and O-ring (103).

7. Re-assembly procedure (see Fig. 2 and Fig. 3)

7.1 To fit internal closure

1. Ensure that the body (1) seat face and disk (51) are clean.

2. Ensure that the locking plate (105) is approximately parallel with the disk (51), adjust with jacking

screw (157a) if necessary.

3. Place a new ‘O’ ring (103) into groove in disk (51) face.

4. Using lifting equipment and the two eyebolts (63), lower the closure assembly into the valve

body (1), being careful not to damage the ‘O’ ring (103) as it passes the body seating face.

5. By tightening the hexagon-head jacking screw (157a) into the locking plate (105) and against the

body, the disk (51) is loaded against the body sealing face.

Undue force is not necessary, it is sufficient to obtain contact of the sealing faces.

7.2 To re-assemble top cover and bonnet

1. Ensure that all components including the body/bonnet sealing areas and segment ring groove

are thoroughly cleaned.

2. Using lifting equipment, lower the bonnet (2) into the body (1).

3. Fit a new pressure seal ring (17) onto the bonnet (2) inside the body

4. Fit the distance piece (37), with tapped holes uppermost, using this to tap the pressure seal ring

(17) into position.

5. Refit the segment ring (76) as described in the section “Removal/replacement of segment ring”.

6. Fit the cover (3) and cover nuts (78), tighten the nuts evenly; this will jack up the bonnet (2) and

load the pressure seal ring (17) against the body (1) and bonnet (2).

Note

Further tightening or “following up” of the cover nuts must be carried out at regular intervals when

raising pressure in the valve pipeline, until there is no further movement.

6.3 Removal/replacement of segment ring (76)

1. Insert the knock-out pin into the knock-out hole located in the side of the body (1). Remove each

segment in the order shown (1, 2, 3 & 4).

2. Clean the segment ring (76) and the groove in the body (1) thoroughly, ensuring that any burrs

or debris are removed.

3. Refit the segment ring (76) in reverse order(i.e. 4, 3, 2 & 1), ensuring that each segment is fully

home in the groove and that they are aligned with the knock-out holes to facilitate their removal

in future.

Caution

Ensure that the valve pipeline is

depressurized and drained before

dismantling the valve.

Valve body

Segments

Knock-out

holes

Segment

knock-out pin

for removing

segments

8. Service parts inventory philosophy

The basic objective in formulating a service parts inventory policy is to provide prompt valve

service capability, thus preventing maintenance outage time extension. To accomplish this, it is

necessary to have immediate availability of the proper inventory of service parts for optimum valves

quantities. This can be achieved at minimum cost by defining the inventory on a frequency of need

basis.

To assist towards this objective, the field service and repair organization of Raimondi recommends

following these guidelines to establish meaningful inventory levels:

1. Identify the total number of valves in service by size, type number, pressure/temperature class,

tag number.

2. Identify the frequency of replacement tendency of specific parts:

Class I Parts most frequently replaced.

Class II Parts less frequently replaced, but critical in the event of an emergency requirement.

Class III Parts seldom replaced.

Class IV Hardware (e.g. nuts, bolts, pins, cap components etc.).

Class V Parts practically never requiring replacement.

Test pressure caps device – Figure 6072 to 6075

Installation and Maintenance Instructions

Emerson reserves the right to change the contents without notice page 4

3. “Need probability coverage’ is defined as the probable percent (%) of total, uninterrupted

operational time which can be expected by stocking predetermined valve component

classifications.

Determine “need probability coverage” which is compatible with a specific company’s

operational objectives and service parts inventory investment philosophy. Then relate “need

probability coverage” to parts classifications, which will satisfy that need.

Guidelines are as follows:

Parts classification Need Probability Coverage

Class I 70%

Class I and II 85%

Class I, II and III 95%

Class I, II, III and IV 99%

4. Consult the recommended spare parts list by valve type to determine the quantity of valve parts

to be covered by the inventory plan.

5. Select parts and specify quantities.

9. Identification and ordering essentials

When ordering service parts, please provide the following information to ensure receiving the

correct replacement parts:

Identify valve by Specify parts required by

1. Full Product No. 1. Part Name

2. Size 2. Part Number (if known)

3. Type 3. Quantity

4. Pressure/Temperature Class

5. Tag Number

Classification of spare parts

Classification Item No. Description

CLASS I 17 Pressure seal

Parts most frequently replaced 17a Gasket

103 O-ring

CLASS II 124 Screwed plug

Parts less frequently replaced but

critical in case of an emergency

CLASS III 37 Distance Piece

Parts seldom replaced 51 Disk

76 Segment ring

105 Locking plate

157 Shoulder screw

157a Jacking screw

CLASS IV 28 Cover stud

Hardware (e.g. nuts, studs, pins, etc.) 28a Dome nut stud

63 Eyebolt

78 Cover nut

78a Dome nut

CLASS V 1 Body

Parts practically never requiring 2 Bonnet

replacement 3 Cover

Emerson reserves the right to change the contents without notice page 5

Test pressure caps device – Figure 6072 to 6075

Installation and Maintenance Instructions

10. Factory refurbishing

Many customers find it desirable to return their valves to Raimondi for restoration or modernization.

Products returned to the Raimondi valve repair centre are restored to original specifications and

returned with a new valve warranty.

11. Service warranty

Factory repaired valves carry a warranty that covers workmanship and new parts installed during

the repair, for a period of one year from date of repair completion.

11. Raimondi product repair by unauthorized sources

Raimondi has not authorized any outside repair companies, contractors, or individuals to perform

warranty repair service on new products, or field/factory repaired products of its manufacture.

Therefore, customers contracting such repair services from unauthorized sources, do so at their

own risk.

Likewise, if any Raimondi product fails to perform within the scope of its design, Raimondi must be

notified and given the opportunity to inspect and correct the problem. Raimondi will not accept any

back charges for unauthorized repair sources performing corrective repairs on its products.

Raimondi Test pressure caps device F6072-6075 IOM Owner's manual

Raimondi Test pressure caps device F6072-6075 IOM Owner's manual

Raimondi Test pressure caps device F6072-6075 IOM Owner's manual

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