Spirax Sarco BSA3HP User manual

IM-P184-17 CMGT Issue 3 1
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2019
Printed in GB
1847050/3
BSA3HP
Bellows Sealed High Pressure Stop Valve
Installation and Maintenance Instructions
IM-P184-17
CMGT Issue 3

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Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11) in compliance with
the operating instructions. General installation and safety instructions for pipeline and plant
construction, as well as the proper use of tools and safety equipment must also be complied with.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, product markings and Technical
Information Sheet, check that the product is suitable for the intended use/application.
The products listed below comply with the requirements of the European Pressure Equipment
Directive and carries the mark when so required.
The products fall within the following Pressure Equipment Directive categories:
BSA 3HP Size Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP 2SEP
DN40 - DN100 212SEP
i) These products have been specifically designed for use on steam, air or condensate/water,
which is in Group 2 of the above mentioned Pressure Equipment Directive. The products' use
on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted
to confirm the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which it
is being fitted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced by
any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
v) Remove protection covers from all connections, where appropriate, before installation on
steam or other high temperature applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1. Safety information

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1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel
at risk?
Dangers might include isolation of vents or protective devices or the rendering ineffective of controls
or alarms. Ensure isolation valves are opened and closed progressively to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and
dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person. Installation and
operating personnel should be trained in the correct use of the product according to the Installation
and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no such
system, it is recommended that a responsible person should know what work is going on and,
where necessary, arrange to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.

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1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum permitted
operating conditions the surface temperature may reach temperatures in excess of 400 °C (752 °F).
Many products are not self-draining. Take due care when dismantling or removing the product from
an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law, when
returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present
a health, safety or environmental risk. This information must be provided in writing including Health
and Safety data sheets relating to any substances identified as hazardous or potentially hazardous.

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2.1 General description
The BSA3HP is a carbon steel bodied high pressure in-line non throttling stop valve, having a multi-ply bellows
and unbalanced or balanced options. These valves are rated to EN 1092 PN100 or ASME class 600 for use
with both saturated and superheated steam applications and a range of other industrial gases and fluids.
Range and options
Size Unbalanced Balanced
PN100 Class 600 PN100 Class 600
DN15 - DN50 • •
DN65 - DN100 • • • •
Standards
The product fully complies with the requirements
of the European Pressure Equipment Directive and
carries the mark when so required.
Certification
The BSA3HP is available with certification to EN
10204 3.1.
Note: All certification/inspection requirements must
be stated at the time of order placement.
Note: For further product data see the following
Technical Information sheet TI-P184-15.
Fig. 1 BSA3HP bellows sealed high pressure stop valve
2. General product information

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0 20 40 60 80 100
400
300
200
100
0
-10
A
C
Steam
saturation
curve
Temperature °C
Pressure bar g
PN100
A-B-C
B
The product must not be used in this region or beyond the parameter of the PMA or TMA of the
relative end connection.
Body design condition PN100
PMA Maximum allowable pressure 100 bar g @ 50 °C
TMA Maximum allowable temperature 400 °C @ 59.5 bar g
Minimum allowable temperature -10 °C
PMO Maximum operating pressure for saturated steam service 70.5 bar g @ 287.3 °C
TMO Maximum operating temperature 400 °C @ 59.5 bar g
Minimum operating temperature -10 °C
Designed for a maximum cold hydraulic test pressure of: 150 bar g
2.2 Sizes and pipe connections
DN15, DN20, DN25, DN32, DN40, DN50, DN65, DN80 and DN100
Flanged EN 1092 PN100 and ½", ¾", 1", 1¼", 1½", 2", 2½", 3" and 4"
Flanged ASME class 600
2.3 Seat leakage
Plug to seat shut-off conforms to EN 12266-1 Rate A leakage.
2.4 Kvvalues
Size DN15
(½")
DN20
(¾")
DN25
(1")
DN32
(1¼")
DN40
(1½")
DN50
(2")
DN65
(2½")
DN80
(3")
DN100
(4")
Kv3.1 7. 6 8.6 24 28 36.8 80 86 134
For conversion:
Cv(UK) = Kvx 0.963
Cv(US) = Kvx 1.156
2.5 Pressure/temperature limits (ISO 6552)

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0 20 40 60 80 102.1
0 200 400 600 800 1000 1200 1400
425
400
300
200
100
0
-29
700
500
300
100
0
Temperature °C
Temperature °F
Pressure bar g
Pressure psi g
A
Steam
saturation
curve
D
E
Class 600
A-D-E
The product must not be used in this region or beyond the parameter of the PMA or TMA of the
relative end connection.
Body design condition Class 600
PMA Maximum allowable pressure 102.1 bar g @ 38 °C 1 481psi g @ 100 °F
TMA Maximum allowable temperature 425 °C @ 57.5 bar g 797 °F @ 834 psi g
Minimum allowable temperature -29 °C -20 °F
PMO Maximum operating pressure for saturated
steam service 79.8 bar g @ 295.8 °C 1 156 psi g @ 564.4 °F
TMO Maximum operating temperature 425 °C @ 57.5 bar g 797 °F @ 834 psi g
Minimum operating temperature -29 °C -20 °F
Designed for a maximum cold hydraulic test pressure of: 154 bar g 2 233 psi g

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Note: Before actioning any installation observe the 'Safety information' in Section 1.
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet,
check that the product is suitable for the intended installation:
3.1 Check materials, pressure and temperature and their maximum values. If the maximum operating
limit of the product is lower than that of the system in which it is being fitted, ensure that a safety
device is included in the system to prevent overpressurisation.
3.2 Remove the protective covers from all connections.
3.3 Install the valve in the direction of flow given by the arrow on the body. The preferred position is with
the spindle vertical. The valve can be installed from the vertical to the horizontal plane (see Figure 3).
3.4 Always open isolation valves slowly to avoid system shocks.
3.5 Note: It is advisable that when work is being carried out downstream of a valve installation, double
isolation (block and bleed) should be fitted. In addition when installed as the final valve in a pipeline,
as a safety precaution, a blanking plate or blank flange must be fitted to the outlet flange of the valve.
3.6 Important note: When a Balanced Valve is installed, the valve body should be mounted with the
upstream fluid flowing into the upper valve chamber first (as per flow arrow), so that the fluid pressure
acts on top of the Balancing Plug. This is opposite to normal installation. If a Balancing Plug is
upgrading or replacing a standard plug, the original valve body must be turned around in the pipeline
and permanently marked with a new flow arrow indicating the changed direction of flow.
Do not mount the valve upside down.
What is a balancing plug, how does it work and why use it?
-A balancing plug is a two stage on/off mechanism
-(See Figure 2) The pre-lifting plug (A) acts as
a pilot valve and is opened first, allowing the
medium to pass through at a controlled rate.
The differential pressure then reduces across
the valve - allowing the main valve plug (B) to
be easily lifted off its seat. To assist closing
the valve the flowing medium must enter
on the 'Bellows' side, this is the opposite to
normal installation.
-This device is fitted in the first instance to allow
easy closure of the larger valves. In normal flow
conditions it is very difficult on large valves and
high differential pressure to close the valve. By
reversing the flow and installing a pilot valve,
this problem is overcome.
AB
Fig. 2
3. Installation

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After installation or maintenance ensure that the system is fully functioning. Carry out tests on any alarms
or protective devices.
4. Commissioning
5. Operation
5.1 The bellows sealed isolation valve plays an
important role in the conservation of energy
by eliminating fugitive stem seal emissions.
5.2 The valve is operated manually by a
handwheel. Special care must be taken to
ensure that the movement is made in the
correct direction.
To open the valve fully, it is recommended to
turn the handwheel until the shaft is raised
to the maximum position, indicated by the
(+) on the bonnet, then turn the handwheel
clockwise 1¼turns to remove any backlash.
This is to prevent the possibility of
attempting to force open a valve, which is
already fully open, resulting in damage to
the stem, bellows unit or other components.
Spirax Sarco BSA valves are fitted with a
position indicator which can be found on
the stem, and on the bonnet support pillars
(+ = fully open/- = fully closed).
5.3 The use of valve keys is not recommended,
however if used care must be taken not to
damage the valve.
Fig. 3 Incorrect installation Correct installation

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All the internals of the bellows sealed valve can be replaced (See Section 7, Spare parts).
Note: Before actioning any maintenance programme observe the data in Section 1 'Safety information'.
Warning
Before undertaking any maintenance on the valve, ensure that any pressure is isolated and safely vented
to atmospheric pressure. The valve should then be allowed to cool. When reassembling, ensure that all
joint faces are clean.
6.1 Replacing the handwheel
1. Remove circlip (15) with circlip pliers.
2. Slide off existing handwheel.
3. Ensure that thrust washer (13) is still present
on top face of bonnet (5).
4. Ensure that all contact surfaces of the valve
are clean and free of dirt to accept new
handwheel.
5. Align flat of 'D' drive of new handwheel and
that of the bonnet bush. Slide new handwheel
into place.
6. Fit replacement circlip with circlip pliers.
7. Test operation of valve by rotating the valve
between fully open and fully closed several
times to ensure it is working properly before
returning the valve to service.
Fig. 4
Fig. 5
13
5
15
6.2 Replacing the bellows, stem, plug and seat assembly
1. Loosen the gland nut (11) by a couple of turns.
2. Open the valve (using the handwheel) by a single rotation.
3. Loosen and remove the bonnet nuts (20).
4. Carefully lift the top half of the valve including the bonnet, handwheel, stem and plug assembly.
5. Lift the bellows housing (4) off of the studs.
6. Maintenance

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Fig. 6
22
4
3
2
21
20
5
17
23
6 +
7
17
11
Recommended tightening torques
Valve size
mm
or
inch
N m lbf ft
DN15-DN25 22 A/F ½" UNC-13 90 66.4
DN32-DN50 27 A/F 5/8" UN C -11 135 99.6
DN65-DN100 32 A/F ¾" UNC-10 240 177.0
10
9
Section 6.2
is continued on page 12

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6. Carefully remove the old gaskets (22) and clean the contact surfaces of the bellows housing. Also ensure
that the mating surfaces of the body and bonnet are clean and free of dirt.
7. Remove the support cage (3) from inside the body.
8. Lift the seat (2) from the body. The gasket may lift with it.
9. If not, remove the seat gasket (21) and clean the contact surfaces.
10. Fit a new seat gasket (21) into the recess, ensuring that it sits flat.
11. Fit a new seat (2) onto the top of the gasket.
12. Refit the support cage (3).
13. Fit a new gasket (22) into the body recess.
14. Refit the bellows housing (4), ensure that orientation of bellows housing is such that counterbore is
uppermost.
15. Fit a new gasket (23) in to the recess of the top of the bellows housing.
16. Support the bonnet assembly, by holding the bonnet casting horizontally (we recommend clamping in
a vice).
17. Unscrew the two bonnet bolts that retain the stem couplings (17) and remove them from the stem.
18. Take hold of the plug (6) at the end of the stem, so it cannot rotate. Then rotate the handwheel gently
clockwise until the stem is released from the bonnet bush.
19. Carefully slide the plug and stem assembly (6+7) from the bonnet (5).
20. Remove the old gasket (23) from the bonnet and clean the contact surface.
21. Unscrew and the remove the gland nut (11).
22. Remove the gland ring (10) and graphite ring (9) from the bonnet.
23. Fit a new graphite ring (9).
24. Refit the gland ring (10).
25. Refit the gland nut (11) loosely (do not tighten).
26. Fit a new gasket (23) to the bonnet.
27. Carefully slide the new plug and stem assembly into the bonnet (take care not to damage any of the
surfaces).
28. Push the plug and stem assembly into the bonnet bush and rotate the handwheel anti-clockwise until
the thread engages. Keep rotating the handwheel as the plug and stem winds into the bonnet bush.
29. Wind on several turns until there is enough room to refit the stem couplings (17).
30. Align the flats on the stem to allow the stem couplings to be refitted. Tighten the two retaining screws.
31. Rotate the handwheel anti-clockwise until the the stem couplings prevent further movement.
32. Lower the bonnet assembly gently into the bellows housing, making sure that the bonnet fits over the
studs. Check that the underside of the bonnet has aligned with the bellows housing.
33. Replace the nuts and tighten by hand.
34. Rotate the handwheel, winding the valve into the closed position (clockwise). Close the valve gently,
do not apply full torque.
35. Open the valve by unwinding the handwheel by several turns.

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Fig. 7
22
4
3
2
21
20
5
17
23
6 + 7
17
11
10
9
36. Tighten the bonnet nuts (20) in sequence to approximately half of the full torque.
37. Repeat instructions 34, 35 and 36, but tightening the bonnets to full torque setting.
38. Hand-tighten gland nut (11) after valve has been fully assembled.
39. The valve is now ready for use.

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Warning
The body/bonnet collar gaskets contain a thin
stainless steel support ring which may cause
physical injury if they are not handled and disposed
of carefully.
Care must be taken when opening and closing the
handwheel to prevent any possible injury to the
hands from the locking screw.
Spare parts
The spare parts available are detailed below.
No other parts are supplied as spares.
Available spares
Seat/body/bonnet
gaskets and
graphite ring
9, 21, 22 and 23 (2 off)
Seat, plug, stem and
bellows assembly
(Gaskets not included)
2, 6 and 7
Handwheel and circlip 14 and 15
How to order spares
Always order spares by using the description given
in 'Available spares' and state the size and type of
stop valve (balanced or unbalanced).
Example: 1- Seat, plug, stem and bellows
assembly for an unbalanced DN15 Spirax Sarco
BSA3HP bellows sealed high pressure stop valve
having EN1092 PN100 connections.
Fig. 8 DN25
PN100 BSA3HP shown
9
6+ 7
23
14
15
22
21
2
7. Spare parts

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How to order
Example: 1 off DN25 Spirax Sarco type BSA3HP bellows sealed high pressure stop valve, flanged ASME 600.
Note: Should the differential pressure exceed those listed against the respective sizes in the table below,
then please ensure balancing discs are specified for use in the valves (see the illustration opposite).
Size DN65 DN80 DN100
Differential pressure (bar g) 12 12 4

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