Schuck Group SHD User manual

SCHUCK INSTALLATION/OPERATION MANUAL
Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
Translation of the original German Operation Manual
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2
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Introduction
Introduction
This manual is written for installation, operating, maintenance and supervisory
personnel.
This manual also describes components and auxiliary units that are not included
or are only partially included in the scope of supply.
The manual must be read, understood and observed by the user. We emphasize
that Franz Schuck GmbH assumes no liability for damage or malfunctions arising
from non-compliance with this manual.
With regard to the illustrations and information in this manual, we reserve the right
to make technical modifications.
Copyright
The copyright for this manual remains with Franz Schuck GmbH.
The instructions and drawings contained herein may not be reproduced or dissem-
inated either fully or in part, nor used for competitive purposes or communicated
to other parties without authorization.
Contact address
Franz Schuck GmbH
Daimlerstraße 5 – 7
89555 Steinheim
GERMANY
Phone [phone]
Fax [phone]
[email protected]
www.schuck-group.com

I
Table of Contents
Table of Contents
Chapter 1 1-1Preliminary remarks
1.1 1-1Legal notes
1.2 1-1Application range
Chapter 2 2-1Safety
2.1 2-1Fundamental safety instructions
2.1.1 2-1General
2.1.2 2-2Intended use
2.1.3 2-3Organizational measures
2.1.3.1 2-3Special hazard points
2.1.3.2 2-4Workplace and personal protective gear
Chapter 3 3-1Description
3.1 3-1Types
3.2 3-2Task, function and components
3.3 3-4Designation
3.4 3-4Accessories and connections
Chapter 4 4-1Installation
4.1 4-3Preparing the installation
4.1.1 4-3As-delivered condition
4.1.2 4-4Inspection
4.1.3 4-4Storage
4.2 4-5Installation
4.2.1 4-5General installation instructions
4.2.2 4-6Installation
4.2.3 4-7Function test
Chapter 5 5-1Operation
Chapter 6 6-1Maintenance
6.1 6-1Faults and troubleshooting
6.2 6-2Repairs

II
Table of Contents
Chapter 7 7-1Appendix
7.1 7-1Tightening sequence for flange bolts
7.2 7-2Conversion factors
7.3 7-3Calculation formula to determine the carbon equivalent (CEV)
7.3.1 7-3Calculation formula (standard)
7.3.2 7-3Calculation formula for steels with different consistencies
7.4 7-4Maximum permissible torsional moments for insulating joints with socket screw
threads

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
1-1
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Preliminary remarks
1 Preliminary remarks
CAUTION
Danger of consequential damage due to incorrect operation, maintenance
and/or handling!
We explicitly emphasize that we assume no liability for damage or malfunctions
arising from non-compliance with this manual.
ÖTherefore it is important to comply with all instructions in this manual!
This manual is to provide technicians and users with the necessary information
for assembly and adjustment work and to help in performing work quickly and
correctly.
For your own safety, read this manual carefully and pay particular attention to the
highlighted tips. In any case, keep this manual to hand.
Pay special attention to all safety instructions in this manual. You will find the
safety instructions in Chapter 2, in the introductions to chapters and before prac-
tical instructions. The General Terms and Conditions of the company apply exclu-
sively to all deliveries and performances made by Franz Schuck GmbH, including
any future transactions.
1.1 Legal notes
The component may only be installed by skilled staff.
Please check parts upon receipt for any possible damage that may have occurred
during transport. Only undamaged parts may be fitted or used.
No warranty can be claimed if maintenance work is neglected or carried out incor-
rectly. Only original spare parts guarantee quality, reliability and exchangeability.
Any modification(s) of the component are in general prohibited by Franz Schuck
GmbH. The manufacturer guarantee becomes void if this prohibition is not com-
plied with!
1.2 Application range
This operation manual applies to the Franz Schuck GmbH product described in this
manual.
The appropriate operation manuals for optional accessories must also be ob-
served.
These operation manuals are included in the overall documentation if the acces-
sories belong to the scope of supply from Franz Schuck GmbH.

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
2-1
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Safety
2 Safety
CAUTION
Dangers to the health and safety of operating and maintenance staff as well as
to the functioning capacity of the component. Dangers to the environment due
to escaping gaseous or liquid media.
Danger to life due to escaping steam or hot water!
Non-compliance with these instructions jeopardizes the obligation by Franz
Schuck GmbH to follow through on the warranty/guarantee.
ÖThe instructions in the “Safety” Chapter must be unconditionally observed!
2.1 Fundamental safety instructions
2.1.1 General
Modifications on the component which could affect safety may not be carried out
without written permission from the manufacturer.
The guarantee becomes void if this prohibition is not complied with!
i
• This product has been manufactured according to the recognized rules of
technology and according to internal Schuck quality standards; the product is
shipped from the factory in a perfect technical condition
• Nevertheless, components can cause hazards to people, material goods and
the environment if installation personnel use them improperly or in a manner
that is contrary to their intended use
• Any person dealing with assembly, commissioning or maintenance of the com-
ponent must have read and understand this entire manual, and must be able
to prove they possess professional qualifications for implementing the work
• Please observe the valid accident prevention regulations when installing the
component
• Suitable protective gear must be worn when carrying out the works
• The manual must be kept safe and accessible at all times at the place where
the component is in use
• If malfunctions occur, take appropriate measures immediately and notify Franz
Schuck GmbH
• Work on components (such as inspection work, servicing and/or maintenance
work) may only be carried out in a depressurized state
• Components must be effectively covered and/or protected when work is being
carried out that could lead to contamination of or damage to the component,
the assembled parts and/or the anti-corrosion protection

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
2-2
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Safety / Fundamental safety instructions
2.1.2 Intended use
The component supplied is designed exclusively to block completely the metal
conductivity in a pipeline or a cathodic corrosion protection system.
It is not designed to absorb occurring forces and torques. If this is required, this
must be specified in the order or the enclosed specification.
The component can be designed for gas and liquid media.
Any other media and/or applications outside the permissible pressure and temper-
ature range can lead to damage and/or leaks.
Intended use includes observing the instructions in this operating manual and ad-
hering to the operating conditions on the component, the final inspection certifica-
tion and drawings, as well as observing the locally applicable accident prevention
guidelines and regulations for protecting the environment.
Any operating conditions or applications which differ from those prescribed are
only valid with the agreement of Franz Schuck GmbH!
CAUTION
ÖObserve the following specifics regarding operation with oxygen.
• Oxygen pressure surges during operation are not permissible
• Maximum permissible pressure increase = 20 bar / min. (0.33 bar / s)
• Maximum permissible flow speed at pressures ≤40 bar: 25 m/s
• Maximum permissible flow speed at pressures >40 bar: 8 m/s
• The oxygen flow must be free from inflammable particles
• The influence of electrical discharge on the insulating sealing ring must
be eliminated
• Keep insulating joint free from oil and grease!
• Installation must be completely free of grease
• The insulating joint must be free of water and cleaning agent residue

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
2-3
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Safety / Fundamental safety instructions
2.1.3 Organizational measures
2.1.3.1 Special hazard points
There is no immediate danger from a component that is installed according to
instructions.
Life hazard in the case of escaping steam or hot water!
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• Danger from escaping media
– depending on the working medium, fire or explosion hazards can arise from
electrical contact, naked flames, light and/or smoking
– there is a risk of poisoning, chemical burns, scolding and environmental
pollution
– hazardous materials must be collected or sucked up, if necessary, and dis-
posed of properly

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
2-4
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Safety / Fundamental safety instructions
2.1.3.2 Workplace and personal protective gear
Sufficient space is required for carrying out assembly and maintenance work
safely. The operator must ensure that the workplace is clean and clearly arranged.
If media (including residues) can escape in case the component experiences op-
erational faults or malfunctions, then the endangered persons must use suitable
personal protective gear, as far as this is necessary.
Only use components in a technically undamaged condition; use them according
to specifications in a safety and risk conscious manner while complying with the
operating manual! Remedy faults in particular that could impair safety (or have
them remedied)!
The operating manual must be supplemented by instructions which take into ac-
count supervisory and reporting duties with regard to work related particularities,
e. g. in respect of how work is organized, working procedures and the personnel
employed.
Staff commissioned to work on a component must have read the chapter on safety
in this operating manual before starting work. Staff must already be aware of
potential hazard sources when working to be in a position to react quickly and
correctly. This applies in particular to staff who are only employed occasionally to
work on a component, e.g. when setting up or servicing.
Observe all safety and hazard instructions for the equipment/the component!
Make sure all safety and hazard signs are complete and legible!
No modifications, attachments or conversions which could impair safety may be
implemented without authorization from Franz Schuck GmbH!
Adhere to the prescribed deadlines, or the deadlines stated in the manual, for re-
curring tests/inspections!
Make sure the location or fire extinguishers is clearly indicated and operating in-
structions are available!
Make sure to observe the fire alarm and fire fighting instructions!

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
3-1
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Description
3 Description
3.1 Types
Type Connection
SHD, SHD-K with welded connection on both sides
SHDF with flanged connection on both sides
SHDFS on one side with welded connection
and on the other side with flange
connection
SHM two-sided socket screw thread
Tab. 3-1 Characteristics