ADCA ADCATROL PV25 User manual

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
INSTALLATION AND MAINTENANCE INSTRUCTIONS
PNEUMATIC CONTROL VALVE
ADCATROL PV25 –PV40
GENERAL
These instructions must be carefully read before any work involving products supplied by VALSTEAM ADCA
ENGINEERING S.A. is undertaken.
The installation procedure is a critical stage in a life of a valve and care should be taken to avoid damage to the
valve or equipment.
Control valves are designed to give accurate control. They give their maximum performance only when the
equipment and piping associated with them is correctly sized and installed in accordance with our
recommendations.
Referring to the name-plate located on pneumatic actuator yoke, check that the product is suitable for the
intended use/application as follows:
- the body material must be compatible with the process fluid
- compatibility with the pressure and temperature and their maximum and minimum values
Adcatrol control valves are not intended to withstand external stresses that may be induced by any system to
which they are fitted. It is the responsibility of the installer to consider these stresses and take adequate
precautions to minimise them.
Note:
Current regional safety regulations should be take in to account and followed, while doing the installation and
maintenance work.
Handling, installation and maintenance work must be carried out by trained personnel. A supervisor must follow
and check all activities.
For the problems that cannot be solve with the help of this instructions, please contact the supplier or the
manufacturer.
The manufacturer reserves the right to change the design and material of this product without notice.
- If malfunction of any other equipment or system operation failure may result in a dangerous overpressure, over
temperature or even vacuum condition, a safety device must be included in the system to prevent such
situations.
- At start up, the presence of small particles in the fluid (dirt, scale, weld splatters, etc) may cause an imperfect
closure of the seat. If this occurs, proceed to an accurate cleaning.
- Do not touch the equipment without appropriate protection during working operation because it may conduct
heat if the used fluid is at high temperature.
- Before starting maintenance be sure that the equipment is not pressurized or hot. Even if upstream and
downstream isolating valves have been closed care should be taken since fluid under pressure may be trapped
between them.
- The equipments must be used within the working temperature and pressure limits laid down for them, otherwise
they may fail (refer to nameplate and/or IS- Information Sheet).
- Manual handling of products may present a risk of injury. You are advised to assess the risks taking into
account the task, the individual, the load and the working environment.
- Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine ADCA
replacement parts.

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
- Do not remove the nameplate attached to the equipment. Serial number and other useful information is
stamped on it.
- Do not apply the valve for oxygen service, if it hasn’t been specifically manufacture for that purpose.
- During the assembly work, apply protective measures against dirt.
- When connecting flanges, the bolts should be mounted from the counter flange side with the hexagon nuts from
the valve side and it must exist a perfect match between the connection flanges.
- Tighten flange connection bolts uniformly in a diagonal sequence.
- Damaged diaphragms can result in a dangerous media leak through the vent hole. To avoid this, valves should
be requested with appropriate connection in order to allow the connection of a pipe to a safe place.
- Correct installation of the equipment is full responsibility of the contractor
- Valves are designed to be applied in places protected from exposure to weather.
- We recommend special constructions or protective measures for applications on the outside or in adverse
environments like corrosion-promoting conditions (sea water, chemical vapors, etc).
- Avoid painting the bonnet thread (if applicable).
TRANSPORT AND STORAGE
- Handling and lifting of materials should be made with adequate equipments.
- Do not damage the paint job. It protects against corrosion during transportation and storage.
- The valves and equipments should be protected from impacts and forces during transportation and storage.
- The manufacturer doesn’t assume the responsibility of damaged equipments due to inappropriate handling
during the transportation and storage.
- When applicable, the valve should be handled with lifting eyes.
INSTALLATION
- Account for over pressure conditions, according with the local laws or standards.
- Valve mountings such as actuators, handwheels, hoods must not be used with other purpose than the one they
were built for (e.g. climbing aids or as connecting points for lifting gear)

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
- For the problems that cannot be solve with the help of this instructions, please contact the supplier or the
manufacturer.
Installation area requirements:
The installation area should have easy access and provide enough space for maintenance and removing
operations.
The pipework before and after the control valve, must be sized in order to avoid that the max flow speed
recommended, for the fluid in question, is exceeded.
In order to allow installation and maintenance work without emptying the system, stop valves should be installed
upstream and downstream of the control valve.
If the system cannot be stopped for maintenance it is recommended that isolating valves are installed upstream
and downstream of the control valve together with a by-pass manual regulating valve. The process can be then
controlled manually during the control valve maintenance. The by-pass must be kept close during the normal
operation.
To control the pressure, manometers shall be installed upstream and downstream of the valve, (if aplicable).
Procedure:
Prior to install check that the product is suitable for the intended application: materials and
pressure/temperature ratings.
Before installing remove plastic covers placed on flanges or connection ends. The equipment has an arrow or
Inlet/Outlet designations. Be sure that it will be installed on the appropriate direction.
Take care with jointing material to ensure that none may be permitted to block or enter the valve.
Control valves are recommended to be fitted with the centre line of the valve in a vertical position to ensure that
the best results are obtained. For the horizontal installation, please contact the manufacturer.
An ADCA pipeline strainer should be installed upstream of the valve to protect from dirt which could damage
the valve or cause mal-functioning. The strainer must be installed with the sieve sideways, if the medium is
steam, to prevent the collection of condensate.
The control valve pipework should be properly supported and free from strain and it should not be subjected to
undue surges of pressure. For steam installations we strongly recommend that the control valve is positioned
where condensation is unable to collect or that, alternatively, separators and steam traps are fitted so that the
pipework drains correctly. The start-up condition should be considered.
The pneumatic actuator is provided of two 1/4"NPT connections, one of these has a silencer. Connect the air to
the free 1/4" connection. The inlet air must be dry, oil and water free and it’s pressure would not exceed 3,5 bar
(50 psi). The suitable control signal is displayed on the name-plate fixed on the valve yoke. If the valve is
provided with positioner see also the Installation and Maintenance Instruction IMI PE986.10 and IMI PP981.10.
Control valves can be supplied with different kind of actuators, positioners, converters, etc. All these
components have different limiting conditions which are specified on the nameplates and catalogues and they
must be respected. Positioners, electric actuators and other equipment have their own installation instructions.
START UP
- Current regional safety regulations should be take in to account and followed.
- Protective insulation and warning notice may be required.
- Until the start up of an existing or a new plant, the following must be checked:
- All works are completed.
- The valve is correctly installed.
- All the necessary safety devices have been installed.
- At start up, the presence of small particles in the fluid (dirt, scale, weld splatters, joint particles, remains
of Teflon tape, etc) may cause an imperfect closure of the seat. If this occurs, proceed to an accurate
cleaning.

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
- Protection varnishes from pipes and flanges, fats, leftover paint, graphite, etc, should also be carefully
clean, because they can be dissolved in the fluids (like steam) blocking the regulation elements after
the first service stop.
- During operation high flow noises can be heard.
Procedure:
1. All stop valves should be close.
2. Open downstream stop valve.
3. Open slowly the upstream stop valve, in order to avoid water hammer damaging, until the input pressure
reaches its limit.
4. The valve is ready.
Periodical checking:
24 hours after the start up, it is recommended to check pipe connections and verify the tightening of flanges
locknuts. Graphite packing should be compressed by tightening the threaded bushing (3) (see fig.7) about a ¼
of a turn (care should be taken since over-tighten may lock-up the valve stem).
MAINTENANCE
We recommend that the control valves to be serviced as necessary. Control valves should be checked
periodically (at least yearly), to verify that they are operating correctly.
When reassembling makes sure that all gasket faces are clean and always use a new gasket. Tighten cover
bolts uniformly in a diagonal sequence.
Lubrication must be avoided for oxygen service. When it’s necessary, only the lubricants recommended by the
manufacture should be use.
Valves for clean steam service should only be lubricated with the lubricants recommended by the manufacture.
With acetylene gas avoid to use cooper.
For further information refer to the relevant IS brochure or consult the factory or distributor
Replacement of actuator diaphragm:
In reference to the fig.1 and 2 proceed as follow:
1. Remove the housing screws (14) except the long ones (15) which must be gradually loosen only when the other
bolts have been already removed.
2. Remove the housing lid (3) by loosing the plate locknut (13) and removing the disc plate (12) then replace the
diaphragm (4).
3. Refit all the items in reverse order.
Fig.1 –Direct action actuator

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
Fig.2 –Reverse action actuator
Removing actuator from valve:
In reference to the fig.3 proceed as follow:
1. Loosen the lock nuts (4).
2. Release air supply to the actuator and drive it into approximately mid-travel position.
3. Loosen the mounting nut (17) completely.
4. Reduce air supply pressure until housing is pressure free.
5. Check and measure the shifting between yoke base plate (5A) and flange valve body (1A) and take note.
6. Catch the actuator pillars and remove it from valve body. Nuts (10) can be used to fix the valve spindle in order
to avoid its rotation and consequently valve plug damage against the seat. Valve spindles are burnished and if
this super finishing is destroyed doing to the use of wrong tools packing will be consequently damage in a short
period of time.
7. Re-assemble all the items in reverse order ensuring the alignment of spindles and plug-seat consequently.
Fig.3 Fig.4

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
Replacing standard plug:
Separate the actuator from the valve body as described before. In reference to fig.4 proceed as follow:
1. Loosen the threaded bushing (8) and screw off the lock nuts (10).
2. Remove the bonnet (2) from the valve body (1)
3. Take off the complete plug stem (6) from the bonnet (2).
4. Apply silicon oil on the new complete plug stem and introduce it into the bonnet (3).
5. Replace the body gasket (11) after cleaning its housing face carefully.
6. Re-assemble all the items in reverse order ensuring the alignment of spindles and plug-seat consequently.
- Always change the old packing gland when the plug stem replacing is occurred.
Replacing packings:
Take off the complete plug stem as described on paragraph “REPLACING STANDARD PLUG”, then, in reference
to the Fig.5, 6 and 7 proceed as follow:
1. Screw off the threaded bushing (3).
2. Remove spring (4) and packing (graphite type G packing do not have spring).
3. Clean the packing chamber accurately and apply silicon oil to the individual parts of the new packing and the
plug stem.
4. Insert the plug stem in the valve bonnet (see note).
5. Lodge the new packing and its spring following the right sequence.
6. Replace the body gasket (11) (see fig. 4) after cleaning its housing face carefully.
7. Re-assemble all the items ensuring the alignment of spindles and plug-seat consequently.
- The valve stem should be correctly fitted within the bonnet before replacing the packing in order to avoid v-rings
damage.
- Care should be taken when handling the gaskets. Some gaskets are stainless steel reinforced and can easily
cut.

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
Fig. 5 –Packing type V
Fig. 6 –Packing type VV
Fig. 7 –Packing type G
PARTS LIST FOR V SERIES CONTROL VALVES:
Fig. 8 –PV25
Fig. 9 –PV40

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
VALVE SIZE
DN
9.PV25P.0015 Plug with soft seal and gasket 15 6,11 1 set
9.PV25P.0020 Plug with soft seal and gasket 20 6,11 1 set
9.PV25P.0025 Plug with soft seal and gasket 25 6,11 1 set
9.PV25P.0032 Plug with soft seal and gasket 32 6,11 1 set
9.PV25P.0040 Plug with soft seal and gasket 40 6,11 1 set
9.PV25P.0050 Plug with soft seal and gasket 50 6,11 1 set
9.PV25P.0065 Plug with soft seal and gasket 65 6,11 1 set
9.PV25P.0080 Plug with soft seal and gasket 80 6,11 1 set
9.PV25P.0100 Plug with soft seal and gasket 100 6,11 1 set
9.PV25P.1015 Metal plug and gasket 15 6,11 1 set
9.PV25P.1020 Metal plug and gasket 20 6,11 1 set
9.PV25P.1025 Metal plug and gasket 25 6,11 1 set
9.PV25P.1032 Metal plug and gasket 32 6,11 1 set
9.PV25P.1040 Metal plug and gasket 40 6,11 1 set
9.PV25P.1050 Metal plug and gasket 50 6,11 1 set
9.PV25P.1065 Metal plug and gasket 65 6,11 1 set
9.PV25P.1080 Metal plug and gasket 80 6,11 1 set
9.PV25P.1100 Metal plug and gasket 100 6,11 1 set
9.PV25S.0015 Standard valve seat 15 6,11 1 set
9.PV25S.0020 Standard valve seat 20 6,11 1 set
9.PV25S.0025 Standard valve seat 25 6,11 1 set
9.PV25S.0032 Standard valve seat 32 6,11 1 set
9.PV25S.0040 Standard valve seat 40 6,11 1 set
9.PV25S.0050 Standard valve seat 50 6,11 1 set
9.PV25S.0065 Standard valve seat 65 6,11 1 set
9.PV25S.0080 Standard valve seat 80 6,11 1 set
9.PV25S.0100 Standard valve seat 100 6,11 1 set
9.PV25.V11 V-Type packing rings 15-50 7,8 1 set
9.PV25.VV11 V-Type packing rings 65-100 7 1 set
9.PV25.G1 Graphite packing 15-100 7 1 set
9.PV25.0015 Body gasket 15-25 11 1
9.PV25.0025 Body gasket 32-50 11 1
9.PV25.0040 Body gasket 65-80 11 1
9.PV25.0065 Body gasket 100 11 1
QTY.
V25 TWO WAY VALVE
CODE
POS.NR.
DESIGNATION

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
VALVE SIZE
DN
9.PV40P.0015 Plug with soft seal and gasket 15 2,5,10 1 set
9.PV40P.0020 Plug with soft seal and gasket 20 2,5,10 1set
9.PV40P.0025 Plug with soft seal and gasket 25 2,5,10 1set
9.PV40P.0032 Plug with soft seal and gasket 32 2,5,10 1set
9.PV40P.0040 Plug with soft seal and gasket 40 2,5,10 1set
9.PV40P.0050 Plug with soft seal and gasket 50 2,5,10 1set
9.PV40P.1015 Metal plug and gasket 15 2,5,10 1set
9.PV40P.1020 Metal plug and gasket 20 2,5,10 1set
9.PV40P.1025 Metal plug and gasket 25 2,5,10 1set
9.PV40P.1032 Metal plug and gasket 32 2,5,10 1set
9.PV40P.1040 Metal plug and gasket 40 2,5,10 1set
9.PV40P.1050 Metal plug and gasket 50 2,5,10 1set
9.PV40S.0015 Standard valve seat 15 2,5,10 1set
9.PV40S.0020 Standard valve seat 20 2,5,10 1set
9.PV40S.0025 Standard valve seat 25 2,5,10 1set
9.PV40S.0032 Standard valve seat 32 2,5,10 1set
9.PV40S.0040 Standard valve seat 40 2,5,10 1set
9.PV40S.0050 Standard valve seat 50 2,5,10 1set
9.PV40.V11 V-Type packing rings 15-50 4,6 1 set
9.PV40.G1 Graphite packing 15-50 4,6 1 set
9.PV40.0015 Body gasket 15-25 5,10 1
9.PV40.0025 Body gasket 32-50 5,10 1
QTY.
V40 TWO WAY VALVE
CODE
POS.NR.
DESIGNATION
PARTS LIST FOR PA SERIES ACTUATORS:
Fig.10 –PA series actuator

 ADCA
VALSTEAM ADCA We reserve the right to change the design and material of this product without notice.
IMI PV25G.20 E 04.16
USEFUL NOTES ON VALVE AND PIPE SIZING
Never size the valve according to the pipe diameter in which it has to be fitted but according to the required actual
flow of steam or water. Refer to valve calculation data sheet or consult factory.
TYPICAL INSTALLATION
Please consult the available standard assembling drawings or consult the factory for a specific installation drawing.
- LOSS OF WARRANTY: Total or partial disregard of above instructions involves loss of any right to warranty.