Stark S-2000 Guide

STARK® S-2000 2” through 30”
Installation, Operation & Maintenance Instructions
NOTE:
If a 24” to 30” closure was supplied with a screw top and/or load binder assist, please refer to 24” to 48”
S-2000 Closure IOM
GENERAL NOTICE
The information provided in this document is very important and needs to be shared with everyone involved
in the installing, operating and the maintenance of the closure(s).
SAFETY NOTICE
Do not open the closure unless you are sure there is no pressure within the closure. All operators should
use the appropriate Personal Protective Equipment (PPE) and operating tools.
WELDING NOTICE
During welding, warpage can occur due to the heat generated. Please read sections 1.3 & 1.4 for
recommendations to reduce warpage caused by welding. Excessive warpage will damage the product.
STARK® appreciates the support of all supervisors.
Should you have any questions or concerns not addressed in this document,
please contact us directly for assistance.
STARK® SOLUTIONS
10816 Northridge Drive
Conroe, TX 77303
936.539.2386
[e-mail]
www.starksolutions.com
STARK® SOLUTIONS IS ASME “U” & “R” & ISO 9001-2015 CERTIFIED

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Document No: CMM.2000.106 Rev: 1
Version : 22.034
Table of Contents
Section 1: INSTALLATION Page 03
Section 1.1: Installation of Horizontal Hinge Closure Page 03
Section 1.2: Attachment of the Closure Page 04
Section 1.3: Installation of Closure Hub in the Field (Manual Welding) Page 04
Section 1.4: Installation of Closure Hub in the Fabrication Shops (Automatic Welding) Page 05
Section 1.5: Final Tune Up Page 06
Section 2: OPERATION Page 07
Section 2.1: Operation Instructions: Opening the Closure Page 07
Section 2.2: Operation Instructions: Closing the Closure Page 09
Section 4: DOOR ADJUSTMENT Page 11
Section 4.1: Door Adjustment on 4” to 14” Page 11
Section 4.2: Door Adjustment on 16” to 30” Page 11
Section 5: MAINTENANCE Page 13
Section 5.1: General Maintenance Page 13
Section 5.2: O-ring Maintenance Page 13
Section 5.3: PAV Maintenance Page 14
Section 5.4: Clamp Ring Maintenance Page 14
Section 6: REFERENCE DRAWINGS Page 15

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Document No: CMM.2000.106 Rev: 1
Version : 22.034
Section 1: INSTALLATION
Section 1.1: Installation of Horizontal Hinged Closure
NOTE: The lifting eye on the door is the preferred method of moving the closure, but should it be
moved by hand, the handle on the door should be used. DO PULL THE CLOSURE WITH THE LATCH
HANDLE. The latch is not designed to withstand the weight of the closure, as it is a hand operated
safety mechanism to prevent the closure from being opened when the PAV is engaged.
Installation Instructions:
• Ensure the closure is level during the installation process
• Properly align the hub with the mating pipe
• Position the hinge vertically to permit easy opening and closing of the door
Section 1.2: Attachment of the Closure
NOTE: All welding should be performed by qualified welders in accordance with qualified procedures
such as ASME, API, ANSI, etc. These codes require that the welder and the weld procedure be
previously qualified. To avoid hub warpage, complete all nozzle and attachment welds prior to
closure installation.
Standard Hub Materials:
•Non ASME or door only: 2” thru 14” - ASTM A694 Grade F52
•Non ASME or door only: 16” thru 30” - ASTM A694 Grade F65
•Full ASME Code Stamped (door and hub): SA 350 LF2
The above are our standard hub materials, however other material yield strengths may be provided
based on customer requirements. It is important to always refer to material test reports (MTRs) to
determine weld procedure for actual materials being welded.
IMPORTANT: A bleeder valve and a pressure gauge must be installed on the vessel the closure is
welded to. An operator must be able to bleed the pipeline/vessel and determine when there is zero
(0) psig within the pipeline/vessel.

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Document No: CMM.2000.106 Rev: 1
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Section 1.3: Installation of Closure Hub in the Field (Manual Welding)
NOTE: Equally distributed preheating is a recommended practice to prevent warpage and cracking,
especially on high yield material.
Replace the PAV and reassemble the closure. Make any necessary adjustments.
IMPORTANT: When cleaning the hub, be very careful not to damage the O-ring sealing surfaces.
Damage to these surfaces may prevent the O-ring from sealing.
A. Remove the Pressure Alert Valve
(PAV), and O-ring from the closure
hub. Ref. Figure 2
B. Fit the hub to the mating pipe/vessel.
The use of internal or “spider”
bracing is recommended, especially
with thinner wall thicknesses
closures.
C. Weld root and hot passes. The
amount of heat should be minimized
to avoid possible hub sealing surface
warpage. A recommended pass
sequence is illustrated below in
(Figure 3)
Figure 2. Remove O-ring from closure hub
PAV
Figure 3. Recommended Welding Passes in the field

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Document No: CMM.2000.106 Rev: 1
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Section 1.4: Installation of Closure Hub in the Fabrication Shops
(Automatic Welding)
A. Remove the Pressure Alert Valve (PAV) and O-ring, from closure hub
B. Fit the hub to the mating pipe/vessel. The use of internal or “spider” bracing is recommended,
especially with thinner wall thicknesses.
C. Weld the root pass. A recommended pass sequence (Figure 4).
D. Complete the hub to vessel weld using care to minimize heat build up to avoid possible
warpage of the hub sealing face.
E. Before post weld heat treatment, remove all grease from the hub. A coating of an anti-
splatter product used for welding will protect against scale build up during the post weld heat
treatment.
IMPORTANT: During post weld heat treatment, it is recommended that it be accomplished by
localized stress relieving. If that is not possible, the closure door and Clamp Ring must be removed
prior to heat treatment. If this is required, contact Stark for the proper IOM with Door and Clamp
Removal Instructions.
DO NOT PERFORM POST WELD HEAT TREATMENT ON DOOR, CLAMP OR REMOVEABLE HINGE
COMPONENTS ATTACHED TO EITHER THE DOOR OR CLAMP!
F. Replace the PAV and O-ring. Make any necessary adjustments.
IMPORTANT: When cleaning the hub, be very careful not to damage the O-ring sealing surfaces.
Damage to these surfaces may prevent the O-ring from sealing.
Figure 4. Recommended Welding Passes in fabrication

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Document No: CMM.2000.106 Rev: 1
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Section 1.5: Final Tune Up
Before placing the closure in service, all surfaces should be clean, with the O-ring and O-ring sealing
surfaces covered with a thin film of light to medium lithium grease. The closure door face should be
parallel to and concentric with the face of the hub.
Lubricate the closure at the grease fittings on the clamp ring pivot (Figure 4), the door hinge (Figure
5), and the latch assembly (Figure 6).
Figure 5. Lube Point on Door Hinging
Figure 4. Lube Point on Clamp Ring Pivot Pin
Figure 6. Lube Points on latch assembly
2” to 14”

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Document No: CMM.2000.106 Rev: 1
Version : 22.034
Section 2: OPERATION
Section 2.1 Opening the S-2000 Closure
IMPORTANT: A warning plate is attached to the latch handle on closures (Figure 7) and are also
included on the closure nameplate on sizes 16” and larger (Figure 8). This warning concerns personal
safety precautions and must be observed to prevent injury to personnel. Always keep this plate
legible.
Figure 7. Warning Plate on latch Figure 8. Warning on nameplate (closures 16” and larger)
A. Remove the Pressure Alert Valve (PAV) stem (Figure 9), and place in into the PAV retainer.
The PAV is used to alert the operator of residual pressure in the vessel or pipeline. Unrelieved
pressure can cause severe injury or death. If residual pressure is indicated, replace the PAV
stem, and ensure the pipeline or vessel is bled of all pressure.
Do NOT use the PAV to bleed pressure from the pipeline/vessel. The pressure warning lock is integral
to the clamp ring and must be opened before the clamp ring can be spread.
B. The PAV uses a metal-to-metal seal. The
removable stem presses a hard, tapered plug into
the mating tapered surface inside the PAV body.
The position of the PAV on the top of the hub
generally keeps all dirt and debris clean of the
sealing surfaces, resulting in a trouble-free seal.
NOTE: Should any part of the PAV become
damaged, the PAV assembly (Figure 10)can be
easily replaced.
Figure 9. PAV removal

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Document No: CMM.2000.106 Rev: 1
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C. Always clean the interior surfaces of the clamp ring and apply a thin film of lubricant. When
the closure is open, check the lubrication of the hinge point on the clamp ring assembly. There
is a grease fitting on the clamp ring pivot pin (Figure 11)
IMPORTANT: Isolate the vessel from line pressure, bleed the pressure to 0 psig, and drain.
Once the PAV is completely unthreaded, remove the screw, place the PAV in the retainer, and open
the clamp ring by lifting the clamp ring handle (Figure 12) This will spread the two halves of the clamp
ring so that the closure door can be opened (Figure 13).
IMPORTANT: When opening PAV, clamp ring, and door, always stand on the side of the closure that
is opposite the door hinge. Do not stand in front of closure or on door hinge side of closure while
opening.
Figure 10. S-2000 PAV
Figure 11. Lubricate the Clamp Ring Pivot Pin

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Document No: CMM.2000.106 Rev: 1
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Section 2.2: Closing the S-2000 Closure
A. Inspect, clean, and lubricate the O-ring, the O-ring grooves and sealing surfaces, and the PAV.
Replace the O-ring if any damage is observed.
WARNING: Replace damaged O-rings immediately. A damaged O-ring will cause leakage of gases or
fluids that can lead to serious injury and property damage.
B. Push the door firmly shut. Before the clamp ring can be closed, the door must be completely
closed. There should be no gap between the door face and the hub face.
C. Close the clamp ring by pulling the latch handle over the top of the closure and lowering it
fully.
IMPORTANT: The clamp ring does not
use any wedging action during closing
since the clamping surfaces are parallel
to the door and hub faces. Do not force
the latch handle if the clamp ring will
not close freely. Check for proper door
alignment and for debris. As the clamp
ring is closed, the retainers attached to
the back of the clamp ring move closer
together. When the clamp ring is fully
closed, the holes in the retainers are in
alignment. If the holes do not overlap,
as shown in Figure 14, you will not be
able to thread the PAV into the
bushing. If the clamp ring appears to be
closed and the holes still do not line up,
re-open the clamp ring and check for
damage and debris.
Figure 12. Lift Clamp Ring Handle to
Spread Clamp Ring
Figure 14. Upper Hole and Lower Hole Are Not
Aligned When Latch Handle Is Not in Closed Position
Figure 13. With Clamp Ring Spread Door Can Be Opened

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D. Install the PAV. Make sure it is not cross threaded into the body. Tighten hand tight, and then
add about one eighth of a turn with a small wrench. Do not over tighten.
WARNING: Never attempt to pressurize the
pipeline/vessel until you have made sure that the
door, clamp ring, and PAV are fully closed and
secured.
Leaks that spray fluid or gas or a door opening
suddenly can result in personal injury or property
damage or both.
E. The pipeline/vessel can now be pressurized.
Figure 15. Tightened PAV in Place

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Document No: CMM.2000.106 Rev: 1
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Section 4: DOOR ADJUSTMENT
After the door has been removed, it may need to be adjusted after being re-installed. Once the door
is properly back in position, swing it toward the hub, stopping when contact is made. Check the
height of the door versus the height of the clamp by inspecting the door OD and the hub OD at the
same location and see if they are at the same height/position. It’s recommended to check the top,
bottom, and sides if possible. It is important to check the door height when it is almost closed and
look for any gaps between the door and hub when it is fully closed.
Section 4.1 Door adjustment on 4” to 14” closures
Section 4.2 Door adjustment on 16” to 30” closures
The closures 16” and above have adjustment journals on the hinging to allow for easy adjustment of
the door position.
IMPORTANT: The lower adjustment cap should NOT be removed. The upper cap is shown removed
here for visual reference.
•Raising/Lowering - If the door needs to be raised, adjust the lower journal inward, and the
upper journal outward; this causes the door to rotate into a higher position. To lower the
door, do the opposite. Small changes to these lateral adjustments cause the door to move
significantly. See Figure 17.
If the door is lower than the hub, the door may
have to be raised to allow the door to properly
close. This is accomplished by removing the
door, and placing a shim washer on the hinge
post, which will cause the door to sit higher in
operation. If a shim washer already exists on the
hinge post, and the door needs to be lowered,
the shim washer should be removed.
Figure 16. Hinge Adjustment Point on 4” – 14”

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Document No: CMM.2000.106 Rev: 1
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•Left/Right –If the door is more left than the hub when almost closed, the door needs to be
moved to the right side. Adjust both upper and lower lateral adjustments to the right, as
equally as possible, and the door will adjust right. See Figure 17.
•Forward/Back - If there is a gap between the top of the door and hub when the door is closed,
the door needs to be rotated inward (toward the hub) at the top. Adjust the upper journal
inward (See Figure 18). If the gap is at the bottom, the lower journal should be adjusted
inward.
Figure 17. Lateral Adjustment Point
Figure 18. Upper & Inward Adjustment
NOTE: The adjustment screws are tightened at the factory prior to shipment. To make any
adjustments, it is important to loosen the opposite screw compared to the screw you want to tighten.
Otherwise, you will overtighten, and possibly damage the bearing in the adjustment assembly.

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Document No: CMM.2000.106 Rev: 1
Version : 22.034
Section 5: MAINTENANCE GUIDELINES
Section 5.1: General Maintenance
Every time you open your S-2000 closure, visually inspect to ensure trouble free reliable service:
•Clean the interior surfaces of the Clamp Ring, Hub sealing surface, O-ring and O-ring groove.
•Lubricate the sealing surfaces and the O-ring groove with a thin film of grease, just enough
to support the O-ring to sink into the O-ring groove smoothly.
•Use anti-galling lubricant, like light to medium lithium grease. Do not use silicone type grease
•If adjustment to the horizontal hinge is needed, reference section “Proper adjustment of the
Closure”.
•Lubricate all hinge points on clamp ring
•Lubricate the pivot point at the bottom of Clamp
Section 5.2: O-ring Maintenance
The S-2000 comes standard with a Viton O-ring that is placed on the closure hub, but it is always a
good idea to ensure material compatibility with the product going through the pipeline. Should the
O-ring material not be suitable, it could swell and prevent proper engagement of the clamps, thus
not sealing properly.
•Inspect the O-ring for rough surfaces, nicks, or cuts. If any defects are found, replace it with
an O-ring from Stark to ensure the dimensional integrity.
•Clean O-rings and lubricate them lightly prior to placing them in the O-ring groove (Figure.
18).
Figure 18. Sealing Surface / O-ring Groove

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Document No: CMM.2000.106 Rev: 1
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Section 5.3: Pressure Alert Valve (PAV) Maintenance
All S-2000 closures are supplied with a PAV
in accordance with UG-35.2 of ASME BPVC
VIII Div. 1. The PAV uses a metal-to-metal
seal.
•Inspect the PAV stem and base.
•Make sure the threads are clean
and free of nicks.
•Keep the vent holes on the side of
the body clean and free from paint.
Figure 19. PAV Assembly
Section 5.4: Clamp Ring Maintenance
•While the clamp ring is disengaged and the door is open, clean the interior surfaces of the
Clamp Ring.
•Ensure that all hinge points and pivot points are lubricated.
•If excessive force has been used on the latch assembly, it is vital that all welds be visually
inspected for defects. Should damage be present, please contact Stark Solutions
immediately for support.
IMPORTANT: The Clamp Ring should always operate freely. Do not force the clamp ring latch
assembly. Damage to these components can inhibit the clamp ring from fully closing.

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Document No: CMM.2000.106 Rev: 1
Version : 22.034
SECTION 6: REFERENCE DRAWINGS
Drawing 1. 4”-14” S-2000 HORIZONTAL CLOSURE
Item No.
Part Name
1
HUB
2
DOOR
3
CLAMP
4
DOOR HANDLE
5
LATCH HANDLE
6
PAV

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Document No: CMM.2000.106 Rev: 1
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Drawing 2. 16”-30” HORIZONTAL S-2000 CLOSURE
Item No.
Part Name
1
HUB
2
DOOR
3
CLAMP
4
DOOR HANDLE
5
LATCH HANDLE
6
PAV
7
ADJUSTMENT SCREWS
8
BEARING
9
HINGE POST
10
ADJUSTMENT CAP
11
GREASE SEAL
12
SHAFT COLLAR