Emerson Asco Bio-Pure User manual

Installation, Operation
and Maintenance Manual
Bio-Pure
Designed and Manufactured by ITT
IOM.BP.ASCO.en-US.2017-11

Table of Contents
Bio-Pure Installation, Operation, and Maintenance Manual 1
Table of Contents
Introduction and Safety .......................................................................................................... 2
Safety message levels ............................................................................................................ 2
User health and safety ............................................................................................................ 2
Transportation and storage .................................................................................................... 5
Handling and unpacking guidelines ........................................................................................ 5
Storage, disposal, and return requirements ............................................................................ 5
Product Description ................................................................................................................ 6
Bio-Pure identification ............................................................................................................. 6
Bonnet description .................................................................................................................. 7
Valve diaphragm identification ................................................................................................ 7
Installation ............................................................................................................................... 9
Install the valve and topworks ................................................................................................. 9
Mount the topworks to the valve .............................................................................................. 9
Tighten the bonnet fasteners .................................................................................................. 9
Fastener torque table for valve body to topworks ............................................................... 10
Operation ............................................................................................................................... 11
Actuator operating pressure .................................................................................................. 11
Maintenance ........................................................................................................................... 12
Precautions ........................................................................................................................... 12
Inspection ............................................................................................................................. 12
Disassemble the valve .......................................................................................................... 12
Replace the valve diaphragm ................................................................................................ 13
Travel (closing) stop for manual valve ................................................................................... 14
Adjust the travel (closing) stop with air pressure ................................................................ 15
Adjust the travel (closing) stop without air pressure ........................................................... 15
Lubrication requirements ...................................................................................................... 15
Parts Listing and Cross-Sectional Drawings ...................................................................... 16
Bio-Pure manual topworks .................................................................................................... 16
Bio-Pure COP manual topworks ........................................................................................... 17
Bio-Pure AXS actuator .......................................................................................................... 18
Designed and Manufactured by ITT

Introduction and Safety
Bio-Pure Installation, Operation, and Maintenance Manual2
Introduction and Safety
Safety message levels
Definitions
Safety message level Indication
DANGER: A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING: A hazardous situation which, if not avoided, could result in death or serious injury
CAUTION: A hazardous situation which, if not avoided, could result in minor or moderate injury
Electrical Hazard: The possibility of electrical risks if instructions are not followed in a proper manner
NOTICE: • A potential situation which, if not avoided,
could result in an undesirable result or
state
• A practice not related to personal injury
User health and safety
General precautions
This product is designed and manufactured using good workmanship and materials, and meets
all applicable industry standards. This product should be used only as recommended by ITT or
ASCO.
WARNING:
• Misapplication of the valve can result in injury or property damage. Select valves and valve
components of the proper materials and make sure that they are consistent with your
specific performance requirements. Incorrect application of this product includes but is not
limited to:
• Exceeding the pressure or temperature rating
• Failing to maintain this product according to the recommendations
• Using this product to contain or control media that is incompatible with the materials of
construction
• Proper containment or protection from hazardous media must be provided by the end
user to protect employees and the environment from valve discharge.
• If the product exhibits any indication of leakage, do not operate. Isolate the product and
either repair it or replace it as outlined within this manual.
Designed and Manufactured by ITT

Introduction and Safety
Bio-Pure Installation, Operation, and Maintenance Manual 3
Qualifications and training
The personnel responsible for the assembly, operation, inspection, and maintenance of the
valve must be appropriately qualified. The operating company must do the following tasks:
• Define the responsibilities and competency of all personnel handling this equipment.
• Provide instruction and training.
• Ensure that the contents of the operating instructions have been fully understood by the
personnel.
Instruction and training can be carried out by ASCO as the reseller of the valve by order of the
manufacturer.
Non-compliance risks
Failure to comply with all safety precautions can result in the following conditions:
• Death or serious injury due to electrical, mechanical, and chemical influences
• Environmental damage due to the leakage of dangerous materials
• Product damage
• Property damage
• Loss of all claims for damages
Operational safety precautions
Be aware of these safety precautions when operating this product:
• Do not leave hot or cold components of the product unsecured against contact if they are a
source of danger.
• Do not remove the contact guard for moving parts when the product is in operation. Never
operate the product without the contact guard installed.
• Do not hang items from the product. Any accessories must be firmly or permanently
attached.
• Do not use the product as a step or hand hold.
• Do not paint over the identification tag, warnings, notices, or other identification marks
associated with the product.
• PTFE diaphragms emit toxic fumes due to thermal decomposition at temperatures of
380°C | 716°F or greater.
Maintenance safety precautions
Be aware of these safety precautions when performing maintenance on this product:
• You must decontaminate the product if it has been exposed to harmful substances such as
caustic chemicals.
• Work on externally actuated valves should only be performed when the valve is removed
from service.
• On completion of work, all safety and protective equipment must immediately be fitted
again or reactivated.
• Before the re-operation, pay attention to the points in the following sections.
Use of unauthorized parts
Reconstruction or modification of the product is only permissible after consultation with ITT.
Genuine spare parts and accessories authorized by ITT serve to maintain safety. Use of non-
genuine ITT parts can annul liability of the manufacturer for the consequences. ITT parts are
not to be used in conjunction with products not supplied by ITT as this improper use can annul
all liability for the consequences.
The use of diaphragms other than genuine ITT diaphragms violates diaphragm valve industry
standard MSS SP-88. Valve pressure, temperature, and overall performance can not be
guaranteed.
Designed and Manufactured by ITT

Introduction and Safety
Bio-Pure Installation, Operation, and Maintenance Manual4
Unacceptable modes of operation
The operational reliability of this product is only guaranteed when it is used as designated. The
operating limits given on the identification tag and in the data sheet may not be exceeded under
any circumstances. If the identification tag is missing or worn, contact ASCO for specific
instructions.
Do not use "cheater bars" to operate manual valves. Damage to the valve or personal injury
could result.
Designed and Manufactured by ITT

Transportation and storage
Bio-Pure Installation, Operation, and Maintenance Manual 5
Transportation and storage
Handling and unpacking guidelines
CAUTION:
Always observe the applicable standards and regulations regarding the prevention of
accidents when handling the product.
Handling guidelines
Follow these guidelines when handling the product to prevent damage:
• Use care when handling the product.
• Leave protective caps and covers on the product until installation.
Unpacking guidelines
Follow these guidelines when unpacking the product:
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. Do not lift or pull on the electrical conduit lines. Doing so may cause the POC switches to
come out of calibration.
Storage, disposal, and return requirements
Storage If you are not immediately installing the product after delivery, store it as follows:
• Store the product in a dry room that maintains a constant temperature.
• Make sure that the products are not stacked on top of one another.
Disposal Dispose of this product and associated components in compliance with federal, state, and local
regulations.
Return Ensure these requirements are met before you return a product to ASCO:
• Contact ASCO for specific instructions on how to return the product.
• Clean the valve of all hazardous material.
• Complete a Material Safety Data Sheet or Process Data Sheet for any process fluid that
could remain on the valve.
• Obtain a Return Material Authorization from the factory.
Designed and Manufactured by ITT

Product Description
Bio-Pure Installation, Operation, and Maintenance Manual6
Product Description
Bio-Pure identification
Model number The Bio-Pure model numbers contains the following:
Table 1: Body type
Code Description
BP Forging
Table 2: Diaphragm type
Code Description
17 EPDM
TM17 PTFE
Table 3: Manual topworks
Code Description
BPM Manual bonnet
BPMC Manual bonnet sealed (COP)
Table 4: Actuated topworks
Code Description
AXS29 Fail close 90# spring package
AXS26 Fail close 60# spring package
AXS1 Fail open
AXS3 Double acting
Table 5: Examples
Model number Description
BP-TM17-BPM Bio-Pure forging with a PTFE diaphragm and manu-
al bonnet
BP-17-AXS29 Bio-Pure forging with a EPDM diaphragm and fail
close 90# spring package
Designed and Manufactured by ITT

Product Description
Bio-Pure Installation, Operation, and Maintenance Manual 7
Bonnet description
Manual and actuator bonnet
The manual bonnet and actuator bonnet are non-sealed and have a weep hole that permits
leakage of the process fluid if the diaphragm ruptures.
Manual bonnet sealed (COP)
The manual bonnet sealed (COP) does not include a weep hole or V-notch vent plug. The COP
manual topworks can only be cleaned (submerged) when the topworks is assembled to a valve
body.
Valve diaphragm identification
Diaphragm tab codes
All diaphragm materials and physical properties are batch traceable via permanent codes
molded into the diaphragm tabs. The molding date, grade of diaphragm, and size provide
traceability to original batch records.
1. Date code
2. Batch code
Figure 2: Elastomer diaphragm front
1. Supplier code
2. Material code
Figure 3: Elastomer diaphragm back
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Product Description
Bio-Pure Installation, Operation, and Maintenance Manual8
1. Date code
2. Material code
Figure 4: PTFE diaphragm
Designed and Manufactured by ITT

Installation
Bio-Pure Installation, Operation, and Maintenance Manual 9
Installation
Install the valve and topworks
NOTICE:
The topworks size and configuration can limit the actual operating pressure. Consult the Pure-
Flo catalog for pressure limitations. Consult the factory or engineering catalog for vacuum
operation.
Consider the following information before installing the actuator:
• The maximum valve operating pressure is 10.34 bar | 150 psig. This pressure is applicable
up to 38ºC | 100ºF. Valves at maximum pressure cannot be used at maximum
temperatures.
• The maximum actuator pressure is 6.9 bar | 100 psi.
1. If you have a weld end valve, then consider the following:
If you are
welding ... Then ...
Manually Remove the topworks.
In line You can weld with automatic equipment. Before you perform the weld:
1. Remove the topworks (optional).
2. If left installed, set the valve to the open position.
3. Properly purge the valve with an inert gas.
2. Install the valve.
3. Prior to pressurization (with the valve slightly open), tighten the bonnet fasteners.
For more information, see Tighten the bonnet fasteners (page 9).
4. If you have an actuated topworks, then connect the air line.
Connection size is 1/8" NPT.
5. Cycle the valve two to three times to verify smooth operation.
Mount the topworks to the valve
1. For actuated topworks, regulate the air pressure.
If the topworks is ... Then regulate the air pressure ...
AXS1, AXS3 In the upper cover to extend the compressor.
AXS26, AXS29 In the lower cover to properly position the valve diaphragm.
2. Install the valve diaphragm.
For more information, see Replace the valve diaphragm (page 13).
3. Assemble the valve body and tighten the bonnet fasteners.
For more information, see Tighten the bonnet fasteners (page 9).
4. If there is a travel (closing) stop, reset it to ensure proper closure.
For more information, see Adjust the travel (closing) stop in this manual.
Tighten the bonnet fasteners
CAUTION:
Do not tighten fasteners while the system is pressurized or at elevated temperatures (greater
than 38°C | 100°F).
1. Depressurize the system.
Designed and Manufactured by ITT

Installation
Bio-Pure Installation, Operation, and Maintenance Manual10
2. Position diaphragm so that valve is slightly open.
For valves with an actuator, you may need to use regulated air pressure to actuate the
valve.
3. Tighten the bonnet fasteners in a crisscross pattern.
For more information, see Fastener torque table for valve body to topworks (page 10).
4. Make multiple crisscross passes to build up torque to the final table value. Make additional
crisscross passes using final table values to evenly tighten each fastener to within 5% of
torque value.
5. Retighten the bonnet fasteners as noted above at ambient conditions after the system has
cycled through operating pressure and temperature.
6. Monitor the valve for leakage:
If leakage ... Then ...
Occurs at the body/bonnet flange
sealing area Depressurize the system and retighten the bonnet fasteners as noted above.
Continues Depressurize the system and retighten the bonnet fasteners as
noted above. (maximum 3rd re-torque)
Continues Replace the valve diaphragm.
For more information, see Replace the valve diaphragm (page 13).
Fastener torque table for valve body to topworks
Values given are for lubricated fasteners.
Valve size Bolt size PTFE diaphragm Elastomer diaphragm
DN Inch Metric Imperial N-m in-lb N-m in-lb
Bio-Pure
(8, 10, 15) Bio-Pure (0.25,
0.375, 0.50)
M4 Not avail-
able 1.7-2.0 15-18 1.4-1.7 12-15
Designed and Manufactured by ITT

Operation
Bio-Pure Installation, Operation, and Maintenance Manual 11
Operation
Actuator operating pressure
Maximum permitted air supply pressure
bar kPA psi
6.9 690 100
Actuator pressure rating
The actuator will withstand pressures well in excess of the rated pressure without risk of
bursting. Maintaining operating pressure at or below the pressure rating will ensure optimum
life of the operating components.
bar kPA psi
6.9 690 100
Designed and Manufactured by ITT

Maintenance
Bio-Pure Installation, Operation, and Maintenance Manual12
Maintenance
Precautions
WARNING:
• All procedures must be performed by qualified personnel.
• When the process fluid is hazardous, thermal (hot or cold), or corrosive, take extra
precautions. Employ the appropriate safety devices and be prepared to control a process
media leak.
• O-ring failure on the upper cover of a fail open or double acting actuator can pressurize a
switch package, if present. This may result in catastrophic failure of the switch package,
causing the switch package cover to be released at high velocity. O-ring failure can be
caused by:
• Damage to the o-ring
• O-ring material degrading
• O-ring wear over time
• Always wear protective clothing and equipment to safeguard the eyes, face, hands, skin,
and lungs from the fluid in the line.
• Do not disassemble the actuator in the field. The actuator contains energized springs
which can cause injury. The product is designed to be recycled in its entirety.
CAUTION:
• Disconnect electrical, pneumatic, and hydraulic power before servicing actuator or
automation components.
Inspection The actuator cannot be disassembled and reassembled.
Inspection area What to look for Action if problem is found
External valve parts Excessive wear or corrosion • Replace the affected parts
• Contact ITT to obtain re-
placement parts or for specif-
ic instructions
Non sealed bonnet Fluid weeping from the plug Replace the valve diaphragm
Actuator's bonnet weep hole and
air ports Air pressure Contact ITT for specific instruc- tions
Topworks Spindle binding, excessive noise,
or dried lubricant • For manual topworks, lubri-
cate the valve spindle
• For actuated topworks, con-
tact ITT for specific instruc-
tions
O-ring for COP manual topworks Signs of wear or nicks Replace the o-ring
Diaphragm and valve body Leakage between the diaphragm
and valve body Tighten the bonnet fasteners
For more information, see:
•Replace the valve diaphragm (page 13)
•Tighten the bonnet fasteners (page 9)
Disassemble the valve
1. Remove all line pressure.
Designed and Manufactured by ITT

Maintenance
Bio-Pure Installation, Operation, and Maintenance Manual 13
2. If the actuator mode of operation is fail open or fail close, then load the actuator with air.
If the actuator mode of operation is ... Then ...
Fail open Load the actuator with sufficient air to partially close the
valve.
Fail close Load the actuator with sufficient air to partially open the
valve.
3. Remove the bonnet fasteners.
4. Lift the topworks assembly from the valve body.
5. If the actuator mode of operation is fail open, then remove pressure load from the actuator.
Replace the valve diaphragm
1. Disassemble the valve.
For more information, see Disassemble the valve (page 12).
2. Remove the diaphragm by rotating the diaphragm 90° so it slides out of the compressor.
The replacement diaphragm must be identical in grade to the original diaphragm.
3. If replacing a PTFE diaphragm, locate a new elastomer backing cushion over boss in
diaphragm.
Align the bolt pattern of the backing cushion with that of the diaphragm.
4. If you have a fail open or double acting actuator, add air to the upper chamber to expose
the compressor.
5. Invert diaphragm by pressing the center of the diaphragm face with your thumbs while
holding the edge of the diaphragm with your fingers.
NOTICE:
Do not to scratch the diaphragm bead while inverting the diaphragm.
6. Insert the diaphragm into the compressor.
a) Insert the diaphragm stud with a cross pin into the compressor.
b) Rotate the diaphragm 90° to capture the pin in the compressor.
c) Lightly tug on the diaphragm to ensure the pin has engaged in the compressor.
Designed and Manufactured by ITT

Maintenance
Bio-Pure Installation, Operation, and Maintenance Manual14
This also properly positions the bolt pattern of the diaphragm with that of the bonnet.
7. If replacing a PTFE diaphragm, re-invert the diaphragm.
8. If the actuator mode of operation is fail open or fail close, select one of these steps.
If the actuator
mode of
operation is ...
Then ...
Fail open 1. Connect the air line to the upper actuator chamber.
2. Load the chamber with the full recommended air pressure. Be sure to apply
enough air pressure to prevent inversion of the diaphragm.
3. Reduce the air pressure until the back of the diaphragm is flat against the
bonnet.
Fail close 1. Connect the air line to the bonnet’s cylinder.
2. Load the chamber with sufficient air to move the diaphragm upward until the
back of diaphragm is flat against the bonnet. Do not apply excessive air
pressure that results in inversion of the diaphragm.
Double acting Remove the air line.
9. For more information, see Tighten the bonnet fasteners (page 9).
10. If the actuator mode of operation is fail open, then release the air, allowing the valve to
open.
11. If there is a travel (closing) stop, then reset it to ensure proper closure.
For more information, see Adjust the travel (closing) stop (page ).
Travel (closing) stop for manual valve
A travel stop is included in all manual valve configurations. The purpose of the travel stop is to
prevent over closing of the valve and prolong diaphragm life. ITT recommends you adjust the
travel stop:
• during valve installation
• after diaphragm replacement
• after any other maintenance procedure
Designed and Manufactured by ITT

Maintenance
Bio-Pure Installation, Operation, and Maintenance Manual 15
Use one of the following procedures to adjust the travel stop. ITT recommends you adjust the
travel (closing) stop with air pressure whenever possible.
If ... Then use this procedure ...
You have air pressure available Adjust the travel (closing) stop with air pressure
You do not have air pressure available Adjust the travel (closing) stop without air pressure
Adjust the travel (closing) stop with air pressure
1. With the valve slightly open, apply air pressure at 150 psig (10 bar) to the upstream side.
NOTICE:
Make sure that seal leakage is not excessive at this time as it will result in the whipping
action of the flexible tube.
2. Connect the downstream side to a flexible tube immersed in a container of water.Air
bubbles should be evident in the water.
3. Remove the screw that secures the handwheel to the spindle.
4. Turn the handwheel clockwise until the air bubbles stop.
5. Push down on the handwheel and reinstall the screw.
The maximum allowable torque on this joint is 32 in-lbs (3.6 N-m).
Adjust the travel (closing) stop without air pressure
1. With system pressure vented, remove the screw securing the handwheel to the spindle and
handwheel.
2. Using a wrench applied to the spindle flats, close the valve to the final torque as follows:
If diaphragm is ... Then close to torque of ...
Elastomer 4 in-lbs (0.45 N-m)
PTFE 6 in-lbs (0.68 N-m)
3. Slide the handwheel over the spindle, push down, and reinstall the screw.
The maximum allowable torque on this joint is 32 in-lbs (3.6 N-m).
Lubrication requirements
NOTICE:
Standard lubricants are as outlined below. Special lubricants may be required for oxygen or
other unique services. Contact ITT for evaluation of non-standard lubricants.
Re-lubrication is not intended for actuated valves. Actuator is not intended to be disassembled
nor assembled in the field.
Lubrication schedule
Remove residual grease prior to re-lubrication. Lubricate the spindle, o-rings (for COP manual
topworks), and mating surfaces whenever the topworks is disassembled.
Acceptable lubricants
Brand Lubricant type
Chevron FM ALC EP 2 (FDA Compliant)
Fuchs Cassida FM CSC EP2 (FDA Compliant)
Designed and Manufactured by ITT

Parts Listing and Cross-Sectional Drawings
Bio-Pure Installation, Operation, and Maintenance Manual16
1Recommended spare part
Parts Listing and Cross-Sectional Drawings
Bio-Pure manual topworks
List of parts
Figure 5:
Item Description Material Quantity
1 Body Stainless steel 1
2 Screw Stainless steel 4
3 Washer Stainless steel 4
4 Compressor Stainless steel 1
5 Bonnet Stainless steel 1
6 Spindle Stainless steel 1
7 Indicating label Mylar 1
8 Handwheel Plastic 1
9 Screw Stainless steel 1
10 Diaphragm As required 1
111Backing cushion As required 1
Designed and Manufactured by ITT

Parts Listing and Cross-Sectional Drawings
Bio-Pure Installation, Operation, and Maintenance Manual 17
2Recommended spare part
Bio-Pure COP manual topworks
List of parts
Figure 6:
Item Description Material Quantity
1 Body Stainless steel 1
2 Screw Stainless steel 4
3 Washer Stainless steel 4
4 Compressor Stainless steel 1
5 Spindle Stainless steel 1
6 Bonnet Stainless steel 1
7 Indicating label Mylar 1
8 O-ring FKM 1
9 Handwheel Plastic 1
10 Screw, self sealing Stainless steel, FKM 1
11 Diaphragm As required 1
122Backing cushion As required 1
13 O-ring FKM 1
Designed and Manufactured by ITT

Parts Listing and Cross-Sectional Drawings
Bio-Pure Installation, Operation, and Maintenance Manual18
3Recommended spare part
Bio-Pure AXS actuator
List of parts
Figure 7:
Item Description Material Quantity
1 Body Stainless steel 1
2 Screw Stainless steel 4
3 Washer Stainless steel 4
4 Compressor Stainless steel 1
5 Spindle Stainless steel 1
6 Bonnet Stainless steel 1
7 Upper cover Stainless steel 1
8 Indicating spindle Stainless steel 1
9 Diaphragm As required 1
103Backing cushion As required 1
Designed and Manufactured by ITT