Pipeline Engineering ,

Gatherley Road, Catterick Bridge, Richmond, North Yorkshire, DL10 7JG, England.
Tel. 00 44 (0) 1748 818341, Fax. 00 44 (0) 1748 818039
E.Mail: sales@pipelineengineering.co.uk

INSTALLATION, OPERATION AND MAINTENANCE PROCEDURE

FOR

HORIZONTAL RAPID OPENING CLOSURE

 INDEX

HORIZONTAL CLOSURE

1.0 General Safety

2.0 Installation Note

3.0 Rapid Opening Closure

Main components of locking mechanism
And various schematic diagrams

4.0 Operating Instructions

4.i Unlock and Open
4.ii. Close and Lock
4.iii Operating Notes

5.0 Maintenance
5.i. Lubrication Points
5.ii. Sealing Faces
5.iii. Long Term Storage

6.0 Adjustment
6.i. Door Height
6.ii. Door Angle

7.0 Replacing Door Seal

8.0 Installation Notes.

8.i. Fabrication Distortion
8.ii. Post Weld Heat Treatment
8.iii. Painting

9.0 Bolting Torque Settings

 1.0 GENERAL SAFETY

1. General Operation.

i. Always use the handle / tools provided to operate the Open/Close

mechanism.

ii. Do not attempt to rotate the door mechanism further than its nominal
Degree of movement.

2. Orientation of Horizontal Rapid Opening Closures

The PE Rapid Opening Closure must always be installed in the true horizontal
position.
If the vessel is inclined or declined to the horizontal (between 1 and 10 Deg) a
mitred weld preparation must be added to the closure hub. The closure will then be
horizontal whilst accommodating the slope angle of the vessel.

RAPID OPENING CLOSURES SHOULD NEVER BE

INSTALLED IN A POSITION THAT IS NOT TRULY
HORIZONTAL
 2.0 INSTALLATION NOTE

IMPORTANT.

Prior to any installation work refer to Sections 8.i, 8.ii and 8.iii of this manual. These
sections provide essential information with regard to avoidance of distortion during
fabrication and notes/requirements for closures that are to be stress relieved.

For stress relief it is recommended the closure door be removed. The removal operation is
detailed in Section 8.ii.

IF A PROBLEM EXISTS OR ASSISTANCE IS REQUIRED, PLEASE CONTACT PIPELINE

ENGINEERING.
E-mail: technical@pipelineengineering.co.uk.
 3.0 RAPID OPENING CLOSURE
MAIN COMPONENTS OF LOCKING MECHANISM AND VARIOUS
SCHEMATIC DIAGRAMS

SKETCH 1
SKETCH 2

SKETCH 3
SKETCH 4
SKETCH 5
 4.0 RAPID OPENING CLOSURE: OPERATING INSTRUCTIONS

4.i. UNLOCK AND OPEN.

REFER TO MAIN COMPONENTS SECTION 3.0.

1. Prior to attempting to open the closure door, check the vessel is fully isolated from
any pressure source (main line valves are closed) and is fully vented and drained,
(vent and drain valves are open), i.e. the vessel is at zero ‘0’ internal pressure.

2. Loosen the Vent Plug (see sketches 1 & 3) – do not at this stage attempt to remove
it – any residual pressure left in the vessel will vent past the loosened Vent Plug
seal. If this pressure release is excessive and unrelenting, retighten the Vent Plug to
reseal the vent hole and investigate / check valve status – DO NOT PROCEED
FURTHER – DO NOT RELEASE THE MECHANISM / OPEN THE DOOR.

3. When completely satisfied the vessel is at zero ‘0’ pressure and that it is safe to
open the closure, remove the Vent Plug from the closure. The Open/Close
mechanism is now free to operate.

4. Slide and positively locate the lock/release handle into the handle post (see sketch
2) attached to the Open/Close Mechanism. Using the handle rotate the mechanism
anti-clockwise (for right handed closure) (see Sketch 4 ). This will retract each of the
locking segments from within the hub recess into the door area.

5. Relocate the handle to its storage location in the door hinge centre post. Using the
handle in this position, swing the door out and clear of the hub.

6. The door is mounted on a double hinge arrangement that allows initial straight line
movement to clear the hub recess and rotation once clear to access the seal and
locking segments.

IMPORTANT SERVICE/MAINTENANCE NOTE:

For prolonged service life and reduced maintenance costs rustproof or protect the
sealing faces and machined areas of the closure immediately after opening. Even
short-term unprotected exposure can cause corrosion or pitting to important seal
areas.

IMPORTANT SAFETY NOTICE / WARNING

Ensure the parent vessel IS FULLY DRAINED /ISOLATED FROM PRESSURE SOURCE
AND VENTED before opening the closure.
Observe safety precautions at all times.
4.ii. LOCK AND CLOSE.

REFER TO SECTION 3.0.

1. Remove any deposits of rust-proofing from closure door and hub seal faces.

2. Wipe clean closure door and hub seal faces.

3. Inspect the pressure lip seal ensure it is in good condition – check the seal is free
from cuts and abrasions.

4. Check and ensure the seal, seal face and seal groove in both the hub and door are
clean and free from debris.

5. Lightly smear the seal, sealing faces with silicon grease for corrosion protection.

6. Ensure the locking segments are fully retracted into the door area.

7. Swing the closure door around to the hub aperture, align the door so it enters
squarely into the hub. Carefully push the door down into the hub aperture.

8. Locate the handle into the handle post (Sketch 2) on the Open/Close mechanism.
Whilst pushing the door to compress the seal, use the handle to rotate the
Open/Close mechanism clockwise (for right handed closure) – this movement will
engage the locking segments into the hub recess and locking tabs on the rear of the
Segment Drive plate (Sketch 5) under each locking segment ensuring they positive
location. Visually check around the edge of the Drive plate that all segments are
engaged in the recess.

9. With the segments now in the closed position, the operating mechanism can be
lubricated using the 12 grease nipples located on the Drive plate. Upon completion,
open & close the operating mechanism (see Sketch 4) twice to distribute the
grease.

IMPORTANT NOTE: the contact faces of the Locking Segments / Closure Hub
should be dry and free from grease.

10. With the mechanism in the closed position the vent hole in the closure door and
vent plug hole in the Drive plate should align (sketch 3) – insert then screw home
the Vent Plug with its metal bonded ‘face’ seal. Tighten to a torque of 27Nm – Do
not use excessive force.

NOTE:
Ensure the hub Sealing Face is clean before closing the door.
WARNING:
If the Vent Plug access hole in the Drive/Lock Plate and Vent Plug hole in the closure door
do not align – Do Not Force or Alter to fit. If proper fitting cannot be achieved the closure
locking elements may not be properly located. Check and Adjust / rectify as necessary.
Observe Safety Precautions at all times.
4.iii. OPERATING NOTES.

Notes and Points to Watch.

1. Check the door seal is not damaged.

2. It is important the door is always kept central to the hub recess/aperture. Adjust as
required – see Section 6.0

3. Ensure Open/Close Mechanism sliding surfaces are kept lightly greased and free
from dirt/debris (sketch 5). Inspect regularly. (The contact faces of Locking
Segments and Closure Hub must not be greased during operation).

4. In the event of seal leakage at low pressure.

i. Check if the leak is from the Vent Plug metal bonded ‘face’ seal – if so
replace the seal.

ii. Check for dirt/debris/corrosion etc on the sealing faces and the seal groove.

iii. If suspect replace the main door seal.

5. IMPORTANT NOTE:
NEVER PUT THE CLOSURE INTO SERVICE / UNDER PRESSURE WITHOUT THE VENT
PLUG FITTED.
 5.0 MAINTENANCE

5.i. LUBRICATION POINTS

The Rapid Opening Closure is designed for minimal maintenance and lubrication.

Ensure the following areas are kept well greased/lubricated.

1. Hinge Arm Pivot Points - Use the grease nipples provided.

2. Sliding surfaces of Door, Segments and Segment Drive Plate. See Sketch 5. - Use the
12 off grease nipples provided in the Drive Plate.

Acceptable grease types – Castrol Spheerol LMM/ BP Universal Energrease / Copperslip

Note. Contact areas between Locking Segments and Closure Hub should not be greased.

5.ii. SEALING FACES

The sealing faces or machined faces of the Rapid Opening Closure Hub and Door must be
protected from rust/corrosion immediately after opening – even very short periods
without adequate protection can result in the formation of rust and lead to pitting.
Immediate coating with a thin film of silicon grease or rust preventative is the best way to
ensure a prolonged service life.

Before closing / putting the closure back into service ensure any deposits of heavy grease /
rust-preventative are removed from the sealing faces – reapply a thin film of silicon grease
to all unprotected/unpainted surfaces.

5.iii. LONG TERM STORAGE

If the Rapid Opening Closure, with/or without the vessel to which it is attached, is to be
placed into long term storage, (1 month or greater out of service). The hub sealing faces,
internal door surfaces and seal groove should be treated with a rust-proofing coat of
Waxoyl or similar rust preventative. Remove and replace the main door seal to allow
coating of the inner seal groove surfaces. In addition pack and coat hinge pivots with
grease and ensure/re-apply a grease coating to all open/close mechanism sliding surfaces.
 6.0 ADJUSTMENT

6.i. DOOR HEIGHT

The door height is factory set for correct alignment when inserting into the hub. Therefore
avoiding any contact with the hub edges in entry. If at any time this height requires
adjustment. (see Sketch below).

1. Loosen the Lock Nut on the outer Hinge Pin.

2. Turn the Adjuster Nut to raise or lower the door.
3. When the correct position is reached, tighten up the Lock Nut to retain in this position.
4. The door may also be adjusted in the horizontal position if necessary by loosening the 8
off socket head capscrews on the bottom of the hinge post brackets. The hinge posts can
then be adjusted by turning the jacking capscrews on the bottom of the hinge posts. When the
door is central re-tighten the 8 off socket head capscrews.

SKETCH 6
6.ii. DOOR ANGLE

The door is factory set so the door face and hub sealing face are parallel. Therefore
avoiding, when the door is closed, the seal being offered out of square to the hub sealing
face.

Should for any reason the door becomes mis-aligned, add shims between the hinge bracket
and hub to correct – See Sketch below. NOTE: Factory fitted shims may be found.

If sealing problems exist and correction to door height /angle settings do not correct.
Examine closely the door seal and sealing faces and ensure each is free of defects. On seal
faces lightly dress with emery cloth if corroded or pitted. If pitting is found increase the
frequency of closure maintenance / cleaning – excess pitting can be the cause of low-
pressure leakage. Replace the door seal if at all suspect.
 7.0 REPLACING DOOR SEAL

Should it be required to replace / remove the main door lip seal – simply and carefully prise
the seal out of the groove.

WARNING
DO NOT use sharp tools or objects to remove or replace the closure door seal – damage
may occur to a serviceable seal or the seal groove / sealing face.

1. To refit the door seal , with the lip outwards, press the seal into the seal groove at
the top edge, then press into the bottom edge – ensure the seal is central in the
groove.
Press in further at each side (45 Deg / 270 Deg positions) – the remaining seal can
now be evenly pressed into the seal groove.

2. The closure door seal is of a factory prepared fixed/predetermined length for

correct fitting and must under no circumstances be altered. Any surplus seal must
be worked into the groove.

VIEW INDICATING CORRECT

SEAL POSITION

WARNING:
Routine and regular maintenance, greasing, checking and cleaning of seal and sealing faces is
essential and MUST NOT be neglected. Heavily pitted sealing faces will require the attention
of a PE Service Engineer.
Contact : PE Technical Department for information.
 8.0 INSTALLATION NOTES

It is important for the sealing integrity of the closure that any distortion that may be
generated due to fabrication, welding and any post weld heat treatment is keep to an
absolute minimum. Hence the following recommendations should be noted and utilised
wherever possible.

8.i. FABRICATION DISTORTION

a. Any branch connection, especially a set-in nozzle type, should be located at least
one nominal diameter of branch away from the edge of the closure joining weld.
b. The hub of the closure (with the door removed) should be welded after welding of
all vessel branch connections.
c. It may depend on the parameters of the Weld Procedure Qualification to be used,
but a minimum pre-heat temperature of 200C is recommended.
d. An automatic / semi-automatic process should be used, so a constant heat input is
maintained.
e. Utilise a staggered welding sequence when welding with shielded metallic arc
process.
f. Do not use the closure hinge arm or hinge bracket to support or lift the
closure/vessel during Post Weld Heat Treatment.
8.ii. POST WELD HEAT TREATMENT

Before Welding / Post Weld Heat Treatment (PWHT) it is recommended that the closure
door be removed.

Remove the closure door as follows:-

a. Place the closure assembly, weld preparation down-wards on wooden

packing/protection.
b. Retract the segments to the Open/Unlocked position.
c. Referring to Sketch below - Remove the the 4 off socket head capscrews (Items 1 to
4).

d. The closure door can now be carefully lifted from the hub.
e. Store the door with care – ensure seal area and machined surfaces are protected
from damage / rust.
f. PWHT can now be carried out. PWHT to be in accordance with BS5500 or ASME VIII.
If any not to BS or ASME procedures – contact Pipeline Engineering for advise.
g. After PWHT remove any scale/deposit build up on the sealing face with light emery
cloth.
h. Support door in a suitable lifting sling and position to allow re-fitting of the 4 off
socket head capscrews.
i. Check hinge operation – perform two open/close cycles to confirm correct
alignment – adjust if required as per Section 6.0.
8.iii. PAINTING

When applying a paint system the areas

indicated for masking in the sketches
below should not be painted.

Ensure all ‘Masking’ is Blast Proof.

Protect Hinge Pins, Hinge Pin Threads,

Vent Plug, Grease nipples and Tapped
Holes from Shot-blast and Paint.

9.0 BOLTING TORQUE SETTINGS

Recommended bolt torque settings are:-

1. Vent Plug 27 N.m

2. Door Screws 100 N.m