Dixon Loading Arm Manual

Dixon Loading Arm Manual
Dixon Specialty Products
Loading Arm
Manual
Dixon Specialty Products
225 Talbot Blvd. • Chestertown, MD 21620
ph: 888.226.4673 • fx: 410.778.1958
dixonvalve.com
Introduction
This manual contains an order guide, installation and operating instructions, maintenance, trouble shooting and safety notes for the
Dixon Specialty Products Loading arm. Please read and understand this manual prior to installing, operating or servicing this product.
Table of Contents
How To Order Guide........................................................................................................................................................................ 3 - 5
Installation Instructions.......................................................................................................................................................................... 6
Operating Instructions...................................................................................................................................................................... 7 - 9
Loading Arm Maintenance........................................................................................................................................................... 10 - 13
Trouble Shooting................................................................................................................................................................................. 14
Safety ................................................................................................................................................................................................. 14
Limited Warranty................................................................................................................................................................................. 15
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Loading Arm Manual
How To Order Guide
1. Counterbalance part number sequence
1
Part Number
Orientation
Spring Color
Load capacity1
ESB1-A
Right-hand
White
Light-weight
ESB1-B
Right-hand
Yellow
Medium-weight
ESB1-C
Right-hand
Red
Heavy-weight
ESB1-E
Left-hand
Black
Light-weight
ESB1-F
Left-hand
Gray
Medium-weight
ESB1-G
Left-hand
Orange
Heavy-weight
Contact Dixon® for appropriate spring based on individual application.
2. Common Accessories: (Many others available upon request such as: deadman style valves and ball-style handles.)
D-handle
Breakaway
Cam & groove
Flange extension
API
Split-flange swivel locking devices (single hole location)
Sight glass
Deflectors
Split-flange swivel locking devices (multiple hole locations)
Note: Dixon® offers a full engineering team to design and develop any product or new idea. We offer loading arms as either new turnkey systems or replacement parts for any loading arm application.
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How To Order Guide, cont.
3. Configuration(s)
b.
c.
A-frame
Upfeed
Left-hand
Downfeed
Right-hand
Le
a.
Leg B
gA
Horizontal (top load)
Leg B
Leg A
d.
Other style arm:
4. Component Measurements and Material (measure from center of swivel to center of swivel to the whole foot, i.e. 48", 60", etc.)
Leg A
Length:
Material:
carbon steel
aluminum
stainless steel
Leg B
Length:
Material:
carbon steel
aluminum
metal hose
stainless steel
composite hose
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How To Order Guide, cont.
5. Application Information
a. End User:
Distributor:
Contact Name:
Number:
Email:
Contact Name:
Number:
Email:
b. Quantity:
c.
Pipe size:
2"
d. Base swivel:
3"
Type of media:
Misc.
Split flange style
e. Riser stand pipe connection:
f.
4"
Asphalt
"
V-ring style
150 ANSI flange
Fuel
O-ring style
300 ANSI flange
TTMA flange
Other:
Other media
g. Terminal end connections (optional items for each media):
45° pipe cut
bucket hook
deflector
handle
API coupler
breakaway
flange extension
sight glass
D handle
ball handle
locking mechanism
h. Seals (Dixon can recommend based on media):
Buna-N
Viton™
PTFE
FKM A&B
EPDM
6. Site Limitations:
a.
Ceiling or roof height from riser pipe connection distance:
b.
Additional items (vapor hoses, drip buckets, hold-down
chains etc. and estimated weight (pounds):
c.Range of motion required (list approximate range of motion
desired by clock method or degree method):
7. Sketches / Notes:
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Installation Instructions
1.Wear Personal Protective Equipment (PPE). When performing maintenance or working on the Loading arm always wear adequate
personal protection, including hard hats, gloves, safety glasses and steel-toed work boots.
2. Lift using appropriately rated straps using the shown possible attachment points.
3. Bolt torque chart and tighten sequence (use appropriate gaskets and bolts)
4 Bolt
8 Bolt
12 Bolt
a. TTMA flange bolt(s) = 25 Ft.Ibs. (tank truck flange)
b. 150 Pound Flange bolt(s) = 32 Ft.Ibs.
c. Counterbalance clamp bolt(s) 30 Ft.Ibs.
4. Prior to installing the loading arm on an existing riser pipe flange, inspection of the riser piping and connection flange should be
conducted. Ensure that the inlet is leveled and plumb which will prevent the loading arm from rotational drift. Also, confirm the
flange sealing surface is not damaged to prevent leaks.
5. The entire loading arm should be assembled on the ground in a horizontal position and then raised to the inlet piping flange as a
complete overall unit. Most of our assemblies will be shipped completely assembled. Be sure to align all flange gaskets properly in
between the flanges and tighten connections per the Bolt tightening sequence diagram.
6.Once installed, adjust the spring tension per the spring adjustment section and position the upward/downward travel stop(s).
Reference Operating Instructions on pages 7 - 9.
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Operating Instructions
Item
Qty
Part Number
Description
1
3
AT1321
Button head stainless steel Allen screw - metric 4
2
1
AT1299
Stainless steel name plate
3
1
AT1320
Stainless steel grease fitting
4
1
AT1264
Carbon steel side mounting
5
2
AT1302
Socket head stainless steel Allen screw - 5/16" x 1½"
6
1
AT1301
Stainless steel travel stop
7
1
AT1325
Brass bushing
8
1
AT1326
Ductile iron actuator
9
1
AT1255
Carbon steel main body
10
3
AT1318
Stainless steel hexagonal head bolt ⅝"-11 x 1½"
11
3
AT1319
Stainless steel grower washer ⅝"
12
1
AT1324
Torsion spring
13
1
AT1258
Stainless steel cylindrical washer
14
1
AT1262
Adjustment bolt
15
1
AT1327
Brass washer ⅝"
16
84
AT1328
Ball bearings ⅜"
17
1
AT1256
Carbon steel female raceways body
18
1
AT1257
Carbon steel male raceways adjusting device
19
2
AT1296
Stainless steel grease fitting cups
20
1
AT1329
Environmental seal
21
1
AT1300
Stainless steel plate
22
3
AT1321
Button head stainless steel Allen screw - metric 4
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Operating Instructions, cont.
Counterbalance adjustment and balancing. The loading arm is balanced and adjusted at the factory for all complete arm packages
but may need minor fine tuning once installed on-site due to weight of media, shipping vibrations etc.
1. Spring adjustment:
a. Prior to any work, reference the Safety section on page 14. Wear Personal Protective Equipment (PPE) during the installation.
• Remove Dixon® cover on the side with the pivot arm (item 2).
• Remove the mechanical stop secured with two hex bolts (items 5 and 6).
•Remove tension from the spring by lifting the arm up. Lift the loading arm to highest possible position to unload spring
tension and secure the arm.
•Once tension is removed, make small ½ turn increments to the adjustment bolt (item 14). Use caution when releasing the
arm. Allow the arm to 'settle' into a natural position before determining whether or not further adjustment is required.
- Tightening increases spring torque/loosening decreases spring torque.
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Operating Instructions, cont.
2. Spring wear (removal and replacement)
a.As the spring is used over time, the spring wears until the spring has reached the end of it’s service life:
•To change the spring out, all tension must be removed from the spring and the pivot arm bar must be removed.
•
•
•
•
Remove 3 bolts on the pivot arm side of the counterbalance (Item 10).
Pull the carbon steel side mount end plate (item 4) and associated parts of the housing.
Remove the spring (item 12) and replace.
Reinstall in the reverse order.
3. Effects of pipe clamp movement:
a.As the clamp is moved further out on the arm the result will be less felt weight at the terminal end and if the clamp is moved
closer to the pivot location the more felt weight will result.
b. Clamp bolts should be tightened in a crisscross pattern to 30 ft lbs. and checked during a regular maintenance schedule.
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Loading Arm Maintenance
Reference the following information to assist in general maintenance and seal replacement for all Dixon Specialty Products swivel
joints. Take all necessary safety precautions when assembling and operating these units. Handle all components with cleanliness and
care.
1. Lubrication (grease fittings)
a.Grease schedule: Lubrication should be performed on a regularly scheduled basis (e.g. bi-annually, quarterly or monthly),
depending on service and operating conditions.
b.Inject grease and rotate the unit as it is applied to ensure an even application throughout the raceway. Do not over-lubricate,
as this may displace the seals and result in leakage. Use a manual grease gun in order to feel pressure inside the swivel,
if you feel the pressure is high the swivel may be over greased and one of the ball plugs should be removed for a visual
inspection. Periodically remove both ball plugs in order to visually inspect the ball race and one or two of the ball bearings.
If there is material inside this cavity the pressure seal has been compromised resulting in a leak and the swivel should be
rebuilt. If you find metal in the grease or have any concerns about the shape of the ball bearings or races please contact us
immediately as this could be signs of excessive wear.
c.Grease points: all swivel joints are supplied with a grease fitting at each plane of rotation. Special note about the split flange
style swivel: remove the "grease inspection port" prior to greasing(see page 13).
d. Type of grease: all swivels are filled with Renolit Replex 2 grease at the factory with NLGI Grade 2. Some applications may
require different grease available upon request.
2. Re-torque bolts (clamps, counterbalance bolts, flanges etc.) and ensure the E-clips are in place on the counterbalance pivot bar
(e.g. bi-annually, quarterly or monthly), depending on service and operating conditions. We recommend using a thread lock sealant
or lock washers to prevent any loosening due to vibration (Loctite Blue).
3. We recommend a spring adjustment on the counterbalance after the first 2 months in service depending on use to account for
initial spring wear. (see spring adjustment section in this manual)
4.All swivels are designed to be rebuildable once they have reached the end of their service life, refer to pages 11 - 13 for swivel seal
replacement procedures.
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Loading Arm Maintenance, cont.
Swivel work instructions for replacing O-ring swivel seals.
Note: Instructions are not for assembly with spring-loaded PTFE pressure seal, consult Dixon®.
1
Remove the ball retainer screws. Add a sufficient amount of
solvent into each raceway to flush out the lubricant. Rotate
the sleeve, catching the balls as they fall out. When all the balls
have been removed, the body and sleeve can be separated.
Discard old seals. Thoroughly clean the body and sleeve.
2
3
Install the new O-rings on the sleeve, dust seal to the rear,
product (pressure) seal up front.
Lubricate the body and the sleeve with grease.
4
Insert the sleeve into the body, slowly rotate the sleeve while
inserting into the body.
5
When the sleeve is fully inserted, feed the ball bearings into
the raceways while rotating the sleeve. To make space for all
the balls, insert a screw driver into the raceway, while continuing
to rotate the sleeve in one direction (be careful not to damage
the threads). This will cause the balls to jam up, making room for
the remaining balls. Now reverse rotation of sleeve and insert the
remaining balls.
6
Reinstall ball retainer screws until tight. If this
interferes with the smooth rotation of the ball bearings, then
back off 1/8 - 1/4 turn. A thread locking sealant is recommended
to prevent screws from backing off. After pressure testing, the
unit is ready for installation.
Body and sleeve are matched during manufacturing. Do not mix components with other units.
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Loading Arm Maintenance, cont.
Swivel work instructions for replacing V-ring swivel seals.
1
Remove the ball retainer screws. Add a sufficient amount of
solvent into each raceway to flush out the lubricant. Rotate
the sleeve, catching the balls as they fall out. When all the balls
have been removed, the body and sleeve can be separated.
Discard old seals. Thoroughly clean the body, sleeve retainer,
spring retainer and springs. 1
2
4
Set the dust seal into O-ring groove on the sleeve. Place the
seal retainer on the sleeve with the grooved end facing the
V- rings. Lubricate the sleeve with grease.
5
Lubricate the body unit with a moly lubricant or equivalent.
Insert sleeve into body, compressing swivel joint together until
ball races of body and sleeve are in alignment (do not rotate
either unit while compressing). Care should be taken to avoid
pinching or scoring of V rings. Drop balls into raceway holes,
rotating the sleeve slowly as you load. To make space for all the
balls, insert a screw driver into the raceway while continuing to
rotate the sleeve in one direction (be careful not to damage the
threads). This will cause the balls to jam up, making room for the
remaining balls. Now reverse the rotation of the sleeve and insert
the remaining balls.
3
Place the assembled spring retainer unit (spring end first) into
the body. Place the set of V-rings onto the spring retainer. Be
sure V-rings are installed with the sealing lips facing toward the
retainer. Lubricate the body and seals with a Moly lubricant or
equivalent.
6
Reinstall ball retainer screws until tight. If this interferes with
the smooth rotation of the ball bearings, then back off ⅛ - ¼
turn. A thread locking sealant is recommended to prevent screws
from backing off. After pressure testing, the unit is ready for
installation.
1
The last coil of the springs has been upset (OD slightly larger). When upset end is inserted into the holes provided in the spring
retainer, the springs remain secure.
Body and sleeve are matched during manufacturing. Do not mix components with other units.
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Loading Arm Maintenance, cont.
Swivel work instructions for replacing Split flange swivel seals.
Nose piece (2)
Seal pack: pressure seal
O-rings (2) and
PTFE retainer
Grease
inspection
port
Grease fitting /
bearing port
Dust seal O-ring
Ball bearings and spacers
Instructions to replace the seal pack:
1. Remove the bolts connecting the nose piece on only one side of the swivel body (bearing pack).
2. Pull out the seal pack and install the new seals (ensure the o-rings are in the groove of the PTFE retainer.
3. Reinstall the bolts and torque in an alternating star pattern to 25 ft. Ibs.
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Trouble Shooting
Problem
Solution
Loading arm becomes un-balanced
Check clamp placement (ensure the clamp did not slide). Re-adjust
and torque bolts
Use adjustment nut as describe previously to re-adjust spring
tension
Consult Dixon® for further information
Swivel leaking
Re-torque flange bolts
Grease per the loading arm service section on pages 10 - 13.
Replace seals
API coupler leaking
Visit dixonvalve.com for information on rebuilding, maintenance and
operating.
Loading Arm adjustment limited by obstructions (ceiling
height, pipings, etc.)
Remove all the spring tension and turn the adjustment bolt using a
standard wrench. Never use a cheater or breaker bar:
The entire Loading Arm should be removed from the inlet stand
pipe connection, brought to the ground, adjusted, and then reinstalled. To avoid this step, use a shorter inlet stand pipe.
Safety
All counterbalances are shipped with the following label:
DANGER! Be aware of several pinch points around
moving loading arms.
DANGER! Prior to any maintenance, secure the Loading Arm and remove tension from the spring inside the counterbalance
housing. The Loading Arm utilizes a torsion spring which contains a substantial amount of tension. Tension must be
dissipated prior to any disassembly. Failure to remove all tension from the spring may cause serious injury.
Warning: Never exceed the rated working pressure of the unit. Never modify or alter a unit beyond that to which it has been
designed. Should any unit appear damaged, remove it from service immediately and contact Dixon®.
CAUTION: Loading arms are not provided with a pressure relief valve. Temperature variations and thermal expansion of
liquid media can cause increased internal pressure. Therefore a pressure relief valve prior to the inlet connection point is
required. Failure to install a relief valve prior to the loading arm may damage the equipment and cause injury.
Users must consider the size, temperature, application, media, pressure and hose and coupling manufacturer's recommendations
when selecting the proper hose assembly components. Dixon® recommends that all hose assemblies be tested in accordance with
the Rubber Manufacturers Association's recommendations and be inspected regularly (before each use) to ensure that they are not
damaged or have become loose. Visit RMA.org for more information.
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Loading Arm Manual
Limited Warranty
DIXON VALVE AND COUPLING COMPANY (herein called "Dixon") warrants the products described herein, and manufactured by
Dixon to be free from defects in material and workmanship for a period of one (1) year from date of shipment by Dixon under normal
use and service. It's sole obligation under this warranty being limited to repairing or replacing, as hereinafter provided, at its option
any product found to Dixon's satisfaction to be defective upon examination by it, provided that such product shall be returned for
inspection to Dixon's factory within three (3) months after discovery of the defect. The repair or replacement of defective products
will be made without charge for parts or labor. This warranty shall not apply to: (a) parts or products not manufactured by Dixon,
the warranty of such items being limited to the actual warranty extended to Dixon by its supplier; (b) any product that has been
subject to abuse, negligence, accident, or misapplication; (c) any product altered or repaired by others than Dixon; and (d) to normal
maintenance services and the replacement of service items (such as washers, gaskets and lubricants) made in connection with
such services. To the extent permitted by law, this limited warranty shall extend only to the buyer and any other person reasonably
expected to use or consume the goods who is injured in person by any breach of the warranty. No action may be brought against
Dixon for an alleged breach of warranty unless such action is instituted within one (1) year from the date the cause of action accrues.
This limited warranty shall be construed and enforced to the fullest extent allowable by applicable law.
Other than the obligation of Dixon set forth herein, Dixon disclaims all warranties, express or implied, including but not limited to any
implied warranties of merchantability or fitness for a particular purpose, and any other obligation or liability. The foregoing constitutes
Dixon's sole obligation with respect to damages, whether direct, incidental or consequential, resulting from the use or performance of
the product.
Some products and sizes may be discontinued when stock is depleted, or may require a minimum quantity for ordering.
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15
Dixon®, founded in 1916, is a premier manufacturer and
supplier of hose couplings, valves, dry-disconnects, swivels,
and other fluid transfer and control products. The company’s
global reach includes a wide range of products for numerous
industries including petroleum exploration, refining,
transportation, chemical processing, food & beverage, steel,
fire protection, construction, mining and manufacturing.
Dixon®'s strategic objective is to create solutions that make
products safer, leak-free, longer lasting, and always available.
dixonvalve.com • Customer Service: 888.226.4673
Dixon Specialty Products
225 Talbot Blvd
Chestertown, MD 21620
Customer Service: 888.226.4673
Fx: 410.778.1958
© 2019 DVCC
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