Safety Breakaway Coupling ABV Series

Operating instruction

www.rs-seliger.de

RS Roman Seliger Armaturenfabrik GmbH

MADE IN GERMANY

Dear customer, Thank you very much for your purchase at RS. We are glad about your decision for one of our first class quality products and that we could convince you of our capabi-lity. Ultimate perfection is our duty… i.e. our consequent and complete quality ma-nagement throughout the whole production process guarantees that only faultless products leave our premises… quality does not allow any compromises! For further detailed information about our products or an individual solution for your scope of work, do not hesitate to contact our sales team. We will assist you with all our experience and product know-how. A visit of our sales representatives can be arranged by appointment. It’s worth it! Further information about us and our multifarious product range can be found on our web site www.rs-seliger.de. We are looking forward to continuing our cooperation with you. Yours sincerely Dr. Jens Reppenhagen Managing Direktor

Safety breakaway coupling ABV Operation instruction

Subject to change without prior notice August, 2017

Safety breakaway coupling ABV Operating instruction

Page 2

1 General description

Function:

The safety breakaway coupling (ABV) consists of two case halves with a check valve in each. The cases are held together by breaking pins during normal operation. The two check valves support each other during normal operation and keep the conduit open. In case the tank wagon rolls away or someone forgot to disconnect the supply line before the truck drives off, the ABV is activated as follows: Before the supply line is stressed by undue external forces the two case halves of the safety breakaway coupling are separated from each other by the breaking of the three breaking pins that have predetermined breaking points. The force needed to separate the safety breakaway coupling is significantly less than is the force that would rip the hose or tear it off of its fittings. The spring-loaded check valves instantaneously close both ends of the line in case of a separation. One half of the coupling remains firmly connected to the tank wagon while the other half of the coupling remains connected to the supply line. This prevents the outflow of liquids or gases from both product carrying ends of the line. IMPORTANT: The tensile strength of the hose used must be at least 1.3 times greater than the coupling release force. Refer to Table 3.3 for the release forces.

For the operator:

The safety breakaway coupling ABV has to be checked once a month for proper condition. The results of the inspection have to be documented.

In so far as the safety breakaway coupling ABV is part of a mandatory inspected system, the safety breakaway coupling ABV has to be checked by a technical expert during the first as well as all repeating inspections.

Only qualified personnel may be assigned with assembling the safety breakaway coupling ABV. (Qualifications: experts, technicians, vocational training, job experience)

We would like to point out the professional obligations according to German law §62 WHG.

Page 3

2 Nominal widths and pressure level

Type Nominal width Connection Nominal Pressure Wrench size

ABV DN 25

BSP 1“ female

1“ NPT female

Flange EN 1092-1

Flange ASA-150 psi

Flange ASA-300 psi

PN 16/25

PN 16/25

PN 16/25

PN 16

PN 25

SW 41

SW 41

ABV DN 50

BSP 1“ female

1“ NPT female

Flange EN 1092-1

Flange ASA-150 psi

Flange ASA-300 psi

PN 16/25

PN 16/25

PN 16/25

PN 16

PN 25

SW 70

SW 70

ABV DN 65 BSP 1“ female PN 16/25 SW 85

ABV DN 80

BSP 1“ female

1“ NPT female

Flange EN 1092-1

Flange ASA-150 psi

Flange ASA-300 psi

PN 16/25

PN 16/25

PN 16/25

PN 16

PN 25

SW 100

SW 100

ABV DN 100

BSP 1“ female

1“ NPT female

Flange EN 1092-1

Flange ASA-150 psi

Flange ASA-300 psi

PN 16/25

PN 16/25

PN 16/25

PN 16

PN 25

SW 125

SW 125

Page 4

3 Technical data

3.1 Materials

Component Material no. Material Temp. range

Case

Spider 1.4408 GX6CrNiMo18-10 -40 / +150°C

Case, Closing cone,

Spider

1.4571 X6CrNiMoTi17122 (AISI 316 Ti) -40 / +150°C

2.4602 NiCr21Mo14W (Hastelloy C22) -40 / +150°C

2.4610 NiMo16Cr16Ti (Hastelloy C4) -40 / +150°C

Case 3.3547 Aluminum -40 / +60°C

Spring / ball 1.4401 X12CrNi177

3.2 Seals

Component Material Designation Temp. range

O-ring

NBR Perbunan -20 / +100°C

Ethylene-Propylene-Diene-Monomer EPDM

Buna AP -40 / +150°C

Perflouoroelastomer FFKM KalrezTM

ChemrazTM

-40 / +150°C

Fluoroelastomer FKM Viton -20 / +150°C

Thread seal PUR Vulkollan -40 / +150°C

PTFE Teflon -40 / +150°C

Kalrez, Viton, Teflon = registered Trademarks of DuPont

Page 5

3.3 Release force

Nominal

width

Nominal

Pressure

Unpressurised

kN

PN 16

kN

PN 25

kN

Release force

kN

DN 25 PN 16 3,2 2,2 4,2

PN 25 7 5,4 9,1

DN 50 PN 16 10 7,8 13

PN 25 15 11,5 19,5

DN 65 PN 16 15 11 19,5

PN 25 20 14 26

DN 80 PN 16 20 14 26

PN 25 28 18,4 36,4

DN 100 PN 16 30 20 39

PN 25 44 28,5 57,2

The release force is set up by the selection of the breaking pins. The breaking pins should be chosen according to the release force unpressurised.

The breaking pins are marked with the value of the release force in kN (third column). The marking is always valid for the sum of used breaking pins per coupling.

The release force can vary about +/- 10% max.

Breaking pins for other release forces on demand.

Page 6

4 Range of applications

4.1 Industrial

Plant engineering and construction

Power plant construction

Chemical industry

Food processing industry

Process technology

Tank cleaning

Filling systems for:

airfields

railroad tank wagons

tanker trucks

ships

tank containers

4.2 Media

Lyes and acids

Fuels and oils

Gases

Materials hazardous to the environment and water

The coupling may not be used for:

When exceeding or undercutting the temperature ranges specified in chapter 3 for the chosen material combination

As safety device for pressure limitation

If it is required outside this range please ask the manufacturer!

Page 7

5 Installation / assembly

The ABV may be installed by qualified personnel only.

(Qualifications: experts, technicians, vocational training, job experience)

We would like to point out the professional obligations in acc. to German law § 19 I WHG.

The safety breakaway coupling is delivered ready for mounting and can be installed directly into a supply line.

The installation is as follows:

a. Remove the packaging and the tread protection caps.

b. Check the coupling for damages before mounting.

c. To prevent damages during mounting a suitable tool should be used for the intended nut flats on the coupling.

d. Screw the one end of the coupling to the tank wagon and connect the hose line end firmly to the other coupling end.

e. The maximum release angle should not exceed 90°.

f. Check the sealing of the connections.

g. All excessive external forces, such as bearing or leaning on by persons or objects must be avoided, because this could trigger the coupling.

6 Start-ups

The following points should be checked before any start-up:

Check the coupling for leaks.

Check the connection of the system to the coupling for leaks.

Check the breaking pins for damage; faulty breaking pins have to be replaced immediately.

7 Cleaning

Check the seal of the connections before every cleaning.

In case the coupling is used for materials that harden, stick, etc., the coupling has to be cleaned of residues after every use.

Before dismantling, the coupling always has to be cleaned with a suitable cleaning agent (regardless of the product carried).

8 Maintenance / repair

Maintenance should be done regularly; after one year at the latest. After release of the safety breakaway coupling, a maintenance also is necessary.

Maintenance and repair of the safety breakaway coupling may be carried out only by Roman Seliger Armaturenfabrik GmbH or by companies/technicians authorized by Roman Seliger Armaturenfabrik GmbH.

Page 8

9 Identification

An identification is engraved in the case on each half of the coupling.

The following information always has to be given on the case:

TÜ AGG 214-94

CE 0575 II 2G TX

Manufacturer ID: RS

Article no.: 555.200200,121-xx

Serial number / Year manufactured

Consecutive no. / material name (housing)

Ü-Sign 1

DN PN

10 Miscellaneous

Roman Seliger Armaturenfabrik GmbH accepts no responsibility for damages due to faulty installation, faulty handling, as well as negligent or incorrect maintenance.

The operator is solely responsible for the installation, operation, and maintenance of the coupling.

11 Manufacturer

1 Typ approval no. Z-38.4-99

RS - Reliability in Quality and Service

Dear Customer,

Our highly developed dry disconnect and breakaway couplings render reliable services as important

safety elements in many loading processes throughout the world in daily use. High stress and the

often rough ambient conditions, the couplings are exposed to, require regular inspection. This is the

only way to ensure proper functioning.

Striving to hold these service times as short as possible and thus to reduce your customers’ down-

times to a minimum, we have overworked and reorganised our service process. In this way we have

succeeded in offering you clearly reduced service throughput times. Thus future service and, if neces-

sary, repair of a dry disconnect and breakaway coupling with nominal widths DN 25 - DN 100,

equipped with FKM or EPDM seals, will be completed within one week. Service or repair of couplings

with larger nominal widths or equipped with special sealing materials may require slightly more time,

though.

To be able to return your serviced couplings immediately, we have established a cost fee and estimat-

ed amounts system. In the future, we will be able to inform you in general about the costs of the

standard service already before the inspection of the dry connect and breakaway couplings to be re-

paired. These costs include the following works:

- Disassembling the coupling an cleaning the component parts

- Inspecting all component parts and necessity of replacement check

- Replacing all O-rings and seals

- Remounting as well as leak and functional testing

Components that need to be replaced in addition will be charged separately. In the future, we will ask

you to approve an estimated amount in addition to the standard service fee. In order not to jeopardise

the service process, we will then carry out works whose overall costs are below this approved estimat-

ed amount without consulting you again.

In order to ensure a smooth and efficient process, the future service process will be as follows.

1. Notification of required service: Prior to dispatching the coupling to be serviced/repaired to

us, please contact our sales department and state the item number - and ideally the serial

number (engraved in the coupling) as well. You will receive from our sales department an offer

on the standard service as well as information on the amount of the additional cost fee within

24 hours.

2. Coupling dispatch: If you accept our offer, you will send us the couplings to be serviced

along with the according declaration of contamination. Please note that we must not work

on couplings without a declaration of contamination due to employment protection reasons!

Items without corresponding declaration will be brought to a quarantine store and will have to

be disposed of with costs as hazardous waste, unless the missing declaration will be submit-

ted within a period of 72 hours.

3. Service and return: The coupling is serviced and tested according to the submitted offer. If

the approved estimated amount is exceeded, the responsible sales staff will contact you to de-

termine further steps. After completion of the works, the coupling is immediately returned to

you.

Please find enclosed a leaflet containing all important information on how to initiate service or repair.

We already now thank you for your assistance. We shall always strive to continually optimise both our

products and processes in the future in order to be able to offer you both the best couplings and an

excellent service.

Yours sincerely

RS Roman Seliger Armaturenfabrik GmbH Dr.-Ing. Jens Reppenhagen Managing Director

Leaflet RS Roman Seliger Armaturenfabrik - Service Process

Have you got a coupling that needs service or repair? No problem! Initiate professional and

quick service/repair in two simple steps.

Step 1: notification of required service

How to do?

o By telephone: +4940 52306499

o Email: service@rs-seliger.de

o Fax: +4940 52306425

What information is required?

o Item number of the coupling(s) to be serviced/repaired

o Serial number of the coupling(s) to be serviced/repaired

(Both found in the coupling gravure)

You will receive an offer for the standard service1 along with information on po-

tential service maximum costs without consultation.

Step 2: dispatch of the coupling when you accept the offer

Where?

Roman Seliger Armaturenfabrik

An´n Slagboom 20

22848 Norderstedt

What documents have to be added?

o Delivery note

o Completed declaration of contamination (see the appendix)

Caution! Due to employment protection reasons, a coupling without valid dec-

laration of contamination must not be worked on and is disposed of with costs

as hazardous waste if the declaration will not be submitted within a period of

72 hours.

Your repaired/serviced coupling will be dispatched to you by RS within one

week’s time2.

1 Dismounting, cleaning, visual inspection, replacement of gaskets and O-rings, mounting, testing

2 Subject to standard component replacement; there may be a delay in individual cases.

This list is to be filled out and countersigned by the coupling operator and vendor. For our employees industrial safety reasons, the repair can only be made according to this check list. The coupling to be repaired was used with the following product: Chemicals-/ product name: ________________________________ EG-/ CAS-/ UN-Nr. ___________________ Aggregate state:

firm liquid gaseous xxx Water hazard class : 0 1 2 3

The product is without foreign contamination:

yes no

The product reacts: yes no

Inflammable/ easily inflammable

Hazard class acc to VbF____________

Injurious to health

Toxic or very toxic

Corrosive or irritating

carcinogenic

Biological hazard possible

other

With water

With air If yes:

The developing gases / vapours are:

Ignitable/ selft inflammable

Injurious to health

Toxic or very toxic

Corrosive or irritating

carcinogenic

Check list for the repair and maintenance of Dry Disconnect– and Safety Breakaway Couplings according to BG T002 9/95

Were the couplings cleaned, and are therefore harmless to deal with?

Which rinsing media were used during production? ____________________________________________________ In which period was the coupling used? From _______ to ________ How often was the coupling used? Per day _____ per week ____ per month ______ Wurden Wartungs– und Reparaturarbeiten selbst vorgenommen?

The following preventive measures are recommended:

Other preventive measures _____________________________________________

none

Vacuum cleaning of workplace

Closed extraction unit

Sufficient room ventilation

Eye protector

Full mask

Rubber gloves

We thank you for the support of our industrial safety. Date: _____________ Operator: ________________ Distributor: _____________________

www. rs-seliger.de