Redi Controls RuptureSeal RS-2 Guida alla risoluzione dei problemi

RuptureSeal™

Model

RS-2

Rupture Disk

Backup

Relief Valve.....

PatentNumbers5,577,389 & 5,644,930

.....forLowPressure Centrifugal Chillers

R-11 R-113 R-123

Manufactured inaccordance with

ASHRAE Guideline 3-1990 Sec. 4.6

Flow Tested per ASMEStandards

Redi Controls, Inc.

Installation Operation &Maintenance Manual

FileLiteratureNo. 1028-04

RevisedTechnicallyas of April 15, 1996

This Copywas Printed as of February 4, 2005

This product is marketed andsoldbyRediControls, Inc.,

under licensefrom Indianapolis SpecialtyValve, Inc.

Table of Contents

............................................................................................................................................Page

GENERALINFORMATION........................................................................................................4

Specifications.............................................................................................................................5

GeneralOverview.......................................................................................................................5

Installation Kit.............................................................................................................................6

Field Provided Items...................................................................................................................6

INSTALLATION .........................................................................................................................7

Figure 1. - Typical Installation.....................................................................................................8

Figure 2 - Hook-up to Vent Pipe.................................................................................................8

Figure 3 - Cutaway View ............................................................................................................9

Pressure Gauge and Auxiliary Alarm .........................................................................................9

SupplementalMounting Support ................................................................................................9

Double Check Pressure Equalizing Valve................................................................................10

Chillers utilizing R-123 (special piping instructions) .................................................................10

Leak Testing Procedure ...........................................................................................................10

MAINTENANCE .......................................................................................................................11

Following a Rupture .................................................................................................................11

Annual ......................................................................................................................................11

Servicing and Replacing O-Rings ............................................................................................12

Appendix“A”(Table fordetermining size of vessel RS-2 can be installed on) .........................13

Appendix“B”(Excerpt fromGuideline BSR/ASHRAE 15-1992R) ............................................14

Appendix“C”(Non-typical installations and theireffect on valve’s operation)..........................15

Parts List ..................................................................................................................................17

Warranty.................................................................................................................... Back Page

GENERALINFORMATION

YOU AREURGEDTOREAD THISMANUALCOMPLETELY BEFORE

INSTALLINGTHISVALVE

Upon Receiving YourUnit

Inspectthe unitforpossibledamage caused during shipping.Contact Equipment Servicing

before attemptingto use a damagedunit. (317)865-4130.

Warningsand Cautions

NOTE: Warnings and Cautions appearinhighlighted boxesasillustrated belowatappropriate

pointsthroughout thismanual. Givespecialattention totheseitems.

Warnings:areprovidedto alertyouto potential hazardsthatcouldresultinserious

personal injuryanddamageto your equipment.Warningsmayappearinthis manual

oronthe equipment. Heedall Warnings.

Cautions:aredesignedto alert youto situationsthatmayresultindamageto your

equipment.

Personalsafety and the properoperation of yourequipment requirestrict observance of

these precautions.

THIS VALVE SHOULDBE INSTALLEDONLYBY

QUALIFIEDPERSONNEL

Warning: Certainservicingprocedures mayexpose youto harmfulmaterials and

dangerousconditions. Tominimize thepossibilityof injury,followsafetyprocedures

andinstructions describedinthis manual, onproductlabels andinmaterial safetydata

sheets provided.

NOTE: The manufacturerhasacontinuousequipmentimprovementpolicy and reservesthe rightto

change specificationsand design of itsproductswithout notice.

Specifications

Flowcapacity:940 SCFM

Setpressure:15 psig

Reseals“bubbletight”within 3psiofset

pressure

Refrigerantcompatibility:R-11

R-113 &R-123

Weight:17 pounds

Dimensions(approximate):Length13

inches;height13 inches;width6inches

Inlet - 2-inchmaleNPTpipethreads

Outlet - 2-inchfemaleNPTpipethreads

IntegralsupportBoss - 3/4-inchpipe

O-Ring seat - sealsbubbletight

VALVE CONSTRUCTEDOFSTAINLESS

STEEL

Tell-talepressuregauge 30”Hg -0- 30 psig

Doublecheck pressureequalizing valve

(included)

Everyvalve100%testedfor pressure

setting and leakage

O-Ringsserviceablewithoutdisturbing

pressurereliefcalibration

Carbon fragmentcollection trapwith

speciallyformulatednon-toxic, non-

corrosivetack compound

Directspring acting

Pivotedspring action correctsmis-

alignmentand compensatesfor spring

sidethrust

Calibration isfactorysealedtoprevent

inadvertenttampering or dis-assembly

High capacityfull nozzledesign

Instantaneous“pop open” action

BACK PRESSURE COMPENSATED

General Overview

The RuptureSeal™rupturedisk backup reliefvalve, withits exclusivecarbon fragment collection trap,

isdesigned specificallyforinstallation inserieswithexisting carbon type fragmenting rupturedisks

used on lowpressure(15 psiorbelow) centrifugalchillers.

The primaryfunction ofthe RuptureSeal™isto minimizerefrigerantloss tothe atmosphereinthe

eventofaburstrupturedisk.The RuptureSeal™accomplishesthisvitalfunction byautomatically

closing off the ventpath,thusre-sealing the chilleroncepressurereturnstonormal.Inthe eventof a

burst rupturedisk, the RuptureSeal™alsoservesasthe interim primaryrelief.

NOTE: The RuptureSeal™ modelnumberdesignatesthe sizeofcarbon fragmenting rupturedisk it is

designed tobe used with(i.e., the “RS-2”isdesigned tobe used withatwo (2”) inchcarbon

fragmenting rupturedisk designed forcentrifugalchillers)..TheRS-2hasaflowcapacityof940

SCFM,however(perASHRAEguidelines),thiscapacitymustbede-rated10%wheninstalledin

serieswitharupturedisk.Whenfitting theRS-2 toachiller,theinstallermustdetermineifthe

de-ratedflowcapacityisadequatefor thatchiller.INCLUDEDFORYOURCONVENIENCEAS

Appendix“A”ISATABLEOFVARIOUSVESSELDIMENSIONSCOVEREDBYTHEMODELRS-2

RuptureSeal™ AFTER10%DE-RATING based on computationsusing the formulaprovided bythe

Guideline BSR/ASHRAE 15-1992R. Appendix“B”ofthismanualcontainsthe excerptfromthe

Guideline BSR/ASHRAE 15-1992Rwhich can be used todetermine the minimumflowcapacity

requirement forapressure-relief deviceasapplied toalowpressurecentrifugalchiller.

Installation Kit

Kitincludes:

Warning: Removal of thewiredscrews andleadseal (16) fromthe valve body (7) will

destroythepressurereliefcalibrationandvoidthewarranty!Ifservice to thevalve

assemblyeffectingcalibrationis required,itmustbereturnedto manufacturerfor

service.

FieldProvidedItems

Itemstobe supplied byinstaller:

(see Figure2on page 8)

Pipe & FlexibleMetalConnection (33)

Pipe Fittings

Dripleg (31) withDrainPort (38)

¼” line (37) toconnect ValveBodywater

drainhole (24) toDripLeg (31)

A twoinch (2”) FemaleNPTPipe Union (12)

(see Figure2on page 8)

Materialsforproviding supplementalsupport of

valve(3/4”iron pipe)

Typical Installation

One (1)Pre-assembled RS-2 RuptureSeal™

whichincludes:

3O-rings (1),(2) &(3)

Eight (8)1/4”Stainless SteelCap Screws (4)

One (1)Collection Trap ChamberCover (5)

One (1)Carbon Fragment Collection Trap CanisterInsert

withSpecialTack Compound (6)

One (1)Tee Connection (14) withplug

One (1)Tell-TalePressureGauge 30”Hg - 0-30 psig (21)

One (1)DoubleCheck PressureEqualizing valve (22) withFilter/Vent (34)

One (1)Installation Operation & MaintenanceManual

NOTE:

See Figure

3on Page9

for location

ofpartson

assembled

unit.

Chiller

INSTALLATION

Installation ofthe RuptureSeal™shouldbe performed onlybyqualified personnel.The following

installation instructionsshouldbe thoroughlyread and understood beforeattempting installation.

Minoralterationstothe existing rupturedisk ventpiping arenecessarytoinstall the RuptureSeal™

valve. The installershoulddetermine inadvancewhat toolsand materialswill be needed.

Warning:Wheneverpossible, theRS-2 shouldbeconnecteddirectlyto thechiller’s

outerrupturedisk flangeto assurethat,ifthereis arupture, ALL of thecarbon

fragmentsof thedisk will be projectedstraightinto the RuptureSeal™ carbonfragment

collectiontrap. Ifthis is not possible, see Appendix “C” forfurtherinformation.

Also,ifthereis arestrictionorconstrictionintheventpipeafterthe

RuptureSeal™ valve, orifa numberof chillerreliefs are ventedinto one inappropriately

sizedpipe, theoverall flowrateof thesystemmaybenegativelyaffected.Each

installationmusthavesuchfactorstakeninto consideration.(Forreference, see

ASHRAE Guidelines relatingto pipingaftera rupture device.)

Warning: DO NOTinstall anRS-2 RuptureSeal™ ona3” rupturedisk. Likewise,

DO NOTinstall anRS-3 RuptureSeal™ ona2” rupturedisk. Theratedflowcapacities

of theRuptureSeal™ reliefvalveare accurateonlywhentheappropriateModel is used

onanappropriatesizedrupturedisk. MISMATCHING MAYCAUSE THEVALVE NOTTO

OPEN, HENCEFLOW CAPACITYMAYBE(0)ZERO.

Installation Steps1thru 7 - (see below)

Warning: DO NOTattempt to install a damagedvalve!

NOTE: ITIS NOTNECESSARYTOREMOVE THECHILLER’S RUPTUREDISKTOINSTALL THE

RuptureSeal™.The valve’s2”carbon fragmentcollection trap inlet (13) (see Figure3on page 9for

location) shouldbe screwed directlyintothe chiller’souterrupturedisk flange (see Figure1on Page

8).If thisisnotpossible,see Appendix“C” forotherinstallation possibilities.If the installerwantsto

avoidputting stress on the rupturedisk assembly, astraight, 2inchIDflexiblecoupling can be used

between the rupture disk flange and the RuptureSeal™.

INSTALLATION(continued)

1.Determine the bestmounting arrangementforthe RuptureSeal™inrelation to

the chiller’sexisting rupturedisk, vent piping, and the recommended supplemental

support. The bestarrangementisone thatplacesthe RuptureSeal™asclose

aspossibletothe rupturedisk.The valvebody (7) can be rotated toorientthe

“outlettoventpipe” (8) inanyhorizontaldirection bylooseningthe three (3)valve

bodylocking screws (9) (forillustration,see the firstrowof Appendix“C” on page

16).Onceinposition,be suretore-tighten the three (3)valvebodylocking

screws (9).

2The RuptureSeal™“valve”shouldbe mounted inthe verticalposition withthe

carbon fragmentcollection trap chamber (10) inthe horizontalposition (see

Figure1 - TypicalInstallation).The RS-2can be mounted inotherpositions

(exceptupside down),however,the valveiscalibrated forthe verticalposition and

itshouldbe mounted inaposition otherthan verticalonlyif absolutelynecessary.

READWARNING BELOW.

Warning: YOU MUSTREADAppendix “C” ifmountinginpositionsotherthanas

illustratedinFigure 1.

Warning: Regardless of RS-2’s position, the Double Check Pressure EqualizingValve

(22) MUSTbemountedverticallywiththefilter/vent (34) pointingup(é).Anyposition

otherthanwiththe filter/ventendpointingupwill create a serious safetyhazard.

3. Determine howmuchofthe existingrupturedisk vent piping will havetobe removed to

accommodatethe RuptureSeal™. Cut out and removethissection ofpiping.

4.Itisrecommended thatyou utilizeaflexiblemetalconnection (33) tomakethe installation easier.

You must usea2”NPTunion (12) forfutureservicing.

5.The installershall determine the bestwaytoplumbthe exhaust

ventline using the hook-up toventpipe illustration inFigure2as

aguide.

6.Applythread sealantcompound tothreadson the valve’s2”

carbon fragmentcollection trap inlet (13) and install (see Caution

below.)Thisshould be screwed DIRECTLY intothe existing

rupturedisk flange wheneverpossible.Inno eventshouldthe

valvebe installed withan extension pipe morethan 14 inches

fromthe rupturedisk.(See Appendix“C” on Page 17 for

illustrationsifextension mustbe used.)IFANEXTENSIONPIPE

ISUSED,ITMUSTBESTRAIGHT(NO45ºor 90ºELBOWS)

and havea2”inside diameter.[Ifthevalveisnotverticalafter

tightening intotherupturediskflange,itmaybenecessaryto

install a2”pipeunion betweenthevalveand theouter

rupturediskflange.]

Caution: Be surethereis agasketbetweenthecarbonrupturedisk andtheouter

flange. Ifthere is not, one mustbe installed.

Figure1.

Typical Installation

(See Appendix“C”for

other installations)

Chiller

(33)FlexibleMetal Connection

(31)DripLeg

(38)Capped

DrainPort

(11)VentPipe

(8)OutlettoVentPipe

(12)2" NPTUnion

(24)Valve

Bodywater

drainhole

(37)Valve

Bodywater

drainhole

connection

toDrip

Leg

Figure2.

Hook-up to Vent Pipe

INSTALLATION(continued)

7.Determine best method forconnecting dripleg (31) tothe “outlet tothe vent pipe” (8) (see figure2

on page 8).Again, the “outlet tovent pipe” (8) can be adjusted topoint inanyhorizontaldirection

byloosening the 3valvebodylocking screws (9) and turning the valvebody (7) (see firstrowof

Appendix“C” on page 16 forillustration).Run a¼” line (37) fromthe ValveBodywaterdrain

hole (24) tothe DripLeg (31). (Don’t forget tore-tighten the 3valvebodylocking screws (9).)

(10 )Carbon fragment

collection trap chamber

(26 )Tension bar

(29 )Spring tension adjusting

mechanism and isolation

chamber upper part

(17 )Pin holefor spring locking

when servicing O-rings

(15 )3/4"non-threaded Boss

(18 )Collection

chamber

flange

(3)Collection chamber

flangeO-Ring

(4)Eight1/4"

SS cover

screws

(35 )Alarmport

with plug

(5)Collection trap

chamber cover

(14 )1/8"NPT Tee

(34 )Filter/vent

(22 )

Double

check

pressure

equalizing

valve

(6)Carbon fragment

collection trap

canister insert

with tack compound

(replaceable)

(21 )

Pressure

gauge

(8)Outlet to ventpipe

(23 )Water drain holein

isolation chamber

(1)Valve seat O-ring

(2)Valve bodyO-ring

(32 )Valve neck

(25 )Pull Ring

(30 )Spring

(39) Stem Seal

(9)Three valve body

locking screws

at 120 degrees apart

(28) Isolation Chamber

lower part

(13 )2"carbon fragment

collection trap inlet

(7)Valve body

(24) Valve Body

water drain hole

(16 )Calibration locking

screws and seal

Figure3 - Cutaway View

PressureGaugeand AuxiliaryAlarm

The pressuregauge (21) between the rupturedisk and the seating mechanismofthe valveisused to

letthe operatorknowifarupturedisk hasburstorisseeping.Apressureorvacuumreading other

than “0”psigindicatesaproblemwiththe rupturedisk.The doublecheck pressureequalizing valve

(22) isprovided topreventapressurebuild-up between the RuptureSeal™valveand the rupture

disk,usuallyresulting fromaseeping rupturedisk.Thisspecialdoublecheck pressureequalizing

valveallowslowpressurebuild-up tobleed-off,butre-sealsitself athigh pressuresorvacuum.IFAN

ALARMIS DESIRED tosupplementthe pressuregauge (ITIS HIGHLYRECOMMENDED)tosignal

when the rupturedisk hasruptured,itcan be installed inthe plugged alarm port (35) ofTee (14).

The ALARMshouldbe settoactivatebetween 4and 10 psig.Contactequipmentservicing for

information on the optional RediControlsAlarm™.

Supplemental Mounting Support

Itisrecommended thatasupplementalmounting supportbe provided forthe RuptureSeal™valveto

relieveanystress itmayputon the rupturedisk assembly(see Figure1on page 8).Asupport

mounting coupling (15) hasbeen provided forthispurpose.The coupling will accommodate3/4”

non-threaded pipe. The installershall determine the best waytoprovide the supplementalsupport.

INSTALLATION(continued)

Double Check Pressure Equalizing Valve

The doublecheck pressure equalizing valve (22) isprovided topreventapressurebuild-up between

the RuptureSeal™valveand the rupturedisk,usuallyresulting fromaseeping rupturedisk.This

specialdoublecheck pressureequalizing valveallowslowpressurebuild-up tobleed-off,butre-seals

itselfat high pressuresorvacuum.

Warning: DO NOTobstructrelief of Double Check Pressure EqualizingValve (22).

Chillers Utilizing R-123 (special piping instructions)

Warning: WheninstallingtheRuptureSeal™ onachillerutilizingR-123, itis advised

thatyoupipetheoutputof theDouble Check PressureEqualizing Valve (22) [after

removal of thefilter/vent (34)]into thelinerunningfromtheValveBodywaterdrain

hole (24) to theDripLeg (31).Ifthere’s arupture, this will preventseepageof R-123

into theequipmentroom.(See illustrationatbottomright cornerof Appendix “C” on

page 17.)

Leak Testing Procedure

Caution:DO NOTuse this procedureifchilleris atapressurelowerthan15” Hg.

Otherwise, accidental burstingof therupturedisk couldoccur byimplodingthe

rupture disk into the chiller!

1. Removepipe plug (oralarm, ifthe optional RediControlsAlarm™isused)fromalarm port (35)

ofTee (14).

2. Utilizing a1/8”NPTx1/4”Flair halfunion, connect arefrigeration manifoldset (lowside hose)to

the alarm port (35) ofTee (14).

3. Carefullyraisethe pressurelevelto NO MORE THAN5PSIMAXIMUM, and test forleaks using

standardleaktesting procedures.

Warning: Duringtesting,to maintainpressureatsuchalowpsi, youmayhaveto

removethefilter/vent (34) andholdyour fingerovertheoutletof theDouble Check

PressureEqualizingValve. DO NOTuse apluginoutletof theDouble Check Pressure

EqualizingValve. Ifthe plugwere not removed, itwouldcreate a serious safetyhazard.

4. At conclusion ofLeaktest procedure, releasepressureand removehoseat fitting fromTee (14).

Re-install the alarm orplug inthe alarm port (35) ofTee (14) and securetightly. DO NOT

reinstall pipe plug oralarm inanyposition otherthan the alarm port (35) ofTee (14).

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