INSTRUCTION MANUAL FOR

TYPE 2389
SYSTEM DESCRIPTION
AND OPERATING/MAINTENANCE
INSTRUCTIONS FOR

HS-ISO-VAC
VACUUM VALVE

REV. 2
CUSTOMER INFORMATION
OWNER: HULL NO.: PRES-VAC REF. NO.:

PRES-VAC ENGINEERING A/S PHONE: +45 4817 4055

SVANEVANG 3-5 TELEFAX: +45 4817 1788
DK-3450 ALLERD E-mail: presvac@pres-vac.com
DENMARK
INSTRUCTION MANUAL Page 2 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

CONTENTS
Page
1. Functional System Description ....................................................................................... 3

1.1. General ................................................................................................................... 3

1.1.1 Ordering Information ................................................................................................ 3
1.2. Design .................................................................................................................... 3
1.2.1 Product Suitability .................................................................................................... 3
1.3. Function .................................................................................................................. 3
1.3.1 Inspection ............................................................................................................... 4
1.4. Capacity .................................................................................................................. 4

2. Operating Instructions ................................................................................................... 4

2.1. Installation .............................................................................................................. 4

2.1.1 Service restrictions ................................................................................................... 4
2.2. Operation ................................................................................................................ 4
2.2.1. Drainage ................................................................................................................. 5
2.2.2. Deposit indicator ..................................................................................................... 5
2.2.3. Damaged Seals ....................................................................................................... 6
2.2.4. Flushing Port ............................................................................................................ 6
2.2.5. Optional Features ..................................................................................................... 7

3. Maintenance Instructions ............................................................................................... 8

3.1. General ................................................................................................................... 8

3.1.1. Inspection ............................................................................................................... 8
3.2. Corrosion Protection.................................................................................................. 8
3.2.1. Coating Repair ......................................................................................................... 8
3.3. Safety Regulations For Maintenance Work ................................................................... 8
3.4. Onboard Verifying Of Set-Pressure.............................................................................. 9
3.5. Directions For Disassembly / Assembly And Cleaning ................................................... 10

4. Spares ........................................................................................................................... 12

DRAWING NO. 2389-1 (Spare Part Ordering List) ................................................................ 13

5. Trouble-Shooting .......................................................................................................... 14

6. Laboratory Report, Summary ........................................................................................ 17

Enclosures:
(1) Flow Charts
(2) Product Review Document
(2) Certificates
(3) Workshop Test Certificate
(4) Maintenance Log Sheet
INSTRUCTION MANUAL Page 3 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

1. Functional System Description

1.1. General
The purpose of this vacuum valve is to provide automatic control of pressure conditions during
discharging, voyage, and de-ballasting without any manual operation. Additionally, the vacuum valve
protects the tank against excessive vacuum, when the gas return line is connected to the shore facility
and when loading is carried out with forced suction of vapour to the shore1), in accordance with the
VECS-requirements. Furthermore, this vacuum valve provides active protection against fire and
explosions on deck, in terms of preventing a passage of flame into the protected tank.

1.1.1. Ordering Information

Ordering information according to ISO 15364 should be provided by the customer, if not, it is the
customers responsibility that service restrictions, tank pressure limitations, etc. are adhered to.

1.2. Design
The vacuum valve consists of a valve housing with a movable vacuum disc and stem. Correct function of
the valve is tested by check-lifting the movable parts by means of pressing the check-lift handle (or
button on some versions) beneath the vacuum unit from its lower position to its upper position. The
check-lift is designed to be self-closing.

WARNING!
1.4. The
Capacity attending crew must be familiar with the normal friction in the system in
order to valuate when cleaning is required. Being able to activate the check-lift
itself by applying great force does not mean that the moveable parts are freely
moving.

This valve is specifically designed with a view to address in-service maintenance, allow inspection of all
vital parts from the outside without use of tools, and allow wear parts to be replaced in-situ. Essential
functions are reflected by indicators, which are clearly visible from the outside at all times. The system
has the simplicity of a weight-loaded design, while adding the in-service advantages of large net
clearances through gas passage-ways to minimize clogging due to fouling from residue/condensate.

1.2.1. Product Suitability

Besides from complying with ISO 15364, a valve design has to be elaborated on in a Product Review
Document, a product drawing and a manual. The ISO standard does not provide any measures against
which a design can be constructed and considered as being in conformity. The standard merely
provides general guidelines and, in particular, recommendations for maintenance. It is exclusively the
owners/users responsibility to ensure that the valve is adequate for the actual installation and the
usage intended. The owner/user shall do this on basis of:

- A product Review Document describing the valve on basis of ISO 15364.

- A product drawing
- IMO MSC/Circ. 677/1009 certification
- Certified service instructions
- This manual

It is the owners and or users responsibility to review and establish that the selected valve is correctly
sized according to USCG (VECS) rules and IMO MSC/Circ. 731, and made in a design that will match the
available efforts for maintenance. Various types of valves with different maintenance requirements are
available in the PRES-VAC range with escalating prices for less maintenance requiring types.

1.3. Function
Vacuum build-up in the cargo tank forces the vacuum disc from its seat (opening pressure). When the
tank vacuum again drops to the valves preset level, the disc will re-seat. For details of the performance
characteristics, please refer to the certified flow charts as enclosed.

1) Some applications are subject to requirements stating that the capacity shall also cover the loading rate + vapour growth rate.
Confer with the flow chart as this is not always the case.
INSTRUCTION MANUAL Page 4 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

1.3.1. Inspection
Due to the relatively large net clearance through the valve, the inner parts are much less sensitive to
deposits than ordinary designs. If no thick deposits are detected by means of the fouling indicator pins
and by visual inspection after removal of the seat-beds in case of any doubts, the valve is in working
condition and no further precautions are necessary. The allowable thickness of deposits before further
inspection and, as appropriate, cleaning is necessary at a total diameter of the fouling pin of 12 mm. This
measure, however, is only indicative and does not substitute visual inspection after removal of the seat-
bed. See section 2.2.2.

1.4. Capacity
The valve's capacity is rated in standard air. For conversion to maximum loading rates for different
cargoes, please refer to the MASTER'S LOADING CHART as per latest revision of IMO MSC/CIRC. 731.
Other considerations are required for gas collection systems where the vacuum capacity shall equal the
possible suction rate from shore. Please contact Pres-Vac Engineering for further guidance on this
subject.

2. Operating Instructions

CAUTION! Transport, storage and handling of the valve shall take place in upright position.

2.1. Installation
Remove all packing material.

Normally, the vacuum valve and pressure valve are delivered as one unit. For further information, refer
to Instructions Manual for HS-ISO Pressure Valve, section 2.

If this is not the case, installation is accomplished by bolting the valve flange to the tank vent pipe's
mating flange with a suitable gasket between. Check-lift to verify unobstructed movement of disc. Follow
IMO MSC/Circ. 731 pressure drop calculation during system check to verify correct function.

2.1.1 Service Restrictions

See CE certificate for:

1. Minimum MESG of cargo vapour.

2. Minimum vacuum relief setting.
3. Maximum fouling level: See this manual.
4. Maintenance procedures must be observed for proper function of the equipment.

2.2. Operation
Before loading, discharging, and de-ballasting the valve must be check-lifted to ascertain free movability
of the vacuum disc. Correct check-lifting is accomplished by pulling the check-lift handle (or pushing the
button, if no check-lift handle) from its lower position (fig.1) to its upper position (fig. 2) and back again.
The check-lift is self-closing when in proper maintained condition. If not, it should be cleaned and the rest
of the valve inspected/cleaned.

WARNING!
1.4. The attending crew must be familiar with the normal friction in the system in
Capacity
orderisto
The valve's capacity valuate
rated when air.
in standard cleaning is required.
For conversion Being able
to maximum to activate
loading rates for the check-lift
different cargoes,
please refer to itself by applying
the MASTER'S great force
LOADING CHARTdoesasnot
permean
latest that the of
revision moveable parts are731.
IMO MSC/CIRC. freely
Other
moving.
considerations are required for gas collection systems where the vacuum capacity shall equal the possible
INSTRUCTION MANUAL Page 5 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

Fig. 1. Check-Lift closed Fig. 2. Check-Lift open

During normal voyage, the vacuum valve type ISO operates automatically and equalizes vacuum caused
by thermal variations.

WARNING! As per SOLAS-requirements, check-lifting must be carried out before loading,

discharging or ballasting is commenced. If the valve does not move freely,
the cause should be determined and corrected immediately.

2.2.1. Drainage
The valve is self-draining due to large net clearances and no horizontal surfaces on the inside of the
valve.

2.2.2. Deposit Indicator

To examine for build-up of residue in the valve, unscrew the Plug with deposit indicator (pos. 23 on fig.
16, page 10) and check it for residue thickness. If the residue thickness is over 1 mm. (= pin diameter
over 12mm), cleaning of the interior of the valve is necessary. The cleaning method depends on the
cargo type, but basically paragraph 3.5 should be followed. For certain crystallizing cargoes, heating
arrangement may be necessary according to the chemical code.
INSTRUCTION MANUAL Page 6 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

2.2.3. Damaged seals.

It is of outmost importance that the seals are kept in a good condition and are changed before
reassembly, as necessary, to maintain leakage-free operation.

Consequences of damaged or missing seals are as follows:

Type of seal Damaged seal Missing seal

O-rings in flange connections
O-rings in Disc unit
Gasket for Plug w. deposit indicator
Small leak of cargo or inert gas. Leak of cargo or inert gas.
Small salt water ingress in tank
Small leak of cargo or inert gas. Leak of cargo or inert gas.
Small salt water ingress in tank
Leak of cargo or inert gas. Leak of cargo or inert gas.
Small salt water ingress in tank.

2.2.4. Flushing Port

When loading a new cargo, for which cleaning of the HS-ISO Vacuum Valve and vent pipe is required,
this procedure is to be followed:

1) Unscrew the flushing plug (pos. 23) on fig. 16 (only when the tank is depressurized).
2) Connect the hose with the cleaning fluid to the flushing port.
3) Start cleaning.
4) Remove the hose and mount the flushing plug.

WARNING !
The flushing system may only
be used when it is otherwise
safe to clean the piping.

Fig. 3. Flushing of HS-ISO vacuum Valve

INSTRUCTION MANUAL Page 7 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

2.2.5. Optional Features

Optional accessories for special requirements are available.

Fig. 5: Proximity switch for Fig. 6: Fixture for forced Fig. 7: Zero emission kit
stand-by valves closing for PO service for special cargo

Fig. 8: Heating Arrangement Fig. 9: Side mounted Fig. 10: Dual nozzle for im-
(other versions are Gas Freing Cover proved gas disper-
available depending sion of small volume
on size)

Fig. 11: Self closing valve Fig. 12: Gas freeing Cover Fig. 13: Dessicator to prevent
to prevent cargo damage to hygroscopic
escape from sun- cargo
ken vessel
INSTRUCTION MANUAL Page 8 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

3. Maintenance Instructions

3.1. General
As per SOLAS-requirements, the following service intervals shall be followed as a minimum:

A.
After 6 months of operation, the valve shall be inspected for proper function and, if necessary, be
cleaned. However, we recommend that the valve be inspected more often depending on the cargo type.
If the check-lift handle does not operate freely, cleaning is required.

B.
After further 6 months of operation, the valve shall be taken apart and cleaned.

Dismounting the valve house, see fig. 16 on page 10, provides access to do the necessary cleaning, i.e.,
pull of the seat bed and all parts are accessible.

3.1.1 Inspection
Due to the relatively large net clearance through the valve, the inner parts are much less sensitive to
deposits than ordinary designs. If no thick deposits are detected by means of the fouling indicator pins
and by visual inspection after removal of the seat-beds in case of any doubts, the valve is in working
condition and no further precautions are necessary.

3.2. Corrosion Protection

When repairing the coating follow the instructions from the producer of the coating quality referred to in
the vessels general manual.

3.2.1. Coating Repair

Due to the large inner clearance the valve will not block because of surface corrosion, and repairing of
the coating is therefore not necessary from a valve functional aspect, only if the cargo vapor is damaging
to the main body parts.

3.3. Safety Regulations For Maintenance Work

Spark free tools should be used if maintenance work is carried out while the valve is mounted on the
cargo tank.

WARNING! All maintenance work must be carried out with necessary precautions in
regard to the cargos flammability and toxicity.

NOTE! Before dismounting the seat bed and replacing with a new one the tank pres-
sure should be lowered to the same level as when performing ullage measure-
ment through an open deck valve.
INSTRUCTION MANUAL Page 9 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

3.4. Onboard Verifying Of the Set-Pressure

After overhaul, verifying of the set-pressure is recommended. This can be accomplished by either
removing the top cover and controlling the pull-weight of the vacuum disc with a PRES-VAC
Dynamometer and confer with PRES-VAC or use the PRES-VAC Test Rig, type TR or TRM, see fig. 14 and
15 below.

The actual valve set-pressure is stamped on the valve body.

The Test Rig, type TR or TRM, is used for onboard verifying of the set-pressure as well as measurement
of the leakage rate to ensure compliance with environmental regulations.

For further details on type TR or TRM and Dynamometer, please refer to a separate manual. This
equipment can be purchased from PRES-VAC.

Fig. 14: Test Rig Fig.15: Dynamometer

(Mechanical and Ex versions are also available)
INSTRUCTION MANUAL Page 10 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

3.5. Directions For Disassembly / Assembly And Cleaning

Normal cleaning and inspection, see fig. 16:
1. Remove the Interior of the Vac unit by unscrewing the bolts (pos. 32) and washers (pos. 33).

Disassembly of the filter unit:

2. Remove the Screws (pos. 34) and Washers (pos. 35).
3. Tilt the filter element assembly slightly and pull it from the Flange (pos. 2).
4 Remove the check-lift assembly by unscrewing the Nuts (pos. 13).
5. Push carefully the filter element out (pos. 7).
6. Inspect and clean all parts. Repair or replace damaged parts as appropriate.

CAUTION! Apply an even pressure on the whole surface of the filter element to avoid
damage.

Fig. 16: Assembly Drawing for Inspection and Cleaning of HS-ISO Vacuum Valve.
INSTRUCTION MANUAL Page 11 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

NOTE! For cleaning we recommend a thin lubrication oil and a brush. If damage on any
parts is observed, repair or replacement must take place.

CAUTION! Pay attention to filter element during paint work on deck.

Assembly after normal cleaning and inspection

1. Assembly is done in the opposite sequence.

Replacement of vacuum seat (pos. 5 on fig. 16)

1. Unscrew bolts (pos. 32) and remove washers (pos. 33)
2. Pull out the filter unit including the O-ring (pos. 27)
3. Remove the vacuum disc (pos. 4) together with stem (pos. 9), washer (pos. 26) , lock washers
(pos. 11) and nut (pos. 10).
4. Unscrew the seat by means of a key between the ribs.
5. Clean thread and insert new seat after surface lapping.

Assembly
1. Assembly is done in the opposite sequence.
NOTE: Seat-beds can be re-used from PRES-VAC at cost of lapping and re-coating, as necessary.

General
Screws and bolts not protected from loosening, should be secured by a suitable adhesive, such as PRES-
VAC part no.: 1323-8.

RECOMMENDATION
Fill in the maintenance log sheet in connection with inspection and service.
INSTRUCTION MANUAL Page 12 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

4. Spares
There are no class requirements for carrying spares on board. If spares are required, please use the
following procedure:

1. Take a copy of the inserted drawing no. 2389-1.

2. Identify the components and write the required quantities on the part list.
3. Advise builder of ship and new building number.
4. Advise Vessel name.
5. Advise serial number punched into the flange of the valve.

Fax the drawing to our office in DENMARK.

When we have the above information, our files contain all further details.

When ordering spare parts, please call our office in DENMARK.

Our telefax and E-mail are open 24 hours a day

Telefax No. ....... +45 48 17 17 88

E-mail .............. presvac@pres-vac.com

Our telephone is open during normal office hours

Telephone No.: . +45 48 17 40 55

Our postal address:

PRES-VAC ENGINEERING A/S

Svanevang 3-5
DK-3450 Allerd
Denmark
INSTRUCTION MANUAL Page 13 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

SPARE PART ORDERING LIST

INSTRUCTION MANUAL Page 14 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

5. Trouble-shooting

Problem
Tank pressure is too high
Tank vacuum is too high
Remedy
A.
Check in vessels Master Loading Chart according to
IMO MSC/Circ. 731 what the maximum permissible
loading rate is and the corresponding loading rate
with corrections for vapor density and vapor growth
rate. Lower loading rate if necessary.
B.
Check that the valve is clean inside and take care of
maintenance as per Section 3 if necessary.
B.1.
Check that the valve disc is able to travel full stroke
by hand-lifting.
B.2.
Check that pressure seat/disc contact area (width)
is not exceeding manufacturers recommendations
to avoid a aero-dynamic lock (like blowing
between two sheets of paper) as a consequence of
home-made repairs.
C.
Check that the piping is unobstructed by cargo
residue etc.
D.
Check that the pressure-tuning knob has not been
tampered with by use of a calibrated test
instrument.
E.
Contact PRES-VAC to check if the configuration of
magnet-power and booster disc arrangement can
be changed for a more suitable performance for the
actual conditions of installation.
A.
Check in vessels Master Loading Chart according to
IMO MSC/Circ. 731 what the maximum permissible
discharge rate is. Check that pump is running with
the intended delivery head to avoid unintended high
rates. Lower pump rate if necessary.
B.
Check that the valve is clean inside and take care of
maintenance as per Section 3 if necessary.
B.1.
Check that the valve disc is able to travel full stroke
by hand-lifting.
B.2.
Check that vacuum seat/disc contact area (width) is
not exceeding manufacturers recommendations to
avoid a aero-dynamic lock (like blowing between
two sheets of paper) as a consequence of home-
made repairs.
INSTRUCTION MANUAL
HS-ISO VACUUM VALVE
Tank vacuum is too high (continued)
Not fully lifting pressure disc:
The valve is leaking
The valve is hammering
Page 15 of 21
Rev. 2 April 15, 2003
B.3.
Check that the vacuum discs contact area is dry to
avoid a hydraulic lock.
C.
Check that the piping is unobstructed by cargo
residue etc.
D.
Contact PRES-VAC.
Due to the relative large venting capacity required
according to USCG regulations on Vapor Emission
Control Systems, which for some cargoes are nearly
doubling the actual loading rate, valves may in fact
be handling far less than designed for. Especially
when the sizing procedure did not allow the VECS
capacity to be present at an elevated tank pressure
just below the maximum working pressure. In other
words; a generous provision for venting capacity is
a problem and the valve performance might appear
as chattering or fluttering and can severely reduce
the lifetime of seats and discs.
The remedy available is to consult PRES-VAC for
guidance on adjusting the opening setting and/or
the configuration of the booster plate arrangement.
In extreme cases, for instance for slop tanks
equipped similar to the main cargo tanks, it may be
necessary to install a dual, small capacity unit with
a differing setting making the too large original
valve a stand-by safety unit for the rare mal-
operating event.
A.
Clean valve discs and seats.
B.
Check pressure check-lift seal.
C.
Overhaul or replace seats and discs as appropriate.
D.
Contact PRES-VAC.
A.
Check that installation is within the service
restrictions shown in the certification issued by the
CE Notified Body ( FORCE TECHNOLOGY). If not,
contact PRES-VAC.
B.
If the valve is grossly over-sized for the actual
capacity vented, the opening and closing cycle may
reduce the expected lifetime of the sealing parts. If
the differential between the capacity of the valve
based on USCG VCS requirements is too far from
the actual volume vented, the lifetime of the
sealing parts is reduced.
INSTRUCTION MANUAL Page 16 of 21
HS-ISO VACUUM VALVE
Rev. 2 April 15, 2003

The valve is hammering (continued) C.

Check Section 2.2.5 on Valve Misbehaviour.
Hammering is by definition non-intended full stroke
movement of the pressure disc and should not be
misunderstood for non-fluttering.
C.1.
Hammering is not an issue with vacuum valves as
these are modulating and therefore unstable in the
opening phase. Since flash-back protection is not
connected with a high velocity nozzle, disc
movement is no concern, save from a lifetime
aspect.
D.
Contact PRES-VAC to check if the configuration of
magnet-power and booster disc arrangement can
be changed for a more suitable performance for the
actual conditions of installation.
LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009

SUBJECT: HS-ISO VACUUM VALVE

6. Laboratory Report, Summary

The following report is part of the Instructions Manual as required by MSC/Circ. 677, paragraph 4.3 and
should be kept on board the tanker.

The report contains in a condensed form all conducted tests and results obtained, as well as all further
information required, according to the IMO-rules, MSC/Circ. 677 as amended by Circ. 1009 and ISO
15364.

The complete Laboratory Report and test data including video documentation is on file with Force
Technology, the CE Notified Body. The following tests were completed successfully as indicated on the
attached certificates of Type Approval from Force Technology.

Test Description MSC/Circ. Remarks:

677/1009

1 Corrosion test 3.5.1 The corrosion tests were carried out on a test rig as
shown on drawing no. 1194-26. The test results were
to the satisfaction of the Notified body.

2 Hydraulic pressure 3.5.2 The hydraulic tests were carried out on a test rig as
test shown on drawing no. 1194-317. The test results
were to the satisfaction of the Notified body.

3 Flow test 3.3.2 The flow tests were carried out on a test rig as shown
on drawing nos. 1194-148 and 1194-149. The results
obtained appear from the inserted flow curves as
enclosed.

4 Flash-back test 3.2.2 The flash-back tests were carried out on a test rig as
shown on drawing no. 1194-160. In no case did
flash-back occur.

5 Ice test 2.3.4 The ice test was carried out on a test rig as shown on
drawing no. 1194-318. The test valve was cooled to
20 to 30 degrees Celsius. Hereafter the valve was
check-lifted, and it was seen that the valve was fully
operative.

Additionally, separate flow testing has been performed in accordance with API 2000 Standard because
flow testing as per MSC/Circ. 677/Circ. 1009 and ISO15364 does not automatically qualify for API 2000
requirements since higher pressure and vacuum conditions are necessary for some valve configurations.
Please refer to the attached Certificates of Type Approval from Force Technology.
 LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009

SUBJECT: HS-ISO VACUUM VALVE

Drawing no.: 1194-26, Corrosion Test

Drawing no.: 1194-317, Hydraulic Pressure Test

LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009

SUBJECT: HS-ISO VACUUM VALVE

Drawing no.: 1194-149, Flow test

Drawing no.: 1194-148, Flow Test

LABORATORY REPORT - SUMMARY TESTED IN ACCORDANCE WITH MSC/Circ. 677/1009

SUBJECT: HS-ISO VACUUM VALVE

Drawing no.: 1194-160, Flash-back Test

Drawing no.: 1194-318, Ice Test