Safety Breakaway Coupling ABV-S 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

Subject to design changes without prior notice September, 2017

Safety breakaway coupling ABVS Operating instruction

2

Contents Contents ........................................................................................................................................................ 2

1 Introduction ........................................................................................................................................... 3

1.1 Range of applications ....................................................................................................................... 3

1.2 Applicable documents ...................................................................................................................... 3

2 Safety notes .......................................................................................................................................... 4

2.1 Intended use ..................................................................................................................................... 4

3 Description/structure ............................................................................................................................. 5

3.1 Function ............................................................................................................................................ 5

3.2 Storage and transport ....................................................................................................................... 5

3.3 Identification ..................................................................................................................................... 6

3.4 Scope of delivery .............................................................................................................................. 6

3.5 Accessories ...................................................................................................................................... 6

3.6 Technical data .................................................................................................................................. 6

4 Installation and Initial Start-Up .............................................................................................................. 8

4.1 Initial start-up .................................................................................................................................... 9

5 Operation .............................................................................................................................................. 9

5.1 General notes ................................................................................................................................... 9

5.2 For the operator ................................................................................................................................ 9

5.3 Start-ups ......................................................................................................................................... 10

5.4 Cleaning ......................................................................................................................................... 10

5.5 Disassembly ................................................................................................................................... 10

5.6 Improper use .................................................................................................................................. 11

5.7 Maintenance / repair ....................................................................................................................... 11

5.8 Miscellaneous ................................................................................................................................. 11

6 Inspection after Release ..................................................................................................................... 11

7 Maintenance and Repair..................................................................................................................... 11

7.1 General information ........................................................................................................................ 11

7.2 Periodic tests by approved test centres ......................................................................................... 12

8 Manufacturer ....................................................................................................................................... 12

3

1 Introduction

This guide for safety breakaway couplings ABV-S is intended for operators and planners of tankers and

tank systems as well as for hose assembly workshops and hose assembly workshop maintenance

engineers. The safety breakaway coupling acts as a safety component in the supply line of mobile

refuelling systems, preventing damage to the environment whenever the supply pipe bursts during filling

or emptying due to a change in location of the tank. The coupling valves on the tank and on the supply

line immediately close whenever the housing halves break away.

ABV-S safety breakaway couplings of RS include special features:

High quality processing,

sturdy design,

low wear,

tamper-proof, safe operation,

release angle up to 90° through three pressure clamps on activation mechanism,

maintenance-friendly,

approved by TÜV (German Technical Inspection Authority),

meets ATEX standards for Zone 1,

wide spectrum of application.

1.1 Range of applications

Industrial Media Filling systems for:

Plant engineering

Power plant construction

Chemical industry

Food processing industry

Process technology

Tank cleaning

Lyes and acids

Fuels and oils

Gases

LPG/LNG, CNG

Materials hazardous to the

environment and water

airfields

railroad tank wagons

tank trucks

ships

tank containers

liquefied gas

The coupling may NOT1 be used for:

Temperatures below -20°C

Temperatures above 70°C

1.2 Applicable documents

Guidelines for pressure devices 2014/68/EU

German Act for pressure devices (14. GPSGV)

Facts sheet T 002 (09/2014) BGI 572 of BG Chemie

GGVSE (ADR, RID); IMDG, ICAO

1 Dependent on the used metallic and sealing materials!

4

2 Safety notes

The safety breakaway coupling, the tank and the supply line are subject to documentation and

acceptance. All approval procedures, required test specifications and test dates must be observed and

results of tests must be documented. Tests before commissioning and subsequent to repair must be

conducted by qualified persons (competent specialist staff with suitable training and experience). All

required measures for inspection, maintenance and repair must be carried out in accordance with the

national regulations of the country where the system is installed.

WARNING: Injuries or damage are possible when safety breakaway coupling is triggered!

When safety breakaway coupling is triggered, injuries or damage may be caused by the fluid being pumped. When

the safety breakaway coupling is triggered, minimal quantities of the fluid may spurt out (the volume between the

valves and the fluid that is emitted until the valve is closed).

The operator must ensure that suitable drip pans and locks are provided to prevent any danger from the

fluid that is emitted.

Operators must always carry out a risk analysis for the machine and the fluid being pumped (see BG

Chemie facts sheet). Operators must always themselves check whether the equipment is suitable for

transferring the product. This particularly applies for aggressive or abrasive fluids that are likely to

damage the safety breakaway coupling or the components of a supply line as a result of chemical

reaction, corrosion or erosion. Relevant legal regulations for safety of pressure devices must be observed

at all times.

Regulations for plants in explosive areas must always be observed. This particularly applies for

prevention of sparks due to static electricity for the grounding of plant parts and for the volume

resistances of the supply line.

2.1 Intended use

The main purpose of safety breakaway coupling ABV-S is to prevent environmental damage cause by

hose connections bursting on tankers. The coupling may only be operated by qualified persons

(qualifications: experts, technicians, vocational training, and/or job experience) after it has been mounted

on the tank and hosepipe in the proper manner and once a leak test has been conducted. Operators bear

full responsibility for the safety of the plant and are obliged to comply with the applicable regulations for

hazardous substances and highly inflammable or combustible fluids.

The safety breakaway coupling ABV-S may be used only in the temperature range -40°C to 150°C,

dependent on the used metallic and sealing materials. Before filling or emptying tanks, the pull cable must

5

be fastened to a suitable anchor point close to the filling station. Pull cable and fastening anchor must be

checked to ensure they are firm and have sufficient tensile strength.

3 Description/structure

The safety breakaway coupling ABV-S consists of two housing halves with a check valve in each. The

housings are held together by three pressure clamps and a support ring during normal operation. The two

check valves support each other during normal operation and keep the conduit open.

ABV-S, threaded connection

Description 1 Pressure clamp 2 Support ring 3 Pull cable 4 Supply line thread ABV-S 5 Spider 6 Supply line flange ABV-S 7 Tank thread ABV-S 8 Shaft 9 Check valve 10 Tank flange ABV-S

ABV-S, flange connection

3.1 Function

In case the tank wagon rolls away or someone forgot to disconnect the supply line before the truck drives

off, the ABV-S is activated as follows:

Before the supply line is stressed by undue external forces the support ring is pulled out by a pull cable

running parallel to the supply line which releases the pressure clamps. The case halves are separated

from each other and the spring-loaded check valves instantaneously close both ends of the line. 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.

3.2 Storage and transport

The safety breakaway coupling ABV-S may only be transported or stored when absolutely clean. Suitable

sealing must be used for the openings to ensure no damage occurs to the surfaces/sealed areas. The

3

1

4

7

2

9

3 5

6

10

2

9

5

1

8

8

6

seals may only be removed by trained personnel. The storage location must guarantee adequate

protection from corrosion or extreme temperatures.

3.3 Identification

Identification is engraved in the housing on each half of the coupling.

The following information is always available:

TÜ.AGG.214-94

CE 0575 II 2G T(x)

Manufacturer ID: RS

Art.no.:556.400400.12109-xx or 553.600600.720-xx

Serial number / Year ,manufactured

Consecutive no. / material name (housing)

DN PN

3.4 Scope of delivery

The safety breakaway coupling ABV-S will be delivered ready to use with caps for both openings and

transportation lock for pull cable.

3.5 Accessories

When assembling safety breakaway coupling ABV-S, use of an open-jawed wrench with suitable width

across flats is recommended. The open-jawed wrench must be provided by the user.

For servicing purposes, seal sets for valves and spiders may be ordered from Roman Seliger at

authorized hose assembly workshops. A special wrench for the spider can also be delivered.

3.6 Technical data

Special features:

Modular design, expandable with additional screw-on parts, e.g. flange threaded nipples with different flange

sizes

Connection side BSP foll. ISO 228 IG, G2", G3", G4". Flat-packed thread runs to tank. This must not be

sealed with PTFE tape.

release angle up to 90° through three pressure clamps on activation mechanism

Impact ring, protects against impacts

Bellow cover, catches spray water during breakaway, can protect against formation of ice during winter

approved by TÜV (German Technical Inspection Authority)

meets ATEX standards for Zone 1

Housing: In standard stainless steel 1.4571, other materials can be selected by manufacturer or operator

7

Seals: O-rings FKM or FEP sheathed, IG PTFE flat packing

Pressure level: PN25, max. rated pressure 25 bar (except DN 300: PN 10, max. 10 bar nomin. Pressure)

Nominal width, Weight and Dimensions [mm]

Nominal width Connection kg d l

DN 25 G1“ 1,06 100 108,5

DN 25 NPT 1“ 1,27 100 140,5

DN 50 G2“ 2,42 125 123,5

DN 80 G3“ 7,92 188 174,5

DN 100 G4“ 13,8 242,5 208,5

DN 150 Flange PN25/40 50,8 318 306,5

DN 200

Flange PN25

ANSI 150 PSI

ANSI 300 PSI

96,8

423

364

DN 300 Flange PN 10 266 592 600

Materials

Components Material no. Material Operating temperature

Body

Spider 1.4408 GX6CrNiMo18-10

Body

Valve

Spider

1.4571 X6CrNiMoTi17122 (AISI 316 Ti)

2.4602, 2.4600 NiCr21Mo14W

(Hastelloy C22) -40°C bis 150°C

2.4610 NiMo16Cr16Ti

Hastelloy C4)

Spring / ball 1.4401

2.4602, 2.4600

X12CrNi177

NICr21Mo14W

8

Seals

Component Material Description 2 Operating temperature

3

O-ring

NBR Perbunan -25°C to 80°C

Ethylen-Propylen-Dien

Rubber EPDM

Buna AP -40°C to 120°C

Perfluorelastomer FFKM KalrezTM

ChemrazTM

-15°C to 200°C

FEP, FKM VitonTM

-30°C to 200°C

Thread seal PTFE TeflonTM

-200°C to 200°C

4 Installation and Initial Start-Up

The ABV-S may be installed by qualified personnel only (qualifications: experts, technicians, vocational

training, and job experience). We would like to point out the professional obligations in acc. to German

law §62 WHG. The safety breakaway coupling must be connected to the nozzles and connections

provided. Avoid application of any additional forces, bending moments or vibrations at connection

nozzles. Strong cross forces should be kept by fixing supports.

The safety breakaway coupling can be installed directly in the product line and is ready for use after

removing the transport protection. 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 wrench should be used for the intended nut flats on the

coupling

d. Connect the end of the coupling without the pull cable guide to the tank wagon and connect the

hosepipe end firmly to the coupling end with the pull cable guide (the hose may not be twisted). The

thread must not be sealed with PTFE tape.

e. Connect a suitable pull cable to the release cable of the coupling. The pull cable has to be shorter than

the supply line and must be firm enough (Stretching, pulling power).

f. Connect the pull cable to a tie rod. The tie rod of the pull cable may be positioned in a way that in any

thinkable situation the pull cable is stretched earlier than the supply line. A safe release is possible in

the range of 0° to 90° for the pull cable. Observe the minimal tensile strength of the entire cable

connection.

g. Forces on the pull cable

2 Kalrez, Viton, Teflon = registered Trademarks of DuPont

3 the temperature stability of the seal materials used must be considered separately for each individual case

9

Nominal width Release force at 25 bar nominal pressure Residual amount cm3

0° release angle 90° release angle

DN 25 -1“ 0,4 kN 0,5 kN 100

DN 50-2“ 0,3 kN 0,6 kN 160

DN 80-3“ 0,5 kN 0,9 kN 630

DN 100-4“ 1,5 kN 1,8 kN 1100

DN 150-6“ 2,4 kN 4,9 kN 3800

DN 200-8“ 3,0 kN 6,3 kN 10000

DN 300-12“ ( PN

10!)

3,0 kN k. A. 21900

h. Remove the transport protection: DN25 – DN 80: release two hexagon screws and remove red ring from

release ring. DN 100 – DN 300: release three hexagon screws und remove three red separators

4.1 Initial start-up

The start-up may take place only when the safety breakaway coupling has been mounted as instructed

and the necessary function tests and leak tests have been conducted by the approved authorities.

Operators are obliged to provide trained personnel to check the sealing of the connections, the correct

condition of the pull cable and its fitting.

5 Operation

5.1 General notes

Operators are obliged to provide qualified and trained personnel familiar with the handling of supply

pipes, safety breakaway couplings, any fluid being pumped as well as its danger potential. Such staff

must also be familiar with the applicable safety regulations and the regulations of the employer’s liability

association.

The pull cable must be shorter than the supply line and must always be tight and attached in such a way

that the safety breakaway coupling can be safely triggered.

5.2 For the operator

The safety breakaway coupling ABV-S 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-S is part of a mandatory inspected system, the safety

breakaway coupling ABV-S has to be checked by a technical expert during the first as well as all

repeating inspections.

10

Only qualified personnel may be assigned with assembling the ABV-S (qualifications: experts,

technicians, vocational training, and/or job experience).

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

5.3 Start-ups

CAUTION: When released, the safety breakaway coupling disconnects using considerable force! During disconnection, the fluid being pumped may suddenly spurt out. Ensure suitable protective measures are therefore in place!

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

Condition of the pull cable.

Pull cable connection and fitting.

Proper fit of support ring and the clamps.

Check the coupling for leaks.

Check the connections of the coupling's seals to the system.

Check the conductivity of the entire supply line.

The electric contact resistance of R ≤ 10 MΩ needs to be kept.

5.4 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).

5.5 Disassembly

After releasing the safety breakaway coupling and on opening the locks, there is a danger that the fluid

will spurt out. Special protective measures such as personal protection equipment must therefore be

adopted. Always ensure system is cleaned in the proper manner. After cleaning, remove any residue from

the cleaning agent.

How to disassemble:

a. Wear suitable personal safety equipment.

b. Make sure that the coupling halves are depressurized and empty.

c. Clean coupling before disassembly (use cleaning agent suitable for the pumped fluid).

d. Unscrew both coupling halves with a fitting wrench.

11

5.6 Improper use

The equipment should never be used in the case of visible damage or where there is prior knowledge of

damage that may lead to malfunction.

5.7 Maintenance / repair

Maintenance should be done regularly; at least once in the year. Maintenance must always be carried out

after the safety breakaway coupling ABV-S has been triggered. 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.

5.8 Miscellaneous

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

Seliger Armaturenfabrik GmbH accepts no responsibility for damages due to faulty installation, faulty

handling, as well as negligent or incorrect maintenance.

6 Inspection after Release

WARNING: Malfunction may occur due to incorrect assembly!

Whenever the system is released, it must be cleaned and sent in for assembly, otherwise the guarantee for perfect

functioning will be rendered invalid. RS also changes the seal(s) in safety breakaway couplings that are sent in.

The safety breakaway coupling ABV-S is a safety component. Maintenance tasks may be performed only

by trained personnel from an authorised professional workshop. All measures necessary for inspection,

maintenance and repair must be carried out in accordance with the national regulations of the country

where the system is installed.

7 Maintenance and Repair

7.1 General information

The safety breakaway coupling must be serviced regularly by qualified personnel to ensure it is always in

proper working order in the event of any mechanical, chemical and thermal loads caused by the

designated operating method. According to operating conditions and experiences, the operator must

12

stipulate the measures to be adopted, together with intervals for inspection and maintenance in an

operator’s guide (see recommendation of RS, chapter 5.2 and 5.7). These include, for instance, visual

inspection for leaks, function checks, water pressure checks with 1.5 fold excess pressure. All inspections

and their results must be documented. In addition, during maintenance, the implemented measures must

be documented. Any faults ascertained must be rectified immediately, else use of the equipment

discontinued permanently.

7.2 Periodic tests by approved test centres

In Germany, the owner must send the equipment for a safety test at regular intervals in compliance with

§15 of the health and safety guidelines when using equipment in the workplace (BetrSichV). In other

countries, appropriate regulations also exist.

8 Manufacturer

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

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.