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NEW FIELD INDUSTRIAL EQUIPMENT PVT. LTD.

Date : 14.11.2019
Operation & Maintenance Manual of SJAE
Work Order No. : EJ 4396

Purchase order No. : 4509234825 DATE 22.07.2019

End Customer : Green Star Company Limited+ Chosun refrectoriesLimited

: 1 x 6.04 MW STG set – Que Vo waste to energy powerplant


Project Name
project

Equipment : EJECTOR SYSTEM

Prepared By GAURANG GHELANI


NEW FIELD INDUSTRIAL EQUIPMENT PVT. LTD.

INDEX OF MANUALS

Sr. No. Description MAKE

1 O & M Manual of Gland Steam Condenser ‐‐‐‐‐

2 Globe Valves / Gate Valve STEEL STRONG

4 Ball Valve AUDCO (L&T)

5 Ball Float Steam Trap  PENNENT

6 STRAINER PENNENT

7 SRV & TRV FAINGER

8 Rotameter KABIR

9 Instruments (PG/VG) GIC

10 Instruments (TG) GIC
OPERATION
AND
MAINTENANCE MANUAL

FOR

EJECTOR SYSTEM

NEW FIELD

DESIGNED AND BUILT BY

NEW FIELD INDUSTRIAL EQUIPMENT PVT.LTD.


702, YASHKAMAL, SAYAJIGUNJ
VADODARA 390 005.
Phone : ( 0265 )2361834,2362921, Fax. 2361235.

1
ORGANISATION SERVED : SIEMENS LTD

END CUSTOMER : Green Star Company Limited+ Chosun


refrectories Limited
WORK ORDER NO. : EJ 4396

EQUIPMENT : Ejector System

PURCHASE ORDER NO. : 4509234825 DT. 22.07.2019

PROJECT. : 1 x 6.04 MW STG set – Que Vo waste to


energy powerplant project

NEW FIELD

MANUFACTURED BY

NEW FIELD INDUSTRIAL EQUIPMENT PVT. LTD.


702, YASHKAMAL BUILDING.SAYAJIGUNJ.
BARODA 390 005.
Phone: (0265) 261843, 262921, Fax. 261235.

2
MULTI STAGE EJECTOR
After receipt of Ejector system along with its accessories and packed components - the same
shall be stored properly, after verification with packing slip.

For prolonged storage, the Ejector system shall be stored in proper condition without dismantling
any components or unpacking any material from boxes. This will ensure that all the necessary
parts are not misplaced during the storage duration.

Before installation after prolonged storage duration,

1. Cleaning Shell side of Inter condenser and After condenser by water for removing dirt,
Foreign particles for repetitive cleaning of ball float trap.
2. Tube of inter and after condenser. Should be kept clean on water side.

3. Steam line should be blown.

4. Nozzle joint and steam chest joint should be check.


5. Cleaning of strainer and nozzle before starting. Advise to blow off strainer.

6. Cleaning of loop line and trap line by water flushing before installation/ erection.

7. Check nozzles chocking of ejectors if any cleaned ejector nozzle.

EJECTOR is very simple equipment which operates on the momentum transfer principle.

Please ensure the following points,

Prior to starting the operation of the System.

1. Check all Nozzle joints and steam chest joints for Leak Tightness.

2 Take a leak test of system for ensuring the system leak tightness of the Complete System
Which is to be operated under Vacuum.

HOW TO TAKE LEAK TEST OF VACCUM SYSTEM AT VACCUM SIDE?

For leak test put blind over Nozzle Vapor header, Steam header, Hogger out let, after
condenser vent, & Rotameter vent connections.

Kept following valve in close condition,

Condensate loop line valve.

Condensate Trap line valve.

3
Keep open all valve of Ejector vapor (suction) side, Ejector discharge Valve, Ejector
Steam Inlet valve.

Fill water from bottom connection that is from bypass valve of after condenser atoms drain &
Remove entrapped air from the system by venting different location like high points of inter
Condenser, after condenser, vapor header & steam header.

Vacuum (Shell) side to be pressurized at 4.55 kg/cm²(g) with Water.


Keep the system under pressure for minimum 30 Minutes in observation & ensure no
Leakage.

CHECK LIST OF IMPORTANT POINTS BEFORE STARTING THE SYSTEM

 It is Advisable to blow off the Steam line with help of Motive Steam at rated pressure to
remove any dirt, slag etc which could clog the Steam Nozzles.

 Clean the strainers and Steam Nozzle before starting.

 Steam supply pipe must be of proper size, to pass correct quantity at design pressure.

 Tubes of inter and after condenser. Should be kept clean on waterside.

 Ejector should be installed preferably close to the Condenser to which it is connected to


avoid any unnecessary pressure drop across the Vapor line.

 The Ejector inter condenser condensate Loop line keep 2.7 met lg straight & from loop
line there should not be any restriction of flow of the condensate to the Flash Tank.

 Ball float steam trap shall be installed as per in condensate trap line of after condenser.

STARTING

 For starting new installation, steam line should be blown from the steam nozzles to the
atmosphere & Opening the steam side valve.

 For ejector servicing power plant as venting equipment, when not enough condensate from
the main turbine is available to condense the motive steam and cool the air in the ejector
condensers, circulating water from an outside source must be used.

4
 Check and Ensure the Correct Steam pressure & Steam Temperature at ejector steam
header and keep all Steam Valves in closed condition.

 The drain valve if any should be in open condition during start up the pre- heating the
steam piping as well the steam header and also to remove any condensate in the line.

 Start circulating the cooling Condensate through the tube side of the Ejector Inter and
After condensers making sure that there is sufficient flow water coming from Condensate
Extraction Pump a Water pressure should be sufficient working pressure Ejector inter
condenser water inlet.

 For starting Hogger Ejector open Motive steam in let valve and by maintaining correct
steam pressure & temp open the Vapor side (suction) valve

 With the help of Hogger Ejector, the system will be evacuated to attain a Vacuum of 70%
within 30 minutes.

 For taking one pair of service ejector in operation, open Discharge valve of Z stg Ejector
& Open Motive steam valve of Z stg ejector.

 Open Vapor(suction) side of Z stg ejector . After opening vapor(suction) valves.

 Open discharge valve of Y stg Ejector & open Vapor (suction) valve of Y stg Ejector.

 Open Motive steam valve of Y stg Ejector.

5
 Open the condensate line valve of loop seal of Ejector Inter Condenser and condensate trap
line valve of the After Condenser before & after the Steam trap to allow condensate to
flow to the hot well.

After Condensate Loop Trap Assembly

6
Inter Condensate Loop Assembly

 Open the after condenser vent Rotameter line valve.


Or by pass of rota meter.

7
 Once the service Ejector is taken into operation, close shut down the hogger ejector. For
closing Hogger ejector, close vapor (suction) valve of Hogger Ejector & then close the
Motive steam valve of Hogger ejector.

 In order switch over from one side (Operating) Service Ejector to Another side (Standby)
Service ejector, open Discharge valve of Y stg & Z stg standby Ejectors.

 Open Motive steam valve of Y stg and Z stg Ejector & Open Vapor (suction) valve of Y
stg and Z stg Ejector.
 Then close vapor (suction) valve of Y stg and Z stg Ejector and then close motive steam
valve, close discharge valve.

SHUTTING DOWN THE EJECTOR SYSTEM

 First steam valve to be closed first Y stg and Z stg ejector whichever is in operation.

 Then close all isolating valve of both stages of vapor side Valve of ejector discharge side
Valve.

 Close condensate line valve of loop seal and condensate trap line valve.
8
 Close the after condenser vent Rota meter line valve.

 Then circulating water valve to be closed. In the case where ejector operates on condensate
from a surface condenser as the cooling medium for the inter and after condensers shut off
Condensate pumps and then close valve in re-circulating time.

DO NOT DO.

 Do not open drain valve of inter condenser loop drain while system is in operation.

 Do not open ball float steam trap without isolating system side down stream valve.

 Do not kept open Hogger Vapor (Air/Suction) Valve while Motiv Steam valve of Hogger
Ejector in close condition & System in operation.

 Do not open Vapor (Air/Suction) Valve for initial vacuum pulling till Motive Steam
Pressure and Temp reach design parameters.

 Do not operate Vacuum system without achieve desire design parameters at steam header.

 Do not kept open any valve of vacuum system while starting the system.

TROUBLESHOOTING AND CORRECTIVE STEPS

 Leaky Tube:
By replacing defective tube. If a leaky tube is discovered is the condenser, the operating
requirement may not permit sufficient shut down time to allow for removal of the tube.
In this case a wooden plug may be driven in both end of the tube. Until you get time to
replace the tube.

 Fouling of condenser tubes :-

9
By cleaning tubes by wire brush or by blowing with air or steam or by turbine type
cleaner or by proper solvent cleaner for a hard scale.

 The turbine gland may not be seal in properly.

Check vapor/air coming out of the vent of blower if seal may not be there you found air
shucking from out let Conn of blower, at the same time one should isolate ball float trap
from the system & allow to go condensate in atmosphere & by cleaning ball float trap re
fixed up & took in operation in system.

 General air leak through joints and defective packings.

Check on line in system with smoke /candle light if one found smoke/candle light going
in side of joint it seem that there is leakage from that joint. By taking shut down that joint
should be replaced.

 Insufficient condensing water.

Correct C.E. Pump discharge pressure at Cooling Water in let connection of ejector
water in let nozzle.

 Improper functioning of ejector due to :-

Lower pressure of steam than design pressure. Correct steam pressure at design pressure.

 Steam nozzle may be choked.


If vacuum of ejector fall down & found no heat up at ejector discharge nozzle it seems
that there is a chock in steam nozzle. By opening steam in let nozzle cleared chocking &
re fixed up nozzle.

 Worn out Steam nozzle due to long operations:

Replaced the steam Nozzles.

 Leak around the Steam Nozzle throats.

In this case one found ejector suction body heat up & less vacuum for this open steam in
let nozzle of that ejector & apply sufficient packing between nozzle & adopter joint &
tight them faultlessly.

 Flooding of inter and after condenser due to broken or leaking tube.

At that time one should take shut down & replace defective tube.

10
 Breaking of the loop seal between the inter condenser and main condenser.

If it observed that the inter condenser & main condenser vacuum will be same, then
primary cause would be the breaking of loop seal in U loop between the Ejector Inter
Condenser and the Main Condenser. In order to Seal the loop line again in running
system close valve condensate valve for 4 to 5 min & allow to accumulate condensate in
inter condenser & then open valve for sealing loop line.

 Flooding of after condenser due to chocking of ball float trap.

At the time of chocking ball float trap isolate inlet & out let valve of the trap line & allow
to condensate go to atmosphere, by cleaning the trap fit up in line & took in operation.

11
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL FOR
AIL SINCLE PIECE & TWO PIECE
FULL BORE BALL VALVES

1.0 STORAGE OF VALVES

On receipt. check rhe valve to cnsure that it is in full-v


assembled condition and in the open position.

End protectors on thc valve should be kept itttact and


removed only at the time of installation. \"alvc
performance dependson prevention of damage to the
ball,'seatsurfaces.

V'alvesshould be stored in a covered arca. If covered


area is not ar.ailableany water proof covering material
should be sprea<ior.er the valr.es and they should be
kept on a u.ooden pallet at least l50mm above the
ground ler.el.

Do not apply tar. paint. greasc or any other ntaterial


inside the valr-c or on the stcnr.as this could impair
the performance of valve.

2.0 INSTALLATION

2.1 GENERAL

When despatchcd.r'alvescontain a rust prcventor and


if necessarymay,-be removed rvith a solvent.

Before installation cnsurc that thc pipcline has be-en


flushed on line scale. rr'cld spattcr. rust and othcr
foreign mattcr.
Ensurethat the end protectorsare removedat the time
of installation.

3. 0 OPERATION

3.1 GENERAL

AIL Ball valvesprovide bubble tight shut off rvhen


used in accordancervith our publishedpressure/
temperaturechart.

It is not the right practiceto leave the valves in a


partiallyopen(throttled)positionas this can damage
the seatsand adr.erselyaffect its performance.

Any mediathatmay solidify.crystalliseor polymerise


shouldnot be allou.edto rcmain in the rralvecavity
as it can affect the operationof the valve.

3.2 MANUALOPERATION

AIL Ball valveshavea quarterturn operation.closing


in a clocku'isedirection.It is possibleto determine
rvhenthe valve is open or closedby the positionof
the ler.er.When the lever is in line rvith the pipeline,
the valve is open.and u'hen at 90o to the pipelineit
is closed.

REMOTEOPERATION

When manualoperationis not desired,valvesmay be


automatedfor remoteoperation.A rangeof pneumatic/
electricactuatorsand gear units are availablefor
mountingon AIL Ball valves.
No stopperplateis fitted on actuatedvalves/gear unit
valves.as the stop is normallya part of the actuatori
gear unit.

For operationaldetails of thc actuators,refer to


installationmanualof the actuator.

4.0 MAINTENANCE

4.1 GENERAL

AIL Ball Valves have a long trouble free life. and


maintenance is seldomrequired.But rvhennecessary.
valr.esmay be refurbishedr.ery easilyby using feu'
components. u'hichdo not requiremachiningat site.
AIL Ball Valves are designcdfor easy serviceand
a s s e m b l yi'n f i e l d . T h e f b l l o u . i n g p o i n t s r v o u l d .
ho*,ever,help to extendvalve lif-efurtheqor reduce
operationalproblems.

4.2 STEMLEAKAGE

Remove the rvrcnch assemblv.Exarninethe disc


springs(BelleVille'Washer- applicableupto40mnr)
for damage.lf in eractcondition.tightentheglandnut
until thediscspringsarefully compressed.If damaged.
dismantlethe stem dou.n to the gland. fit nerv disc
springsrvith thcir outer edgestouchin-eand tighten
using a ne\\' cland nut. Furthern:aintenancerequires
dismantlingof the valve.

If the stem leakageis not arrestedbir the above


procedure.dismantlethc vah..e.Hott'e\.erdo not disturb
the stem assemblfif no stem leakageis noticed.
4.3 ]N-LINETHROUGHLEAKAGE

C'heckthat the valve is fully closed condition. If it is,


then the leakage is possibly' due to a damaged seat/
ball or sealing surfaces and it s.ill be necessary to
dismantle the valve to rectify it.

4.4 REFURBISHING

Usc only genuine AIL Ball \'alve spares. These can


be ordcred on our distributorsand authorisedstockists.

Parts of r.alves fiom dilfercnt sizes of seriesmust not


be interchanged.

This is irnpor-tantas it ensuresthat the valve is capable


of bein-r.used for the purpose it r.vasdesigned and
constructed and operatcd without risk to health and
safctl.'.

4.5 SAFETYPRECAUTIONS

Bcfbre removitr-uthe valve fiorn the pipeline. enstrrc


that adequatesaf-etyprecautioltsare taken, as the mcdia
floiving through the valve may be corrosive. toxic.
inl'lammable or contantinated. It is advisable to use
shields, gloves anci safety shoes.
safcty gear like e-"-'e

Ensure that bcfbre rerpoyin_ethe r.alve firtrn the line


no pressureexistson the upstreamor domlstream sides
of the r-alve.

Before rentttvitrg thc valre cnsure that any trapped


media is rclcasedb1'openingthe valrc sloil'l-vto half
open position.
i^,tench
i\jut
@-
SranE vliasier

Sloc P'r
3:3nd Nu:: -

Berle!:lje v"r3hers

Gi?na

GiandPac(ing-

Slefi Th.us: Sea'

_-bs

Explodedview of Ball valve 'l5mm to 40rnm

5
iirenc\ ;rx'nE Eoli

i'irenct Fead

Siaqc fiul
Lrcki4g Clip

3land Nui

Slco ind,calor

Gl3nd
Clandoac(nE
Siea Lmatioi Ring Bodv:cnnectol
Seccidan/ Sten Seal 3c'ew

Seat Rrng
- Sail

Seal Rilg

Slefl:hrrsl
Seal

Sler

Explodedview of Ball valve 50mm and above


4.6 DISMANTLING

Removethe valvefrom the pipelineby extractingthe


flangebolting from eachend. Largepipelines(srzes
80mmandabove)har.ea tendencyto springtheflanges
and removalcan be difficult. If necessaryremove
e l b o r v s .c o u p l i n g so r p i p e s u p p o r t st o g e t e x t r a
maneuverability.

The valvecanbe removedin eitherthe openor closed


position.

Hor.vever,if it is open.it ensuresthat no line media


lies pressurised rvithin the vah,e car.ity.

With ther.alvesecurelyclamped(r'crtically,insertside
f-acing thetop)andin theopenposition.undothe insert
usingtheappropriatedrive adaptor.It may benecessary
to use a heavy n-ralleton the tommy bar of the insert
tool to breakthemetalto metalsealandmovethe insert
initially.

Removethe inser-tto allow accessto the cavity.Thc


insertshouldbe remor.edout of the body completely
as otherwise its seal face may be damagedlnot
applicablefor 2 piece design).

In caseof 2 piecedesign.removethe interconnecting


bolts betrveenbody and body connector.

Remor.ethe body sealanddiscard.Ifthe sealis difficult


to renlovethan use a scriberor sharpbladed
scrervdriverand dig into the body sealat an anglefar
enoughto pror.idepositive location.Lever out one
sectionof the sealfrom its recessandpull it out using
a long nosepliers.
Closethe ball and usinga soli drift throughthe body
port. tap out the ball and insert seat.

Turn the stemback to thc open positionand using a


suitablehook pull out the body seatbeingcarefulnot
to damagethe seatsealingface and the fire safelip
on the l.all.e body'.

To dismantlethe stem assembly'removethe rvrench


nut, rvasherand rvrench from the stem. Using the
rvrenchto preventthc stentlrom turning,removethe
gland nut and the gland. Tap the stem dou'n and
rvithdrau.it from insidethc body.The glandpacking,
o' ring and the stem sealcan now be removedfrom
theirrecesses (from 5Ommonu'ards).beingcarefulnot
to dan-rage the seal faces.

All componcntsmust bc inspectedfor u'ear and


dama-sc.Partsthat are not to be replacedshouldbe
thoroughly cleanedand stored in a clean area.All
sealingfaceson the body. insert and ball must be
checkedfor corrosion.erosionandscratches.If dan-rage
doubt.replacethe component.
is foundor thereis an1,'

Cleariingof valve parls sliould be carriedout using


a suitabledegreasinuagent.Hard depositscan be
remor,edusingu'ireu'ool or by usinga hardblunt tool.
Careshor"rldbe takcnnot to dantageor scratchan.vof
the seal facesand machinedfaces.

4.7 REBUILDING

B e f o r c r c b u i l d i n e .c h e c k t h a t a l l t h e c o r r e c t
componentsare availableand thc,vare fit for the
plrrpose. \\"henrebuildingcleanlincss is essentialto
allow long valve life and provide cost effective
maintenance

Fit the new gland packinginto the body recess,the


gland and new disc springs(with their outer edges
touching)onto the stem.This is applicableonly upto
40mm size.

Fit the gland nut, pre\.entthe stem from turning and


tightendou'nto fully compressthe disc springs(only
upto 40mm size).

Fit thervrench,rvasherand rvrcnchnut to the stemand


operatethe stem to the valve open position.

Securethe valr.ein a verticalltosition.rvith insertside


facingupu'ards(upto40 ntm) or body connectorfacing
upu,ards(from 50mnr& above).With the body seat
endon,enterit into thevalvecar.itvpastthestemdrive
tang.then positionit into the seathousing.A silicon
basedgreasemay be appliedto thc seatface to aid
bedding in of the r.alve.

Turn the stemto valr,eclosedand slide the ball into


the body locatingthe stem drir.e rang.

Havin-qapplied silicon greasefor sizesupto 40mm


locatethe insertend seatinto the cavity and the body
sealintothehousing.For sizes5Ommandabove.locate
the body connectorend seatinto the car,ityand bodv
seal in to the housing.

Open the valve and scrervthe insert for sizes upto


40mm into thevalr.ebody usinga suitabledrive adaptor
for sizes50 mm & abovebody connectorshouldbe
put into the body and tighten the fasteners.It is
importantthaton stainlesssteelvalvesan anti scuffins
compoundis usedon the insertthread.It is advisable,
thoughnot mandatoryto use it on carbonsteelvalves.

The valve is now readyto be put in line. If possible,


leaktightnessandeaseofoperationshouldbe checked.

10
lnstallation,Operation &
liiaintenanceManualfor
AIL Ball Valves
( 3 - P I E C ED E S I G N )

1, STORAGE OF VALVES

On receipt,check the valve is in fully assembledcondition and


in open position.

End protectors on the valve should be kept intact and removed


only at the time of installation- Valve performancedepends on
preventionof damage to the ball surface'

Valvesshould be stored in a covered area. lf covered area is not


availableany water proof covering materialshould be spread over
the valves and the valves should be kept on a wooden pallet
atleast6" above the ground level.

Do not apply tar, paint, grease or any other material inside the
valve or on the stem, as this could impairthe performanceof the
valve.

2. INSTALLATION

General

When despatched,valves contain a rust preventiveand this may


be removed with a solvent if necessary.

Before installationremove all foreign matter in the pipeline by


flushingthe line with the water or compressedair, keeping the
valve fully open.
SCREWEDEND VALVE

Do not dismantlethe valve for installation.Screwedends should


treat the valve as a single unit. taper
not be fitted independently,
threadedfittings should not be over tightened.

WELD END VALVE

The instructionsent along with each valve must be followed-

3. OPERATION

AIL BallValveshavea quarterturn operation-closing in a clockwise


direction. lt is possibleto determinewhen the valve is open or
closed by the positionof the lever. When the lever is in the line
with the pipeline,the valve is open: when the lever is across the
pipeline,the valve is closed.

Where manualoperationis not desired,valvesmay be automated


for remote operation.A range is pneumaticactuatorsis available
for mounting on AIL Ball Valves.

No stopper plate is fitted to the remote operated valve, as the


stop is normallya part of the actuators.

For operationaldetails of the actuators, refer installationmanual


of the actuator.
4. MAINTENANCE

General
AIL Ball Valveshave a long, trouble-freelife, and maintenanceis
seldomrequired. But, when necessaryvalvesmay be refurbished
very easily by using few componenls, which do not require
machiningat site. AIL Ball Valvesare designedfor easy service
and assembly in the field. The following checks would however,
help to extend valve life further,or reduce operationalproblems.

Stem Leakage

Examinethe disc springs (BelleVille washer) for damage. lf in


exact condition, tighten the gland until disc springs are fully
compressed. lf damaged,dismantlethe stem down to the gland,
fit new disc springswith their outer edges touching and replace
using a new gland nut. Further maintenance necessitates
dismantlingof the valve.

Leakage at body joint

Check for tightnessof the body connectorbolts. lf slack, tighten


the bolt using standardwrenchesonly. Avoid excessiveforce as
this will be due to the damagedbody connector seal and oil will
be necessaryto dismantlethe valve.

I n l i n e l e a ka g e

Ensurethat the valve is fully closed. Leakageif noticed will be


due to a damaged seal or ball seating surfaces and it will be
necessarvto dismantlethe valve.
lf the stem or body leakageis not arrested by the above simple
procedure,dismantlethe valve. However,do not disturb the stem
assemblyif no stem leakage is noticed.

Leakageat PiPelineioint
Screwed Valves

Testfor tightnessof screwedends. lf slack,tightenwith standard


wrench - excessiveforce will only split the connecter.normal
jointing material should be used in the correct quantity'

Weld end valves

After welding the valves as per procedure detailed in para 8,


pressuretest the welded joints for leakage. lf necessaryre-weld
again as Per the Procedure.

5. REFURBISHING

spare parts can be ordered on our Distributorsand Stockists.

Where a va|ve needs repairing,rather than maintaining,it must


be noted that only genuine spare parts should be used'

Partsof valvesfrom differentseries,should not be interchanged-

This is to ensurethat the valve remainscapable of being used


for the purpose for which it was designed and constructedand
operated without risk to health and safety'
Tools

No specialtools are requiredfor maintenanceof AIL Ball Valves


of 3 piece design.

6 . SA F ET YPR E C A U T ION S

Before removing the valve from pipeline,ensure that adequate


safetyprecautionsare taken, as media flowing through the valve
may be corrosive, toxic, inflammableor contaminaled.lt is
advisableto use safety gear like eye-shields,gloves,& footwear.

Ensuretl-ratbefore dismantlingthe valve no pressureexists either


on upstreamor downstreamsides of the valve.

Ensurethat any trapped media is releasedby operatingthe valve


slowlyto half open position (decontamination).

Body connectors form an integral part of the pipeline and the


valve cannot be removed from the pipeline without being
dismantled(seeDISMANTLINGProceduredetailedin Para 7).

7. DISMANTLING

lf the valve is closed and not in fully open position, refer to


the safety precautionsbefore proceedingfurther.

Also,during dismantling,do not assumethat the valve is totally


decontaminatedas harmfulfluid, may still be trapped in crevices.

To removevalve from pipeline,extract body connector bolts and


slide the body out from betweenthe body connectors.lt is often
not necessaryto remove the body completelyaway from the
pipeline,in such cases,removethree of the body connectorbolts,
and with the fourth bolt slackened,the body may be rotated out
from the line usingthe fourth bolt as hinge.(Feferfig.1)

The ball musf be in the open position since a closed ball


protrudesbeyondthe body cavityand ballwill be damagedagainst
body connectorswhen body is removed or rotated.

lf the body connectorseals come away easilyduring removalof


body, they may be removedat that time. lf not, leavethem until
later .

When the body is free of the body connectors,turn valve to half


closed position and hook out seats with finger. Completelhe
closing turn and - the ball may be pushed out to fall on to- hand-
this must be done carefully,otherwisethe ball will mark against
the body.

The body connectorseals should now be removed. Care must


be taken to avoid scratchingthe machinedfaces on which they
make contact with the valve body.

Todismantlestemassembly,firstremovethe levernut, identification


plate and lever from stem. Using lever to preventthe stem from
turningthe gland nut, disc springsand gland. lt is not normally
possibleto remove gland packing at this stage. Withdraw stem
through body cavity and remove stem thrust seal from stern or
body recess. Gland packing may now be removed.

In the 15mm size.the wrenchfiats on the stern must be aligned


perpendicularto the line to allow withdrawalof the stem.

Cleanall componentsthoroughlyand examineall seatings/sealing


surfaces.
O)
tl-
lf there is a build - up of solids which cleaningfluids will not
dislodge-donot scratchthe machinedsurfaces-use a broad' flat,
blunttool.

No eroded or corroded leak parts are permissible. lf any are


found, the part must be replaced. The ball should not have
scratchesacross its seating surfacesas any damage to the pon
lip as this will destroy the seats. A damagedball must not be
re-used,fit a new one .

8 . R E B U I L D I N G ( R e f e rF i g . 2 l

Before rebuilding,check that all the correct componentsare


availableand ttrat they are fit for the purpose- When rebuilding'
cleanlinessis essentialto allow long valve lile and provide cost
effectivemaintenance.

Fit stem thrust seal to stem and insert stem through body cavity
into stem hole and fully up into body recess. Fit gland packing,
gland and disc springswith their outer edges louching Using
leverto preventstem from turning, fit gland nut and screw down
until disc springs are firmly compressed. Operate stem several
limes and re-adjust. Overtighteningwill only reduce the life of
the assembly. Now fit stop plate, lever, identificationplate and
lever nut to stem assemblyand move leverto the closed position
(leveracross the pipeline). In sizes 112"& 3/4" lever has integral
stopper and there is no separatestop plate.

Wilh the leverstill in the closed position,the ball may be inserted


into the body cavity by sliding the ball slot ovei'the stem tang.
Open the valve.

The ball must be in the open position since a closed ball


protrudesbeyondthe body cavityand ballwill be damagedagainsl
ul
o \
-P rP
F
f,

c o =
? - o
. ! - 2 : < 5
. , " i u c r u
F Y
) = z o -
z < z
ii a zi22
r-
U
z u*
-
O a
6
^
O U
U 6 B H H * H s 3
z - z > z -
d:6 ; ; j j - z ^6 a
P
r
]
r A y Hl
o
<J (A
o o o
J
o
)
c
O
l F * s h ; s ; s B3

_---r__i
body connectorswhen the body is removed or rotated . Also,
with the valve in the open position,the ball is retained by the
stem tang and cannot fall out of the body cavity.

The seat rings and body connectorseats may now be fitted.

A trace of lubricatingoil or petroleumjelly, if compatiblewith the


future pipelinemedia . will easethe rebuildingby holdingthe seat
rings and body connector seals in place. Do not use greases
with abrasiveadditives.

The valve may be installedback in to the pipeline by slidingthe


body in between the body connectors. The pipeline should,
however,be sprung apart sufficientlyto clear valve body and
avoid damage to seat rings, body connectors seals and body
connectorssealingface.

Locate body on center line of pipework,fit body connectorbolts


and nuts and by tightening,pull together body connectors. Use
only standardwrencheslor tightening,as excessiveforce will only
stretch or strip the studs.

Weldinginslructionsfor socketlveld ends - AIL Ball Valves(Size


112"ro 2" )

1. Prepareclean workingarea.

2. Smoothenpipe ends to removeany burrs.

3. With valvein OPENpositron.removelhe body conneclor


bolts. Removethe body connectors from body and
turn the ball to paft ciosed position

4. Carefully remove the ball seats and body seals.


Supportingthe ball so as to prevent it from falling out
of the body,turn to closedposiiionand removethe ball.

1a
5 Place all removed parts in clean and secured position.

o Reassemblethe body alone with body connectorsand


tack weld only the valve to the pipeline. Remove the
body to prevent damage to stem seals from welding
heat.

7. Thencompletethe welding,ensuringthat body connector


faces are protected from weld splatters.

B. When cool clean body connectorfaces carefully.

9. Fit the ball, ball seats and body seals into the'body.

10. In the case of ball valves with graphite body seals


(eg.AW44)care should be taken that the body sealsare
not damaged during disassembly.For this the valve is
tack welded into pipeline without applying excessive
heat. Then the body assemblyis removed intact. Do
not remove body sealsas they are very briftleand likely
to break, if not handled properly.Then weld the enC
connectionsas explainedin steps B & I .

11. Easebody assemblybetweenbody connectorscarefully,


keepingthe ball in open position,withoutdamagingfaces
or seals.
12. Replacebody connectorbolts and working in a diagonal
order tighten the nuts firmly.

Test
A test for leak tightnessis recommended.
PS11
'Y'-Strainer

DESCRIPTION:
Strainers for steam, air, oil or water piping, protect
equipment, steam traps, valves etc. from dirt, rust or
scale, and debris, in the pipeline.

FEATURES:
Simple yet sound construction ensures long service life.
A stainless steel strainer screen with a large surface
area ensures minimum pressure drop and requires less
frequent cleaning. Designed for easy in-line cleaning
and maintenance.
A

LIMITING CONDITIONS:
PMA: Max. allowable pressure 40 bar (g)
TMA: Max. allowable temp. 340 ºC
PMA / TMA for cast iron construction 17.5 bar(g) / 220ºC
Cold hydro test pressure twice the Max. allowable pressure C

1
SIZES: DN 15, 20, 25, 40, 50 B

3
CONNECTIONS: Screwed (NPT, BSPT, BSP) /
2
Socket Weld* (* Not Available In CI)
4
Non IBR1 / IBR
IBR - Available only in CS / SS construction
INSTALLATION:
For horizontal installations, the strainer should be
MATERIAL: installed with the screen in the horizontal plane or below
No. PART MATERIAL QTY. (Nos.) the centre-line of the pipe. Ensure accessibility of the
1. Body CS / SS / CI 01 strainer cap for cleaning.
2. Strainer Cap CS / SS 01 MAINTENANCE:
3. Strainer Screen AISI 304 (40 mesh)+ 01 This product can be maintained without disturbing the
4. Gasket CAF / Non CAF 01 piping connections. Complete isolation of the strainer
+
from both supply and return lines is required before any
Strainer Screen of 60 or 100 mesh available on request servicing is carried out.
The strainer should be disassembled periodically for
DIMENSIONS - Nominal in mm cleaning the screen.
MODEL SIZE A B C Wt. IMPORTANT:
DN15 75 69 91 0.82 kg For new pipelines, ensure that the lines are properly
flushed, prior to fitting the strainer.
DN20 75 69 91 0.77 kg
PS11 DN25 95 87 114 1.6 kg HOW TO ORDER:
DN40 190 157 202 6.850 kg PS11 DN15 BSP NIBR
DN50 190 157 202 6.0 kg ORDERING INFORMATION:
1) Inlet Pressure in bar (g)
AVAILABLE SPARES: 2) Operating Temperature in ºC
Strainer Screen (Packet of 5) 3) Size & Model
4) End Connections.
5) IBR / NIBR
6) Material of construction
Local regulations may restrict the use of this product below the conditions quoted. Limiting conditions refer to standard connections only.
In the interest of development and improvement of the product, we reserve the right to change the specifications without prior notice.

R
USA - 10 Parsonage Road, Suite 312, Edison, NJ, Tel.: 877-597-TRAP(8727) Fax:1-866-682-1244.
Email: info@pennantcorp.com Website: www.pennantcorp.com
August 2010

INDIA - S.No. 116 (New), Gat No. 976 (Old), Wadki, Taluka Haveli, Pune - 412 308, INDIA.
Tel.: +91 (0) 20 2698 9709, Telefax: +91 (0) 20 2698 9470
Email: enq@pennantindia.com Website www.pennantindia.com
FL 549
Assembly of a Spring Loaded Safety Valve Type 549
3
1*= Basic valve assembly
fitted with 2*and 4*
42
Item Part Name
75 1 Inlet Body
2* 2 Outlet Chamber
7 Disc Compl.
90
43 8 Spindle Guide
83 9 Bonnet
80 12 Spindle
1* 14 Split Ring
41 16 Spring Plate
45
79 18 Adjusting Screw
19 Lock Nut
44 50 Name Plate
54 Spring
4* 57 Pin
59 Securing Ring
60 Gasket
61 Ball

75 2 * = Cap H2, gastight


no lifting gear
19
42 Cap H2
75 Spacer
18 2* 85 Lead Seal
46 86 Seal Wire

16 4*= Lifting Gear H4,


85
gastight construction
74
86 50 41 Lever Cover H4
12 43 Lever H4
9 44 Lifting Fork
54 45 Shaft
46 Spindle Cap
60 59 74 Pin
4* 75 Spacer
8 79 ‘O’ ring
80 Supporting Ring/Gland
14 83 Circlip
60
85 Lead Seal
16
86 Seal Wire
2

61

57

FAINGER LESER Jan 2003 3/03


FL 549
Instructions for the Treatment and Installation of
Pressure Relief Valves. 3
1. General Notes According to rules a drain hole of sufficient size must
Pressure Relief Valves are highly quality instruments which be incorporated at the lowest point of pipe work. In all
should be handled with great care. To ensure the correct cases the discharge pipe must first slope in a
performance of a pressure relief valve all parts are made with downwards direction and fitted with a suitable size
exact precision. Only this precision ensures the correct drain hole before any bends are connected (refer to
functioning of the pressure relief valves. Careless handling of sketch).
the finished valve in workshops, stores, during transportation
or installation could cause leakage or possibly permanent Exception:
damage (also refer to API Report Guide for inspection of In special cases, for instance on board of ships an
refinery equipment, Chapt. XVI Pressure Relieving Devices" optional drain hole may be recommended in the valve
Para 1603082 and 1603083). body as it may be that pipe work drainage cannot be
guaranteed at a lower point than the valve. The standard
The sealing surfaces have been ground and lapped with high drain hole which will then be supplied by the factory is
precision to ensure the required tightness. Even though the 1/4" BSP. But, by all means, the discharge pipe must be
surfaces are extremely hard, the seal can still be damaged. drained too. In extreme cases this hole can be drilled
By all means, one must take care to prevent impurities from outside of our factory provided that special care is taken
entering the valve during transportation, installation and to ensure that no damage is done to the sealing
operation. surfaces.

When installing pressure relief valves with threaded All drainage pipes that have been connected must be
connections, use only metal seal washers. Seal materials such free of restriction and the ends easily seen. Care must be
as hemp or PTFE tape should not be used as this type of taken when discharging any drainage to prevent injury
material can break off and enter the valve causing it to leak. to personnel. For example on steam connect a suitable
steam trap.
If valves with open bonnets and/or levers are to be painted
after despatch from the factory, care must be taken to protect Note!
the sliding parts. Otherwise the correct operation of the When valves are supplied with a drain hole that is not
pressure relief valve may be affected. going to be used the plastic plug fitted in the hole must
be removed and replaced by a metal plug.
2. Transport Protection
The inlet and outlet of the pressure relief safety valves are 3.3 Mounting Brackets
protected during transportation with plastic caps. These caps For pressure relief valves with mounting brackets a
should only be removed just before installing the valve. fastening possibility for the brackets should be
provided to withstand the forces of reaction when
The lifting lever of spring loaded pressure relief valves is valve blows off. The bracket holes can be drilled
secured with a wire to the bonnet. This wire should be on request.
removed only after installation. For testing the set pressure or
tightness of the pressure relief valve remove also this wire and 3.4 Insulation
take care that the lever is not engaged with the spindle cap. In case any insulation of the pressure relief valve is
provided, the bonnet must be kept free to avoid
3. Installation/Assembly unacceptable heating up of the spring.

3.1 General Notes 3.5 Inlet Pipe


Spring loaded pressure relief valves should be The inlet pipe for pressure relief valves should be as
installed with the bonnet VERTICALLY UPWARDS. short as possible and should be so arranged, that
when the valve is in its fully open position the pressure
Furthermore, pressure relief valves should be drop must not exceed 3% of set pressure, the edging at
mounted in such a way that no inadmissible static, the inlet pipe should be rounded off or at least be
dynamic or thermal loads can be transmitted to the chamfered.
valve due to up and downstream pipe work. If
necessary, expansion possibilities should be If the calculation results in a higher than 3% pressure
provided. Stresses by incorrect mounting should be drop of set pressure then the inlet pipe size must be
avoided. enlarged.

3.2 Draining of Condensate 3.6 Discharge Pipes/Back Pressure


To prevent dirt and all kinds of impurities from the The discharge piping on vapours and gases should
pressure relief valve the drainage of discharge pipe be installed in an ascending direction, on liquids in an

FAINGER LESER Jan 2003 3/09


FL 549
Instructions for the Treatment and Installation of
3 Pressure Relief Valves.
The discharge pipework of all pressure relief valves It is recommended and in Germany required by Rules to lift
should be so arranged that the back pressure, which manually the valve lifting lever from time to time in order to
is built up during blow off, does not exceed a max. prevent accumulation of deposits that will affect valve
15% of set pressure. operation. For steam generators, the following requirements
are established in the German Technical Rules for Steam
In case of higher back pressure, pressure relief valves Boilers TRD 601, edition 6.83, Section 6.
with pressure compensating metal bellows
(balanced type) shall be used. In case the back "Testing of pressure relief valves is required for plants
pressure is >0.15 times set pressure the capacity of operating with demineralized water and for hot water
the pressure relief valves must be recalculated. generators at intervals of at least 6 months, with the exception
of power plants. For other steam generators, the test interval
3.7 Pressure Relief Valves with bellows should not exceed 4 weeks".
Pressure relief valves with elastomer bellows (TRD 721)
as well as metal bellows have a vent hole in the It is important to ensure that the lifting lever does not engage
bonnet. the spindle cap after the lift operation. The lever must be
deflected towards the center line of the bonnet until the lifting
fork is disengaged.
When fitting pressure relief valve with a vent hole care
must be taken to prevent moisture from entering the
For pressure relief valves with open bonnet, a drain groove is
bonnet. However, fluid escaping from the vent hole
provided in the guide flange. Whilst blowing, condensate
indicates that the bellows have failed. Repair is
escaping through the clearance between guide disc and
required.
spindle is drained through this groove.

When pressure relief valves with bellows are used with According to DIN specification 4754, Oct. 74 Edition
toxic or inflammable fluids, care must be taken to fit a "Explanations", Para 4.4 pressure relief valves represent the
suitable vent pipe to provide safe venting. For this last step in the line of protection for the vessel, and they should
purpose, the vent can be threaded 1/4" BSP female be able to prevent excess pressure when all other automatic
on request. or pilot operated checking instruments have failed. To
guarantee this function pressure relief valves require, like all
4. Mode of Operation/Maintenance other technical equipment, regular service. How often a
The working pressure of the plant should be at least 5% below valve must be checked, depends on the actual operating
the blow down pressure of the valve to enable a correct conditions, so that no general indications can be given.
reseat. When a slight leakage occurs, due to deposits Usually pressure relief valves operating in a corrosive
between the sealing surfaces, surfaces can be cleaned by atmosphere or on laden fluids require service more often than
operating the lifting lever causing the valve to blow off. valves operating clean conditions. This also applies if the
pressure relief valve operates frequently causing a higher
The valve should be closed by sudden release of the lever. If wear out to the seat and disc.
this procedure does not stop the leakage, the valve seals are
probably damaged. Repairs should be carried out at our Special consideration is required if conditions such as
vibration (to be avoided, if possible) pressure pulsation and/or

Add, drain pipe in case of


prepared drain hole

3/10 FAINGER LESER Jan 2003


FL 549
Dismantling and Assembly Instructions
3
1. Loosen the existing lead seal. 15. Replace spring (54).
2. Press the lever (43) towards the middle until it reaches 16. Slip on the upper spring plate (16) onto the spindle
the stop so that the lifting fork(44) no longer holds the (12).
spindle cap (46).
17. Align adjusting screw (18), and bonnet (9), over the
3. Loosen and remove the lever cover (41).
4. Loosen the spindle cap (46) from the spindle (12), spindle (12) and refit.
remove the securing ring (91) and the pin (74). 18. Fit and tighten the hex. nuts (56).
5. Loosen the lock nut (19) of the adjusting screw (18). 19. Load the spring (54) to obtain the required set
6. Turn the adjusting screw (18) anticlockwise to remove pressure. Clockwise rotation of adjusting screw (18)
the all spring tension. increases pressure. Anticlockwise rotation of adjusting
7. Turn the bonnet (9) anticlockwise to separate from
screw (18) reduces pressure.
outlet chamber (2).
8. Lift off the bonnet (9). 20. Tighten the lock nut (19) onto the adjusting screw (18).
9. Remove the upper spring plate (16). 21. Refit and secure spindle cap (46) by pin (74) and
10. Lift of the spring (54) and remove lower spring plate securing (91).
(16) and split rings (14). 22. Screw-on the lever cover (41).
11. Remove spindle (12) with guide (8) and disc (7). 23. Pull the lever (43) towards the middle so that the lifting
12. Carefully clean seat (5) and disc (7), and if required
fork (44) is pushed under the spindle cap (46).
body internals.
13. Refit spindle (12) with guide (8) and disc (7). 24. Test spindle will lift correctly by pulling lever.
14. Fit the split rings (14) into spindle groove and retain
with the securing ring (59); slip on lower spring plate
(16) to locate on split rings (14). These instructions are applicable for Relief Valves,

CAUTION
During all work the spindle has to be secured against twisting in order to prevent damage to the sealing surfaces.

43

44

18
41

19

FAINGER LESER Jan 2003 3/11


@ '.•
INSTRUMENTS.,GONSORTIUM
(Under Technical Colleboretlon with M/e Ge~urdon Ltd. U.I<'.)
AN ISO 9001 : 2008 cOMiiAN\i' .:
Kan;;;;lle,p~%'ei',
P1at'Na. 4.5 & 6. Jawahar Co-op. Industrial Eslate, 410"209. Oisl. Raigad; Mai,~rashlra.
ref: 2742374511095/1903/3744 Fox: 2742'1~lhEmail: gbipl@boma.vs~r.nel.in Website: www.general1lauges.com

OPERATING & MAINTENANCE MANUAL FOR BI METAL DIAL THERMOMETER

"GENERAL" dial thermometers employ a closed system, with its moving


parts enclosed In a weather & shatterproof glass. They are for local
mounting installation, either back. entry or bottom entry or every angle

1. Physical Check;
Following checks are necessary before installation
a) Pointer dislocation
b) Glass broken
c) End nipple loosened

2. Remedies for above


2.1) Fault:. Pointer dislocation
Remedy
aJ Remove the Instrument cover loosening (anticlockwise rotation) and adjust the micro
pointer with the help of adjusting screw Provided on the pointer /if external zero is
provided ,adjust e~ernal screw.(external zero is provided only If specified in P.O.)
2.2) Fault :. Glass Broken

Remedy
a) Ask factory or our nearest branch office for replacement spares. Provide P.O. No. and
instrument No. so that correct spare glass can be provided.
2.3 Fault:. End Nipple Loosened
Remedy
il) Tighten the same firmly along with the asbestos thread by first holding the
Instrument nipple on a rigid vice.(Applicable for Bimetal T.G.only)

3. Calibration Test
3.1 Test:. Check the Dial Thermometer .under test for ambient temp, which should be
measured by Comparision with standard thermometer.
(Std.Thermometer may be glass/RTD/Digital)
Observation :-

The dial thermometer under test must read the temperature within:l: 1% FSD.


"ABL
CE
"010
Remedy:-
If the dial thermometer under test deviates from desired value carry out following
adjustment

aj All the instruments are provided with micrometer pointer & external zero if specified.
Set the instrument to std. ref. temp. by rotating the reset nutl screw clockwise or
anticlockwise with the help of spanner/ small screw driver.

Caution: We recommend that maximum Zero reset should be :!: 10.C angular.

'b) The instrument is provided with micrometer pointer, dismantle the inst. Cover after
loosening the same and with the help of small screw driver, rotate the reset screw of
the micrometer pointer clockwise or anti-clockwise, as required to set the instrument to
correct temp.

Caution: Hold other end of the micro pointer firmly between the thumb and finger.

3.2) Test: Check the instrument at two. different temp. 2/3'. of the temp. span by
immersing the sensing length "0" in a wall stirred and controlled temperature bath and
thus compare the temperature shown by the gauge under test, with standard
thermometer. (Std.Thermometer may be glass/RTD/Digitalj .

Observation:
a) Accuracy should within stipulated limits, as above.

Instruments does not respond.


Remedy:
Contact our nearest branch office or dispatch the instrument to factory for repair
if O.T. does not respond.
FOLLOW THE FOLLOWING INSTRUCTIONSGIVEN BELOW CAREFULLY

INSTRUcnONS FOR CHANGES THE ORIENTATION/ BENDING FOR EVERYANGEL DIAL THERMOMETER

1. First loosen the two nos. end screws for orientation


2. Then loosen the two nos. centre screws for bending
3. Tighten all, after positioning in the required plane.
,Note:- 'caution' Instruction' label carrying above instruction is provided on each and every
BDT/EAModel Bimetallic Dial thermometer, at the back of the case.

DOCNo~:QR/TECH/050
This Drawing and Design is the property of NEW FIELD INDUSTRIAL EQUIPMENT P.LTD and must not be copied or lent without their permission in writing.

DESIGN DATA
DESIGN CODE ASME Sec VIII DIV 1-2017, Tema 'C & HEI'
FIRST CONDENSER SECOND CONDENSER
DESCRIPTION
X
~1731

~1605
Y

1478.7
1

323 O/D
SPECIFICATION FOR EJECTOR

FIRST CONDENSER
SECOND CONDENSER

460
2

100
X Fixed Support
For M16 Bolt 3215 C/C
1 1095

VIEW " X" X " FOR VAPOUR PIPING


Y ELEVATION

M.O.C OF FIRST + SECOND CONDENSER

130
130

65 353
M.O.C OF EJECTOR & HOGGER EJECTOR

INSTRUMENTATION RANGE
PRESSURE GAUGES

TEMPERATURE GAUGES

APPROVED VENDOR LIST


VACCUM GAUGES
Description

100
ROTA METER DETAILS

1
NOZZLE THERMAL MOVEMENTS 1 1095

VIEW " Y" Y "


2
PLAN

INSTRUMENTS HOOK UP
S. NO TAG NOS. RANGE S. NO TAG NOS. RANGE S. NO TAG NOS. RANGE
2
PG

2
VG

PG

PROCESS CONNECTION

PLAN FOR STEAM PIPING

N 5 CONDENSATE LOOP N13 CONDENSATE LOOP 1


(FIRST) (SECOND)
VIEW " Y" Y " FOR STEAM PIPING
610KGS
65 N14 ROTA METER
15
ASSEMBLY
2.7MTRS

28
65

30 - LIFTING LUG NOTES : P.NO. DESCRIPTION SIZE MATERIAL QTY. TAG NO.
BILL OF MATERIAL
3 3215 C/C
3
610KGS 440KGS
M16

125X125 M16
For M16 125X125 5. PAINTING
75
75

Foundation Bolt
Rev.No Date Desription Pre.by Chd.by App.by
370

Fixed Support NEW FIELD INDUSTRIAL EQUIPMENT PVT. LTD


200

For M16 Bolt


1
200
1095 C/C
220 C/C

320

75
300
370

Foundation
ISMC100
Anchor Bolt

QTY:- 4NOS. 75 W.O.NO.: EJ -4396


Nozz Type Face Rating
Service NB/Sch Qty
FOUNDATION PLAN Mark FLANGE DRG.NO. : 30/E/3798/1
610KGS
3 FOUNDATION DETAIL 3
440KGS
BOLT DETAIL FOUNDATION POCKET DETAIL NOZZLE SCHEDULE
UNIT-1110-EJ+X EJECTOR STD MODEL

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