Pneucon 725 Series Operating and maintenance manual

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PVIM-725
INSTALLATION AND MAINTENANCE AND OPERATING MANUAL
FOR SELF ACTUATING PRESSURE REGULATING VALVE
(SERIES – 725)
CONTENTS
Section Desc iption Page No.
1 General 1
2 Warnings / Handling 2
3 Pre-Installation / Installation 3
4 Maintenance 4-5
5 roubleshooting 6
6 Schematic Line Diagram of Accessories 7
>> 1. GENERAL
his manual describes the instructions for handling, storage,
installation, maintenance, and operation of the For self actuating
PRV with spring opposed pneumatic diaphragm actuator.
Instructions not detailed in this document shall be performed in
accordance with standard and safe acceptable practices as may
be required by local codes, specifications and or regulations.
he instruction contained within this manual must be read
before undertaking any work on the equipment supplied and if
there are any questions please contact Pneucon Valves Pvt. Ltd.
or its agent.
When ordering any spares please specify the unique valve serial
number detailed on the equipment nameplate.
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PVIM-725
>> 2. WARNINGS
1. In order to avoid possible injury to personnel or damage to any equipment any ‘WARNING
and CAU ION’ notes must be strictly adhered to. Modification of this product, substitution of
non-approved components and use of maintenance procedures other than those detailed
within this document could drastically affect the performance, nullify any warranty and be
hazardous to personnel and equipment.
2. Personal injury, equipment damage, leakage due to escaping gas or failure of pressure
containing component may result if the valve or ancillaries are over pressured or installed
where service condition exceed the limits detailed in the manufacturer’s specification or on
the valve nameplate. o avoid such injury or damage a relief valve for over pressure
protection should be provide as required by industry and sound engineering practices or
applicable safety codes.
3. Due to the possibility of both elevated and low temperatures occurring on exposed surfaces of
the valve assembly during operation, adequate safety precautions must be taken. his may
involve insulating the valve assembly or the provision of safety clothing and equipment to
avoid personal injury.
4. It is a requirement of PER 1999 that both the maximum working pressure and temperature
of the valve are detailed on the nameplate. he stated values must be adhered to separately
and in isolation. Attention must be paid to the combined pressure and temperature
characteristics of the appropriate valve pressure containment material group as stated in
ASME / ANSI B 16.34.
5. When purchased each valve / trim configuration and construction materials are specifically
selected to satisfy the particular application, conditions of flow, temperature, pressure drop
and controlled fluid conditions for corrosion and erosion. Included within the Pneucon Valve
selection process is the consideration of the amount of power conversion allowed to reduce
vibration levels within the valve and also the materials of construction are specifically
selected for each application. he valve must not be used on any other application, without a
review by Pneucon Valve.
6. he valve is not suitable for fire safe service and is not certified for this application or duty.
Unless otherwise detailed in the quotation and order documentation the valve will not have
been designed to deal with excessive seismic activity or bending moments resulting from
misaligned pipe work.
7. It is not intended that externally applied lever arms will be used on the valve.
>> 3. HANDLING
1. he weight of the control valve assembly can cause serious injury if it is not handled
correctly, using the necessary protective clothing and safety equipment. Adequate lifting
equipment must be used and properly attached. Where lifting eyes are provided with the
equipment these should be used to enable safe handling of the valve. All lifting equipments
should be used within its defined limitations., applicable codes and safe industrial practices
including (but not limited to ) the following :
•Slings to be free of kinks.
•Lifting hooks to be positioned directly over the load to avoid any severe swinging
when lifted.
•he operator shall ensure that the load is safe and well secured.
2. When lifting the equipment ensure that any slings or hoists are positioned to avoid any
damage to the accessories or tubing mounted on the valve.
3. All eyebolts should have a shoulder, which butts against the tapped hole. Use American Drill
Bushing CO ADB2300 series safety hoist rings or equivalent should be used. he following
table details the safety hoist thread size and the appropriate safe loading that can be applied.
Safety Hoist Ring
hread Size UNC
Rated Load lbf
ADB
-
23004
½’’ 13 x 0.75
2500
ADB
-
23002
5/8” 11x1
4000
ADB
-
23007
¾” 10 x 1
5000
ADB
-
23101
7/8” 9 x 1
8000
ADB
-
23105
1” 8 x 1.25
10000
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PVC -110
PVIM-725
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>> 4. PRE – INSTALLATION
1. he assembly should be inspected on receipt to ensure that it has not
been damaged during transit. his inspection should be undertaken
in a safe and controlled manner as valve equipment can be heavy and
have sharp edges. Any damage found should be immediately
reported.
2. If a valve assembly is required to be stored for a significant period
prior to installation it must be stored in a fire resistant, clean, dry
and ventilated environment to avoid damage to the valve, actuator or
accessories.
3. he end caps or other protection devices should not be removed from
the equipment until the time of installation, in order to help avoid
any damage to the flanges and also prevent the ingress of dirt or
foreign particles.
4. he adjacent pipework must be free of dirt, pipe scale, welding slag
and all other foreign objects. Safe operation of the valve could be
impaired by the ingress of line debris or foreign matter. It may be
necessary to remove the valve or internals if the pipework is to be
flushed prior to or during the commissioning period.
5. Sufficient clearance above and around the valve and actuator should
be provided for access and maintenance purposes.
>> 5. INSTALLATION
1. he valve is supplied with a flow direction arrow either cast on to the
body or detailed on the nameplate. It is very important that the valve
is installed into the pipework with the correct flow direction.
2. Install the valve using accepted piping practices and preferably with
suitable lengths of straight pipework both upstream and
downstream.
3. he preferred orientation is for the actuator to be vertically upright. If
a valve is required to be installed in any other orientation the valve
and actuator must be adequately supported.

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PVIM-725
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>> 6. MAINTENANCE
Maintenance such as diaphragm, gland packing or trim replacement can be
done without removing the valve from the line.
1. DIAPHRAGM REPLACEMENT
•Remove the diaphragm case nuts and bolts and Lift the op casing.
•Remove the Diaphragm.
2. REMOVAL OF ACTUATOR FROM VALVE
•Lift the valve plug off the seat ring and remove the stem coupling.
•Unscrew and remove the locking ring from the bonnet threads.
•Remove the actuator from the valve.
3. VALVE DISASSEMBLY
•Remove the gland nuts, gland flange and gland.
•Remove the body to bonnet stud nuts and lift the bonnet carefully off
the valve body while holding the stem ( to prevent the valve plug
assembly dropping out ).
•For cage guided valves remove the cage from the valve.
•Remove and discard the body to bonnet gasket(s).
•Withdraw the Complete Assembly of Cage, Seat & plug and stem
assembly out of the Body.
•Remove the packing set and spacer from the bonnet.
•All the parts should be cleaned and examined for damage.

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PVIM-725
4. VALVE ASSEMBLY
•New plugs are normally supplied complete with stems already fitted. If the replacement
parts are separate the stem should be screwed into the plug. Drill the plug and stem,
countersink the drilled hole, fit the pin and peen. he pin should then be machined
flush to the plug.
•Install the Seat, plug and stem assembly.
•Place a new gasket on the body and install the cage for cage guided valves.
•Lower the bonnet carefully over the plug stem and also over the body studs. he
bonnet should be centered to ensure that the plug and stem assembly moves freely.
•Fit the body stud nuts and tighten evenly. he plug and stem assembly should be
moved in a linear direction only to ensure that it moves freely.
5. PACKING BOX ASSEMBLY
•Ensure that the packing box and gland assembly components are all clean.
•A new stem packing should be fitted.
•Fit the spacer into the packing box.
•Fit the stem seal by individual rings ensuring that each ring is fully installed.
•Fit the gland follower ensuring that it enters the packing box by at least 3mm
•Place the gland flange onto the gland follower and evenly tighten the gland flange nuts.
6. SEAT AND PLUG LAPPING
•Lapping of the plug to seat (if required) should be carried out with the valve fully
assembled and without the actuator being fitted.
•Produce a lapping tool. One option is to weld a nut onto a bar, which matches the
stem thread.
•Apply a lapping compound to the seat seating surface only and apply a light oil in the
packing box area.
•Lap with short oscillating strokes.
•Lower the plug occasionally, raise it to another position and continue the oscillating
strokes to ensure an even lapping over the entire seating surfaces of the plug and seat.
•Disassemble the valve, clean the parts and reassemble the valve using the procedure
detailed in section 6.4.
7. FITTING ACTUATOR TO VALVE
•Lower the actuator over the plug stem and gland flange to seat squarely on the
valve bonnet.
•Rotate the actuator to the required position, screw the locking ring onto the
bonnet and securely tighten.
•o connect the actuator to the valve stem the valve plug must be on its seat and
the actuator in the lowest travel position. Apply one half of the stem coupling to
both the valve and actuator stem. Apply the second half of the coupling carefully
engaging the threads, then insert the coupling cap screws and hand tighten. he
actuator should then be lift off its seat and the plug stem rotate one full turn in
the coupling to provide a seating load. Securely tighten the coupling cap screws.
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8. FITTING ACCESSORIES
•Condensate pot Whenever requited shall be connected in between the feedback point on
the downstream line and the sensing diaphragm.
>> 7. TROUBLESHOOTING
PRV normally require seldom attendance, except for routine check .
SYMP OMS PROBABLE CAUSES CORREC IVE AC ION
Excessive
leakage
when valve
closed
Worn or damaged seat ring or
plug
Disassemble and replace damaged part as
detailed in maintenance manual
Actuator leakage Check for medium leaks with soapy water.
ighten or replace connection / seals.
Valve
operation
not smooth
Gland flange over tightened Loosen gland flange nuts and retighten to
finger tight
Alignment of valve and
actuator stem
Check actuator is square and tight on
bonnet mounting
Excessive
noise
Flashing or cavitations Check that trim is suitable for the
application. Refer to factory
Loose supports ighten the supports sufficiently
Damaged trim assembly Replace the trim parts

04/18 7 of 7
PVIM-725 Designed By : Rajesh
In order to avoid possible injury to personnel or damage to valve parts, WARNING and CAU ION notes must be
strictly adhered to. Modifying this product, substitution non- factory or inferior parts, or using maintenance
procedure other than outlined could drastically affect performance, void product warranties and be hazardous to
personnel and equipment.
While ordering spares, please indicate ‘ Valve Serial No.’ appearing on `Name Plate’ fixed on the Actuator.
he Company’s policy is one of continuous product improvement and the right is reserved to modify the
specifications contained herein without notice.
Plot No: A-35, Road No. 10,Wagle Industrial Estate,
hane – 400 604, India.
Phone: [phone], Fax : [phone]
E-Mail: [e-mail] Web: www. pneuconvalves.com
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UPSTREAM PRV WITHOUT
CONDENSATE
POT
UPSTREAM PRV WITH
CONDENSATE
POT