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Customer: ANDAC

Purchase Order Number: PO/083/2012

SPX/CV SO Number: 1210-1474638

Ultimate User: INDIA GUDELUOER PP

Equipment: GS CONTROL VALVE

    
 


Copes-Vulcan Operation * 5620 West Road * McKean, Pennsylvania 16426-1504 USA

Phone: (814) 476-5800 * Fax: (814) 476-5853
www.spxft.com

Form SRV2 Rev. 3 (02-11)

BE SURE THIS MANUAL REACHES THE PERSONNEL RESPONSIBLE FOR THE

OPERATION, INSTALLATION, AND MAINTENANCE OF THE EQUIPMENT.

COMPETENT AND KNOWLEDGEABLE PERSONNEL HAVE PREPARED THIS

MANUAL FOR USE. IT IS IMPORTANT THAT THIS EQUIPMENT NOT BE

INSTALLED, OPERATED, OR MAINTAINED WITHOUT READING,

UNDERSTANDING, AND FOLLOWING THE PROPER COPES-VULCAN

PROCEDURES, OTHERWISE PERSONAL INJURY OR EQUIPMENT DAMAGE

MAY RESULT.

THIS EQUIPMENT MUST ONLY BE USED WITHIN THE RANGE OF OPERATING

CONDITIONS AGREED UPON.

USING THIS EQUIPMENT AT OPERATING CONDITIONS OTHER THAN THOSE

ON THE MANUFACTURERS SPECIFICATION SHEET CAN HAVE A SAFETY

AFFECT AND CAN INVALIDATE ANY MANUFACTURERS WARRANTY OR

CERTIFICATION.

THIS INSTRUCTION MANUAL HAS BEEN FURNISHED FOR USE BY THE

CUSTOMER INDICATED, CONSISTENT WITH THE TRANSACTION BETWEEN

THIS CUSTOMER AND COPES-VULCAN. NO COPIES OR DATA FROM THIS

MANUAL SHALL BE FURNISHED TO A THIRD PARTY WITHOUT THE WRITTEN

AGREEMENT OF COPES-VULCAN, MCKEAN, PENNSYLVANIA.

Form SRV2 Rev.1 (01-02)

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60:37:30 General Information

01:P112:37 Storage Recommendations for Diaphragm-Operated Valves &

Desuperheaters

SECTION 1.0 GS & SD CONTROL VALVES

Model: 3” (80 mm), CL300, WCB, FLG, GS-700-100 DA

Application: Air heater drain to deaerator
Serial Number: 1000002759595, 6
Tag: 11LCN70AA101;12LCN70AA101

Control Valve Specification Sheet

SK-A-0-1474638-A Control Valve Outline Dimensions
Recommended Spare Parts List

APPLICABLE DRAWINGS & BILLS OF MATERIAL (SEE SECTION 1.1)

C-357184 Actuator Assembly / VACT411030221

C-357058 Manual Actuator Assembly / V357058
C-342113 Trim Assembly / VTRM503090110302
C-359258 Hardware Pack Assembly / VHDP5114112
D-364582 Accessory Kit Arrangement / VAC7A15562010003/V364608
D-380180 Accessory Kit / V408919
C-405623 Accessory Kit / V405623-240
C-364405 Accessory Kit / V364405
D-357435 Accessory Kit / V357435

SECTION 1.0 GS & SD CONTROL VALVES

Model: 3” (80 mm), CL2500, WCB, BW, SD-ROTORK IQM 20

Application: Superheater #1 spray bypass
Serial Number: 1000002759597,8,9,600
Tag: 11LAE21AA102, 11LAE22AA102; 12LAE21AA102, 12LA

Control Valve Specification Sheet

SK-B-0-1474638-A Control Valve Outline Dimensions
Recommended Spare Parts List

Page 1 of 3
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APPLICABLE DRAWINGS & BILLS OF MATERIAL (SEE SECTION 1.1)

C-373182 Actuator Assembly / VACT416032122

C-343541 Trim Assembly / VTRM503330710502
C-342958 Hardware Pack Assembly / VHDP5111111

SECTION 1.0 GS & SD CONTROL VALVES

Model: 3” (80 mm), CL2500, WCB, BW, SD-ROTORK IQM 20

Application: Superheater #2 spray
Serial Number: 1000002759601,2,3,4
Tag: 11LAE23, 11LAE24AA102; 12LAE23, 12LAE24AA102

Control Valve Specification Sheet

SK-C-0-1474638-A Control Valve Outline Dimensions
Recommended Spare Parts List

APPLICABLE DRAWINGS & BILLS OF MATERIAL (SEE SECTION 1.1)

C-373182 Actuator Assembly / VACT416032122

C-343541 Trim Assembly / VTRM503340710302
C-342958 Hardware Pack Assembly / VHDP5111111

SECTION 1.1 APPLICABLE DRAWINGS & BILLS OF MATERIAL

SECTION 1.2 CONTROL VALVE INSTRUCTIONS

GN-01 Guidance Notes for Installation of Control Valves

01:P217:37 Instructions for Single Web “GS” Type Control Valve with
Quick Change Trim

01:P180:37 Instructions for Single Web “SD” Type Control Valve with
Quick Change Trim

01:P224:37 Instructions for Model 700 Direct Acting Actuator

Page 2 of 3
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SECTION 1.3 VENDOR INFORMATION

• ABB Positioner

• Allen-Bradley 802T Limit Switches (2)

• SMC IL-201 Airlock

• SMC AW20 Filter/Regulator

• SMC Solenoid Valve

• ROTORK IQM 20

Page 3 of 3
GENERAL INFORMATION--------------------------------------------------------------------------------------------------------
If your company name has changed since your
Control systems will not operate satisfactory if not Copes-Vulcan equipment was ordered, please refer to the
properly installed, operated, and maintained. old name. This is the name listed in Copes-Vulcan's files.

These instructions outline the correct procedures for Parts prices are not listed in this literature. A quotation will
installing, operating and maintaining Copes-Vulcan be submitted on request, or we will bill for them at the
equipment; follow them closely to be sure of the best lowest prevailing prices.
operating results, trouble-free operation, and long
service. MATERIAL/WORKMANSHIP GUARANTEE

We want your Copes-Vulcan equipment to give you the The Copes-Vulcan warranty that will apply is what is
best possible service. If you have any questions about accepted under the conditions of sale for Copes-Vulcan
operation, maintenance, or related problems, please Equipment purchased under the original contract. Please
contact us. refer to these conditions.

CHECK THE MATERIAL Copes-Vulcan guarantees the control equipment for a period
of one year from the date of shipment against defects in
Do not start installation until the material has been material and workmanship and will replace any defective
carefully checked against the list furnished by Copes- parts F.O.B. Our Factory, if such parts are returned to
Vulcan. Be sure the unpacked material is for the boiler Copes-Vulcan with shipping charges prepaid. An extended
on which it is to be installed. warranty may be negotiated at the contract stage. Refer to
the contract for the applicable terms.
A WORD OF CAUTION
COPES-VULCAN SERVICE POLICY
Carelessness in repairing steam or air control equip-
ment can cause serious injuries, taking simple Copes-Vulcan maintains a staff of competent Service
precautions can prevent accidents. Engineers strategically placed in territories within the United
States. Both Engineers from Copes-Vulcan & Copes-Vulcan
Always get permission and a release from the proper Ltd. in England are available, on receipt of a written
authority before starting any equipment. Use proper purchase order, to provide the following types of service
lifting equipment for heavy equipment. Do not attempt worldwide:
repairs beyond your ability.
1) Supervision of erection.
Before repairing any equipment operated by steam or 2) Make initial start-up of equipment.
air, make sure all supply valves have been closed, 3) Assist in repair or maintenance.
tagged or locked. If steam or air supply lines must be 4) Instruction of operating and maintenance Personnel.
energized for purpose of test, use extreme caution.

ORDERING REPAIR PARTS Copes-Vulcan Service makes sure its equipment performs at
peak efficiency and that the user's operators are taught
When ordering repair parts, always refer to the preventive maintenance to assure effective operation at the
following: lowest possible cost.

Name and number of parts as shown on the bill of Requests for emergency service calls will be handled as
material. quickly as possible, if addressed to Copes-Vulcan's Service
Manager. Such service calls are generally made at the
Serial number as shown on the nameplate attached customer's expense, at a fixed per-diem rate, plus travel and
to the head. living expenses.

The Copes-Vulcan contract or job number issued for

the original equipment.

08/02 Form 60:37:30

 COPES-VULCAN, McKEAN, PENNSYLVANIA

STORAGE RECOMMENDATIONS FOR

DIAPHRAGM-OPERATED VALVES & DESUPERHEATERS

AT TIME OF STORAGE

If the valve or desuperheater is not being installed immediately upon receipt, the points below
should be considered when placing the equipment into storage. If the storage period exceeds six
months, regular inspections of the stored valve or desuperheater should be made as detailed in the
following section.

A. Location During Storage

The valve or desuperheater should be stored indoors in a ventilated area with clean, dry
ambient conditions and protected from vibration and rapid temperature changes. The ambient
temperature should be maintained between 40oF (5oC) and 90oF (32oC).

If indoor storage is not possible, the equipment should not be stored in contact with the ground.
Completely enclose the valve or desuperheater in a waterproof covering.

B. Storage Condition

Preferably, the equipment should be stored in the original shipping container or re-packaged
using a similar method. Uncrated equipment is to be stored off the floor, covered with an
unsealed dust cover with the bottom open and air holes in the sides.

Shipping caps, covers, and plugs used to protect machined surfaces and to prevent the entrance
of dirt should be left in place.
All blocking and cushioning material provided with the shipping container should be left in
place to prevent movement of the equipment.

The equipment should be stored in the position in which it was shipped. If a different storage
position is necessary, additional supports may be needed to protect the equipment properly.
The owner will be responsible for installing these supports in such a way that the equipment
is not overstressed or damaged.

C. Use of Desiccants

When desiccant bags are supplied in carbon steel valves or desuperheaters, a tag will be
attached to an outside surface of the equipment identifying the number of bags, their location,
and the trade name of the desiccant. The desiccant bags are to be replaced every three months
while the valve is stored.

Rev. 7 (01/02) Page 1 of 4 Form 01:P112:37

 COPES-VULCAN, McKEAN, PENNSYLVANIA

STORAGE RECOMMENDATIONS FOR

DIAPHRAGM-OPERATED VALVES & DESUPERHEATERS

D. Protection from Rust

Inspect each valve or desuperheater, making sure that all components are clean, dry, and free
of rust.

Protect unpainted metal surfaces from rust by applying rust preventive compound such as CRC
3-36 or equivalent.

Remove the end covers and spray a film of rust preventive compound on the internals and on
the inside surface of the body. Re-seal the ends securely.

NOTE: Before performing this procedure, make sure that any substance used for this
purpose will not be detrimental to the fluid to be passed through the installed valve or
desuperheater.

The above treatments should be applied annually while the valve or desuperheater is stored.

When a rust preventive compound is not permissible or cannot be used, the equipment must
be enclosed in a vapor-proof envelope, evacuated of all air, and sealed.

INSPECTION WHILE IN STORAGE

While in storage, the control valve or desuperheater must be inspected regularly, as detailed below.

A. Inspection Schedule

Visually examine the exterior surfaces of the equipment on a semi-annual basis; visually
examine accessible interior surfaces on an annual basis.

Disassembly of the equipment is not intended or required during inspection--a satisfactory

inspection can be performed while limiting any disassembly to removal of accessory covers
and shipping caps.

B. Prevention of Contamination

Water, dirt, oil, grease, or other foreign material should be removed from the equipment. The
source or these contaminants should be found and action should be taken to prevent
recurrences.

Rev. 7 (01/02) Page 2 of 4 Form 01:P112:37

 COPES-VULCAN, McKEAN, PENNSYLVANIA

STORAGE RECOMMENDATIONS FOR

DIAPHRAGM-OPERATED VALVES & DESUPERHEATERS

C. Inspection of Desiccants

Equipment stored with desiccants must be inspected to confirm that the desiccant material is
being replaced every three months and is properly located and secured in the equipment.

D. Inspection of Covers, Caps and Plugs

Inspect all equipment covers and temporary shipping caps and plugs to make sure these items
are firmly attached and will prevent the entrance of foreign matter into the valve or
desuperheater and the accessories.

HANDLING OF EQUIPMENT

Large valves and desuperheaters are normally provided with lifting lugs. The lifting lugs may be
used to lift the equipment and are adequate to support the weight of the entire assembly.

Equipment that has not been supplied with lifting hardware is to be lifted and moved using a padded
cable or sling wrapped around the body and adjusted to lift the equipment near its center of gravity.

Desuperheaters are not to be lifted or moved using the cooling water manifold or flange (branch-
welded) or end preparations as points to support the weight of the equipment.

When supplied, actuator eyebolts are not to be used to lift the entire valve or desuperheater--these
eyebolts may be used only to remove the actuator from the valve or desuperheater.

Rev. 7 (01/02) Page 3 of 4 Form 01:P112:37

 COPES-VULCAN, McKEAN, PENNSYLVANIA

STORAGE RECOMMENDATIONS FOR

DIAPHRAGM-OPERATED VALVES & DESUPERHEATERS

FOLLOWING STORAGE

After removing the valve or desuperheater from storage, perform the steps below before installing
the equipment.

A. Replace Packing, Seals, Gaskets, O-Rings and Diaphragm

If the equipment has been stored for a period longer than a year and a half, replace the packing.

Replace any seals, gaskets, o-rings and diaphragms if the equipment has been stored for a
period longer than three years.

B. Inspect the Equipment

Carefully inspect all components of the valve or desuperheater. Components and

subassemblies should be clean and free of foreign material.

Make sure that all temporary shipping caps, plugs, covers and desiccant bags have been
removed.

C. Copes-Vulcan Assistance After Long-Term Storage

If the storage period has exceeded three years, consider hiring a Copes-Vulcan Service
Engineer to inspect the equipment before installation.

Rev. 7 (01/02) Page 4 of 4 Form 01:P112:37

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 Copes-Vulcan, SPX Process Equipment
Bill Of Material
(Type = M)

Parent Item Number:V357058

Description: ACT,MNL,S7-100D Branch Plant: 7000

Component Number Line Number Seq Number Description Quantity Unit of Measure Drawing No Dwg Rev
V357040 1.0 1 ASY,COV,S7-100D,TPHW 1.000 EA V356123 02
V195961 2.0 2 GSKT,NITRILE,7.38X4.25X.06 1.000 EA V195961 00
V356937 3.0 3 HSG,MNL ACT,S7-100/160D 1.000 EA V356937 01
V001898 4.0 4 WSHR,LOCK,SPG,STL,1/2",CAD PL 6.000 EA
V002619 5.0 5 NUT,HX,1/2-13,A307 6.000 EA
V187028 6.0 6 SEAL,PKG,U,PKR #8405-0137 1.000 EA
V357003 7.0 7 STEM,MNL ACT,S7-100/160D 1.000 EA V357003 01
V187026 8.0 8 WSHR,GRLK,#DU-10 THRST 1.000 EA
V187014 9.0 9 BASE,MAN ACT THRUST 1.000 EA V187014 01
V014492 10.0 10 RING,RTNG,EXT,5100-75 1.000 EA
V266542 11.0 11 NUT,JAM,HX,1 1/4-8 1.000 EA
V005903 12.0 12 RING,RTNG,EXT,5100-100 2.000 EA
V003997 13.0 13 KEY,0.25"SQ X 1.13"LG,STL 1.000 EA V194324 11
V357189 14.0 14 HDWHL,S7-100D & 160D,CI 1.000 EA V187042 10

10/3/2005 Page 1
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1115!
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1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!
1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!

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1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!
1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!

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1112 W466837 HMBOE-QLH-! !!!!!!2! FB! W466783!

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1114 W47959: QLH-HSG-! !!!!!!2! QBD !
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1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!
1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!

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1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!
1:/18/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!

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 Copes-Vulcan, SPX Process Equipment
Bill Of Material
(Type = M)

Parent Item Number:V364608

Description: PIPING,ARGT#06,CPR TBG Branch Plant: 7000

Component Number Line Number Seq Number Description Quantity Unit of Measure Drawing No Dwg Rev
V085130 1.0 1 CONN,TUBE,3/8"X1/4"IPT,CMP FTG 3.000 EA
V085129 2.0 2 ELBOW,.38"X.25"NPT MALE,BRASS 5.000 EA
V050141 3.0 3 TBG .375X .032 COPPER ANNEALD 84.000 IN
V085131 4.0 4 TEE,TUBE,3/8"X3/8"X1/4"MALE 1.000 EA

10/11/2005 Page 1
11.01.2012 Dynamic List Display 1

Material V408919
Plant/Usage/Alt. 3210 / 3 / 01
Description
MDL,KIT,TZID-C,V18345-1020121001CS2
Base Qty (EA ) 1,000
Reqd Qty (EA ) 1

Item Object ID Sales Description Quantity Un Draw Doc 1

0001 V408918 PSNR,TZID-C 1 EA

0002 V364454 BRKT,POS, 1 EA V364454
0003 V367204 PIN,PSNR, 1 EA V367204
0004 V021424SST SCREW,HXHD, 5 EA
0005 V059404SST WSHR,LOCK, 7 EA
0006 V005522SST WSHR,STD, 10 EA
0007 V013803SST NUT,HX, 3 EA
0008 V367116 ASY,CONN LINK, 1 EA V367116
0009 V005173 WSHR,STD, 1 EA
0010 V192820 NUT,HX, 4 EA
0011 V090914 WSHR,LOCK, 2 EA
0012 V366316 LEVER ARM,FOR 1 EA
0013 V093731 WSHR,LOCK, 1 EA
0014 V041319 NUT,HX, 1 EA
0015 V021616 WSHR,STD, 2 EA
0016 V367367 SCREW,SCHD CP, 2 EA
0017 V130599 GAUGE,1.5"VERSA, 1 EA
0018 V271057 BSHG,RDCR, 1 EA
0019 V271053 TEE,SST 1/4"NPT FEMALE CONN 1 EA
0020 V379318-0200 NIP,0.25"NPT X 2"LG, 1 EA

17/14/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!
17/14/3124!!!!!!!!!!!!!!!!!!!!!Ezobnjd!Mjtu!Ejtqmbz!!!!!!!!!!!!!!!!!!!!!!!!!!!!2!

Nbufsjbm!
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Qmbou0Vtbhf0Bmu/!
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Eftdsjqujpo! !NEM-LJU-TPM-TND!WY4351H.13O.8H2.C
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TDSFX-TDIE!DQ-!!!!!!!5
!!!!!!5! FB!
FB !!
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1115!
1115!W486637!
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1116 W4:5811 CSLU-NUH-! !!!!!!2! FB W4:5811!

06.02.2013 Dynamic List Display 1

Material V364405
Plant/Usage/Alt. 3200 / 3 / 01
Description MDL,KIT,SMC IL200,ARLCK
Base Qty (EA ) 1,000
Reqd Qty (EA ) 1

Item Object ID Sal.Desc. Quantity Un Draw Doc 1

0001 V359883 VLV,LOCKUP, 1 EA

0002 V364406 BRKT,MTG, 1 EA V364406
0003 V199917SST SCREW,SCHD CP, 2 EA
0004 V013803SST NUT,HX, 2 EA
0005 V059404SST WSHR,LOCK, 2 EA

 Copes-Vulcan, SPX Process Equipment
Bill Of Material
(Type = M)

Parent Item Number:V357435

Description: KIT,ACC,AB LS,S7,(2) Branch Plant: 7000

Component Number Line Number Seq Number Description Quantity Unit of Measure Drawing No Dwg Rev
V357439 1.0 1 PL,MTG,AB,S7 1.000 EA V357439 01
V177596 2.0 2 SWTCH,LIM,AB,802T-ATP 2.000 EA
V282533 3.0 3 SCREW,SCHD CP,#10-24 X 1.75 2.000 EA
V021616 4.0 4 WSHR,STD,#10,.22"X.5"X.06",CP 4.000 EA
V093731 5.0 5 WSHR,LOCK,SPG,CAD PL,#10 4.000 EA
V005650 6.0 6 NUT,HX,#10-24,STL,CAD PL 4.000 EA
V282533 7.0 7 SCREW,SCHD CP,#10-24 X 1.75 2.000 EA
V177692 8.0 8 LEVER,OPER,RLLR,AB 802T-W2B 2.000 EA
V357335 9.0 9 ARM,TRIP,AB,S7 1.000 EA V357335 01
V021424SST 10.0 10 SCREW,HXHD,5/16-18 X 1.00, SST 3.000 EA
V013803SST 11.0 11 NUT,HX,5/16-18,SST 3.000 EA
V005522SST 11.1 11 WSHR,STD,5/16"NOM,.38"X.88X.06 6.000 EA
V059404SST 12.0 12 WSHR,LOCK,SPG,5/16",SST 5.000 EA
V004548SST 13.0 13 SCREW,HXHD CP,5/16-18X.75 SST 2.000 EA

9/25/2010 Page 1