Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

TEMPORARY STRAINERS

Installation, Operating and Maintenance Manual

Document Number: IOM/TEMP/001 Issue: 01

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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IMPORTANT All information and recommendations contained in this manual are to the best of our knowledge correct. Since the conditions of use are beyond our control, users must satisfy themselves that the equipment/products are installed in process lines that are comparable with the design parameters for which the equipment/products were intended as defined in the applicable purchase order. Before installing the equipment it is important that this manual is read and that the relevant precautions stated within are adhered to.

HEALTH & SAFETY AT WORK ACT

Kaysafe Engineering Limited assume that when the unit is to be installed in a hazardous service or environment, operators and maintenance personnel will be adequately protected in accordance with the latest governing legislation, including COSHH regulations. The equipment has been designed and manufactured to provide safety and prevent risk to health when properly used for the use intended. Because the manufacturer has no direct control over the method of operation, it is the responsibility of the user to ensure that the equipment is operated in a safe manner and in accordance with the procedures contained in this manual.

GENUINE KAYSAFE PARTS AND EQUIPMENT

It is our policy to manufacture our products to the high levels of integrity that is required by current legislation applicable to the Health & Safety at Work Act. It is therefore imperative that all spare parts used are of genuine Kaysafe manufacture. Kaysafe Engineering Limited undertakes no responsibility for alternative copies or imitations without written consent.

PRODUCT WARRANTY

Should any after-delivery problems arise, please contact Kaysafe’s Customer Complaints office during normal business hours. 01737 772210 or e-mail: quality@kaysafe.co.uk

WE RESERVE THE RIGHT TO CHANGE PRODUCT DESIGN AND PROPERTIES WITHOUT NOTICE.

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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TABLE OF CONTENTS SECTION TITLE PAGE

1 INSTALLATION ………………………………….… 4 1-1 Unpacking ……………………………………… 4 1-2 Installation ……………………………………… 4

2 COMMISSIONING ………………………………… 4 2-1 Commissioning ………………………………... 4 2-2 Special Tools ………………………………….. 5 3 OPERATION ……………………………………….. 5 3-1 Operation ……………………………………… 5 3-2 Safety …………………………………………. 5 3-3 Training ……………………………………….. 5 4 MAINTENANCE …………………………………… 6

4-1 Maintenance …………………………………… 6 4-2 Recommended Cleaning Techniques …...……...

4-3 Recommended Torque Values ………………… 8 4-4 Fault Finding …………………………………... 9 5 5-1 Dimensional Data Sheet ……………………….. 9 LIST OF TABLES TABLE PAGE 4-1 Recommended Torque Values ………………………... 8 4-2 Fault Finding Chart …………………………………… 9

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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SECTION 1

1-1 UNPACKING All Kaysafe Engineering products are tested and inspected during manufacture and prior to shipment. However, an inspection should be carried out at the time of unpacking to detect any possible damage that may have occurred during shipment.

1-2 INSTALLATION

Temporary type Strainers are delivered completely assembled for fitting into the pipeline. The following notes and checklist should be observed prior to installation:- a) The strainer must be fitted in line with the flow direction in accordance with

The drawing requirements. If mesh is fitted it must be on inlet flow side.

b) Check adjoining pipework for cleanliness and obstructions.

c) When bolting up the pipeline flanges, ensure that the correct bolting and gaskets are used in accordance with the size, type and rating of the relevant flange specification.

d) The fitting of a differential pressure gauge is recommended to monitor pressure differentials and to

indicate when the screen should be cleaned. These can be supplied and fitted upon request by Kaysafe Engineering Ltd.

IMPORTANT NOTES a) Ensure that the Strainer is in the correct orientation. b) For flanged units, always tighten the flange bolting in a diagonal sequence gradually up to the torque

specified. Refer to Recommended Torque chart, page 11 of this manual.

SECTION 2

2-1 COMMISSIONING

Ensure that the strainer has been installed in accordance with section 1 of this manual. For flanged units, check that the flange bolting has been adequately tightened to the correct torque. Refer to Table 4-1 page 11 of this manual. Seal off any drain and vent connections and return line process (utilising vents for dispelling air as appropriate). The pipline should be pressurised gradually up to approximately 50% of the normal working pressure. Check flanges for leaks.

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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Any detected leaks must be rectified accordingly. Check any instrumentation where fitted in accordance with manufacturers instructions. Upon satisfactory completion of all necessary checks, pressurise the strainer gradually up to full working pressure and flowrate. Re-check for leaks and rectify accordingly.

2-2 SPECIAL TOOLS

There are no special tools required for this equipment.

SECTION 3

3-1 OPERATION

Temporary Strainers are mechanical devices for removing solids and other contaminants from the process fluid by means of a perforated plate/mesh screen. They are designed for system start up / flushing of system and should be removed are start up unless agreed otherwise. If required for permanent operation they should always be cleaned prior to exceeding the agreed differential pressure. In general DP should not exceed 0.5 Bar, and cleaned at 0.3 Bar unless agreed otherwise. Temporary Strainers are simple and have no moving parts, they do not require any operating procedure.

3-2 SAFETY

Kaysafe Engineering Limited assume that when the unit is to be installed or maintenance work is carried out, particularly in hazardous services or environments, all operators/maintenance staff will be adequately protected in accordance with the relevant governing legislation and codes of practice. It is also assumed that the Health & Safety at Work Act is strictly adhered to.

3-3 TRAINING

No special training is required for this type of equipment, however, we recommend that all installation and maintenance work be carried out by a skilled/qualified competent fitter.

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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SECTION 4

4-1 MAINTENANCE

The only maintenance required for this type of equipment is to remove and clean the screen periodically, which will depend largely upon the amount of contaminants in the process fluid. The cleaning interval can be best determined from the installation of a differential pressure gauge or by operational experience and scheduled maintenance periods. When removing the screen, the following procedure should be observed: - a) Before attempting any maintenance whatsoever, it is essential that the process line is depressurised

by either a by-pass system or by closing the inlet/outlet valves (if fitted) or by what ever means necessary to ENSURE THAT THE PRESSURE AND FLOW HAVE BEEN SHUT-OFF AND THAT THE PIPELINE IS DEPRESSURISED OF ANY INTERNAL PRESSURE OR VACUUM.

b) The strainer should then be vented off within strict safety precautions to reduce hazardous conditions developing i.e. blow out, flashing etc. and drained of service via the drain connection (if fitted).

c) Slacken the bolting on the spool gradually using a suitable wrench whilst supporting the spool to

prevent over stressing of the flange interface joints. Remove the nuts/washers and retain for re-assembly and then remove the cover.

d) The screen should be cleaned in a suitable medium compatible with the process fluid taking care not

to damage the screen during handling, refer page 10 of this manual. DO NOT bang or hammer the screen as this may cause damage. Where compressed air is available, the contaminant may be blown off the perforated plate/mesh by applying air to the outside of the strainer for 'In to out' process flow and inside for 'Out to in' process flow. WHEN USING COMPRESSED AIR ALWAYS WEAR THE APPROPRIATE SAFETY GLASSES/CLOTHING.

e) Coarse retention screens may be cleaned using a stainless steel wire brush.

f) Always inspect the screen for any damage or wear. Damaged screens should always be rectified or

replaced before re-assembly into the strainer.

g) Fit the screen into the pipeline and secure between flange faces.

h) When the screen in service is ready for cleaning, as indicated by an increased pressure drop across the strainer, it should be removed and cleaned immediately. The flange gasket should be replaced. Where conditions permit the bolt threads should be lubricated with a compatible lubricant. NEVER USE OIL OR GREASE ON STRAINERS HANDLING OXYGEN!

CAUTION! OPENING A CLOSURE CAN BE A HAZARDOUS ACTIVITY. ALL PERSONNEL ENGAGED IN THE OPERATION AND MAINTENANCE OF THIS EQUIPMENT SHOULD READ ALL INSTRUCTIONS CAREFULLY.

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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i) Install the flange nuts/washers and hand-tighten. Ensure that covers fitted with drain connections are re-fitted in the same orientation as originally fitted. In certain cases this may be shown by markings on both the branch and cover flanges.

j) Proceed to tighten the bolting in a diagonal sequence up to 30% of the final torque value; refer to

Table 4-1, page 11 of this manual.

k) Check that the mating flange faces are bearing uniformly, and then continue to tighten in a diagonal sequence gradually until the final torque setting is achieved.

l) Seal off any drain and vent connections and return line process (utilising vents for dispelling air as

appropriate), check for leaks and rectify accordingly.

m) Damaged or broken screens should always be replaced with the correct Kaysafe replacement

GENERAL NOTES All gaskets and seals should be inspected upon installation and at regular scheduled maintenance intervals. If there is any sign of damage or deterioration then they should be replaced. All bolting should be checked periodically for tightness and re-tightened as necessary. Bolting should also be kept lubricated to aid maintenance purposes.

Periodic inspections should be made to monitor corrosion and damage to the screen.

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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4-3 RECOMMENDED TORQUE VALUES.

The values shown below are intended to assist the user of this manual in determining the correct value to torque standard flange bolting. Due to the many standard flange specifications and bolting diameter, the responsibility for assessing torque values that are not shown on the table below rest with the user.

TABLE 4-1 Recommended Torque Values Bolt Material - High strength alloy steel bolting e.g. ASTM A193 B7 Bolt Stress – The table below gives torque values required to achieve an average bolt stress equivalent to 50% of the bolt Yield Stress. (Care should be taken to select the correct coefficient of friction).

Lubrication / (Coefficient of friction µ) Bolt Size Moly

(µ=0.06) Copper (µ=0.10)

Nickel (µ=0.11)

Dry (µ=0.20)

mm In

Min. Yield (psi)

Torque required lbf.ft (Nm)

13 ½” 105000 19 (26) 24 (33) 26 (35) 45 (61)

16 5/8” 105000 52 (71) 79 (107) 85 (115) 146 (198)

19 ¾” 105000 92 (125) 139 (188) 151 (205) 258 (350)

22 7/8” 105000 146 (198) 223 (302) 242 (328) 415 (563)

25 1” 105000 219 (297) 333 (451) 362 (491) 620 (841)

28 11/8” 105000 331 (449) 508 (689) 553 (750) 953 (1292)

32 1¼” 105000 459 (622) 710 (963) 773 (1048) 1338 (1814)

35 13/8” 105000 616 (835) 959 (1300) 1044 (1415) 1816 (2462)

38 1½” 105000 804 (1090) 1258 (1706) 1372 (1860) 2393 (3245)

41 15/8” 105000 1027 (1392) 1614 (2188) 1761 (2388) 3081 (4177)

44 1¾” 105000 1288 (1746) 2031 (2754) 2216 (3004) 3888 (5217)

47 17/8” 105000 1592 (2158) 2519 (3415) 2751 (3730) 4836 (6557)

50 2” 105000 1937 (2626) 3074 (4168) 3358 (4553) 5914 (8018)

56 2¼” 105000 2766 (3750) 4411 (5980) 4822 (6538) 8521 (11553)

62 2½” 105000 3805 (5159) 6091 (8258) 6663 (9034) 11806 (16007)

69 2¾” 95000 4602 (6239) 7392 (10022) 8089 (10967) 14367 (19479)

76 3” 95000 5976 (8102) 9627 (13052) 10540 (14290) 18753 (25425)

Kaysafe Engineering Limited 2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59 Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295 Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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4-4 FAULT FINDING. TABLE 4-2 FAULT FINDING CHART

FAULT POSSIBLE CAUSE CORRECTIVE ACTION Closure bolting loose. Re-tighten bolting. Closure seal/gasket worn. Replace seal/gasket. Closure seal/gasket joint fouled with debris or foreign matter.

Clean joint.

Flange faces damaged. Re-machine faces.

Leaking through flange joint connections.

Flanges not bearing uniformly due to incorrect bolt tightening sequence.

Slacken bolting and re-tighten in correct sequence to recommended torque.

Clogged strainer screen. Clean or replace screen. High pressure loss across Strainer. Process change i.e. increase

in flow-rate, viscosity, dirt levels etc.

Check process parameters and adjust accordingly to design data.

Process fault. Check process. Clogged strainer screen. Clean or replace screen. Pipeline blockage. Check pipeline.

Decreased flow-rate.

Major leak. Rectify leaks. High dirt carry-over. Damaged strainer screen. Replace screen.

SECTION 5

5-1 DIMENSIONAL DATA SHEET

A dimensional data sheet is available upon request. Please contact our Technical Sales Department - Tel: +44 (0)1737 772210 or e-mail: sales@kaysafe