POLNA BR 33 User manual

CONTROL VALVE WITH ROTARY
PLUG
TYPE BR 33 (Z33)
with pneumatic actuators BR 99 (P/R 99)
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL

2 Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022)
TABLE OF CONTENTS
1. Principle of operation
2. Standard operating conditions
3. Storage and transport
4. Installation
5.
Start-up
6. Operation, maintenance and repair
7. Changing the KvS flow rate value
8. Changing the operation mode of the valve
9. Changing the actuator position in relation to the valve
10. Changing the internal characteristics of the valve
11. Spare parts list
12. Safety conditions for use
13. Product disposal
14. Figures
13. Additional requirements resulting from the equipment operation in an explosive
atmosphere in accordance with Directive 2014/34/EU (ATEX) )*
)* - No (Ex) designation on the product plate and page 2 of this manual means that the product
in the delivered condition must not be used in explosion-risk atmospheres.
DESIGNATION ........................................................................................
DN ............... PN (ANSI) TS ................................ °C
PT .............. . bar Pressure test date ...................................................
Body material ..........................................................................................
Category .............. Fluid group................. Liquid
☐
Gas
☐
Serial no./year of manuf. ...............................
............................................................. ..............................
Conformity marking QC mark
Caution:
1. The product is intended to be used within pipelines.
2. Prior to commencing installation and operation, read this manual carefully.

Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022) 3
1. PRINCIPLE OF OPERATION
The adjustment of the amount of working medium flowing through the valve is carried out
by rotating the valve plug connected with the actuator stem and connecting rod.
An input signal, i.e.:
a) in actuators with pneumatic positioner, compressed air with a pressure range of
20...100 kPa
b) in actuators with electro-pneumatic positioner, current signal 4...20 mA, causes the
valve stem with plug to move through the system of two angular levers. The rotation angle
is proportional to the input signal. Actuators can be equipped with limit switches and 4...20
mA position transmitter.
2. STANDARD OPERATING CONDITIONS
Control valves should be operated in conditions whose parameters comply with
parameters assumed for calculation of values and defining the structural and material type
of a valve.
In order to ensure problem-free operation throughout the entire operation period, the
control valve, including its fittings and equipment, must be protected against impact and
damage, and subjected to regular maintenance and periodical inspections.
Additional operating conditions:
- ambient temperature from -40 to + +80°C;
- relative humidity up to 98%
- supply and control air should not contain any mechanical impurities, oil and substances
causing corrosion of steel, copper and alloys; it must be dried so that the dew point is
equal to temperature lower than the minimum operating temperature of the positioner
by at least 10°C;.
3. STORAGE AND TRANSPORT
Control valves should be stored in closed, dry and airy storage rooms with relative humidity
not exceeding 80%. The room atmosphere must be free of vapours and aggressive gases.
Valves can be transported by any covered means of transport, with or without packaging,
with necessary protection against impact, tipping over and excessive vibrations. While
packing, loading or unloading, valves should be handled using flexible clamping rings (e.g.
rubber V-belts) wrapped around valve body flanges and actuator housing (through an eye
bolt - for pneumatic actuators).
4. INSTALLATION
Prior to assembling the valve with a pipeline, carefully remove all impurities, metal chips,
rust, welding and mill scale, fats and grease as well as other foreign bodies from the
pipeline. The valve must be installed in such a manner that the direction of the working
medium flow conforms to the direction defined by the arrow located on the valve body. The
working pressure of the medium flowing through the valve must conform to the content

4 Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022)
assumed to determine the nominal pressure, as specified on the valve rating plate. In case
the valve nominal diameter is smaller than the pipeline diameter, apply reducing pipes of
length conforming to applicable standards. In such cases, avoid using reducing pipe
connectors, e.g. threaded, screw-in/screw-out and other pipe connectors. In cases
particularly vital for the process system, install a by-pass system consisting of three
additional valves facilitating isolation of the control valve from the system (to perform
repairs, grind in the seats, replace parts) without interrupting the operation.
NOTE!
The allowed position of the control valve is with the stem vertically up. In justified
cases, it is possible to install a valve with a permissible deviation from the vertical
by ±30°. Other positions may cause uneven and accelerated wear of internal parts
of the valve (plug, seat, stem, guide sleeve) and seals. If it is necessary to use a
different position of the valve on the pipeline than the permitted one, it is obligatory
to consult the valve manufacturer. Without the approval of the manufacturer, an
unauthorised installation position will result in the loss of the warranty.
5. START-UP (Figure: 1)
Prior to process installation commissioning, check the operation of the valve installed. To
this end, activate an actuator and check if the valve stem (10) moves smoothly without
jamming, within the entire range of the rotation angle. During technological start-up, the
bonnet seals (23) can be slightly pressed by tightening the bonnet nuts (29), until
necessary tightness within the plug stem is obtained.
6. MAINTENANCE AND REPAIRS
Maintenance of the control valve during operation consists in ensuring correct tightness
of the valve stem in the bonnet. Tighten the sealing pack periodically by tightening the
nuts (29).
If the pressure sleeve (16) rests against the upper surface of the bonnet, remove the
sleeve and add at least one seal. After installation, adjust the pressure to obtain a tight
seal.
As necessary, the scope of maintenance and repairs must include:
- cleaning the valve and assessing the wear and tear of components;
- replacing the plug and seats
- replacing the valve bonnet seals
- replacing the actuator diaphragm;
6. 1 Disassembly of the valve (Figure: 1)
During the disassembly of the valve, all protective measures required for a given medium
should be taken. The valve should be thoroughly cleaned of residues of the flowing
medium.
Each time, during a periodical inspection, the following actions must be taken to clean,
inspect or repair the valve:

Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022) 5
a) disconnect the lines supplying the input signal to the actuator and remove the valve
from the system,
b) disconnect the connection of the valve stem with the actuator connecting rod by
removing the screws (26C) in the coupling (26),
c) remove the screws (154) securing the actuator yoke to the valve body and remove the
actuator from the valve,
d) remove the screw plug (8) using a special wrench and remove the socket (6) so as not
to damage its seating surfaces,
e) disconnect the connection of the valve stem (10) with the bridge (2) by turning the
valve stem by 90° and knocking out the conical pin (20),
f) remove the nuts (29), the pressure lever (15) and the valve stem,
g) remove the pressure sleeve (16), the sealing package (23), the lubricating sleeve (18)
or the spacer sleeve (17) and the stem guide sleeve (13),
h) remove the bridge (2) with the plug (4) by lifting it slightly upwards and extending it to
the opposite side of the seat,
i) remove the plug guide sleeve (12),
j) disconnect the plug-bridge connection by knocking out the cylindrical pin (21).
6.2 Replacing the valve seat (Figure: 1)
If excessive internal leaks are found, it is necessary to replace the seat. To do this, after
removing the valve according to 6.1. a, b, c, d it is necessary to:
a) insert a new seat and centre it on the valve plug (valve in closed position) while holding
the valve stem with your hand,
b) pre-tighten the seat with the screw (8),
c) set the valve plug in the open position and tighten the screw plug (8) with a wrench.
NOTE! Before screwing in the screw plug (8), lubricate its thread with a thin layer of
sealing and anti-seizing paste (e.g.: LOCTITE 767).
6.3 Replacing the plug (Figure: 1)
In case the plug face is excessively worn out or the profile section is eroded, the head
must be replaced.
The plug is replaced after dismantling the valve according to point 6.1.
6.4 Replacing the valve bonnet seals (Fig: 1)
In case adding single seals to the bonnet chamber is insufficient or it is necessary to
change the sealing type, the entire packing must be replaced. For this purpose, after
removing the valve according to 6.1. a, b, c it is necessary to:
a) remove the nuts (29), take off the pressure lever (15),
b) remove the pressure sleeve, sealing package, lubricating sleeve;
c clean the bonnet chamber,
d insert a set of new gaskets and other parts in the correct order into the bonnet
chamber,

6 Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022)
e) press the gaskets evenly by tightening the nuts (29) and assemble the valve in
reverse order of disassembly,
NOTE! The final adjustment of the sealing package pressure is made during the
start-up of the repaired valve.
6.5 Disassembly of the actuator (Figures: 1,2)
Each time, during a periodical inspection, the following actions must be taken to clean or
repair the valve:
a) disconnect the lines supplying the input signal to the actuator and the supply air and
remove the actuator from the valve according to 6.1 b, c,
b) remove the front plate (14A and 14B). To do this, use a thin screwdriver to pry the
protective plugs (45), remove the screws below them (47) and remove the plugs (46),
c) remove the screws (30) with nuts and washers, remove the upper housing (5) and
remove the diaphragm (74),
d) remove the cap (66) and unscrew the nut (41). Hold the diaphragm plate (36) lightly
until the spring is completely relaxed. Remove the diaphragm plate, spring (73) and
washers (43),
e) remove the BR92 positioner with a set of limit switches if the actuator is equipped with
them,
f) remove the caps (65), remove the spring ring from the bearing pin (72), remove the
pressure screw (50), lightly knock out the pin from the actuator body and remove the
lever (38) together with the stud screw (76),
g) disassemble the connector unit (26) and carefully hitting the connecting rod face (3)
with a copper punch, knock it out of the actuator body,
h) remove the sealing ring (55) and replace it if worn.
6.6 Replacing the diaphragm (Figure: 1, 2)
To replace a worn diaphragm, follow these steps:
a) disconnect the air supply lines to the actuator,
b) remove the upper housing (5) according to 6.5c and remove the worn diaphragm,
c) install a new diaphragm with the fabric side onto the diaphragm plate and install the
upper housing.
6.7 Disassembly of the actuator manual drive
6.7.1 Disassembly of manual drive in BR 99-1 actuators (Figure: 2) After removing the
ring (153) and ring (151), unscrew the drive screw (150) with the drive gear (101) from
the actuator body.
6.7.2 Disassembly of manual drive in BR99-2 and BR99-3 actuators. After removing the
four screws, remove the manual drive from the actuator body.

Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022) 7
7. CHANGING THE Kv
s
FLOW RATE VALUE (Figure: 1.2) The design of the actuator
allows you to change the Kv
s
flow rate value without the need to replace the plug and seat.
The change in the flow rate value can be made in the range of 45%, 75%, 120% of the
nominal KV
s
.
Flow rate values are given in the data sheet. To change the flow rate:
a) remove the actuator front plate (14A and 14B). To do this, use a thin screwdriver to pry
the protective plugs (45), remove the screws below them (47) and remove the plugs
(46),
b) apply the pressure on the actuator diaphragm or open the valve using a manual drive,
c) unscrew the groove nut (44), move the pin (62) to the desired KVs position according
to the marking on the lever (38), tighten the groove nut (44) and reinstall the face plate
(14A and 14B).
8. CHANGING THE VALVE OPERATION MODE (Figures: 1,2,3)
The reversible design of BR33 actuators allows to change the operation mode of the valve
assembled with this actuator from - "increase in the control air pressure OPENS" to -
"increase in the control air pressure CLOSES" and vice versa.
To do this, change the operation mode of the actuator. After removing the actuator
according to 6.5 a, b, c, d it is necessary to:
a) remove the screw (51), take off the travel indicator (19), remove the spring ring (36 fig.
3) unscrew the screws (30 fig. 3) securing the positioner cam, remove the feedback
lever (4 fig. 3) from the fork pin (77) and remove the pin,
b) pull out the stud screw (76) together with the fork (78),
c) remove the caps (60) and insert it into the hole in the body on the opposite side of the
actuator,
d) connect the stud screw and the fork with the pin lever (77) on the free side of the
actuator and secure with the slotted set screw (49),
e) place the feedback lever, turn the positioner cam so that the measuring spring (20 fig.
3) at increasing pressure in the actuator diaphragm chamber is always tensioned, place
the travel indicator and screw in the screw (51),
f) install the other components of the actuator.
9. CHANGE THE POSITION OF THE ACTUATOR WITHIN THE VALVE (Figure: 1)
The design of the actuator allows to change its position in relation to the valve by 90°
without the need to remove the actuator or valve.
To do this, loosen the fastening screws of the connector unit (26), unscrew the screws
fixing the actuator yoke (9) to the valve body, move the actuator to the desired position
and tighten the screws.
10. CHANGE OF INTERNAL VALVE CHARACTERISTICS (Figure: 3) BR33 valve has
internal characteristics similar to equal-percentage in the range of opening angles up to

8 Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022)
30°, and to linear in the range of opening angles 30...90°.
When using the BR 99-2 positioner, it is possible to select the linear or equal-percentage
internal valve characteristics in the entire valve opening angle range. This is carried out by
appropriate installation of the cam in the positioner. After dismantling the actuator
elements as in 6.5.b it is necessary to:
(a) unscrew and remove the screw (30) with washer (31), remove the spring ring (36) and
reverse the cam (6);
b) install the spring ring, screw in the screw (30) set the cam to the desired characteristics,
making sure that the tension spring (20) is tensioned when the air pressure in the
actuator diaphragm chamber increases;
c) adjust the positioner according to its operating instructions;
d) assemble the actuator components in reverse order of removal
11. LIST OF SPARE PARTS
11.1 Valve spare parts
Drawing number Part name Number of parts
4 Plug 1
6 Seat 1
12 Plug guide sleeve 1
13 Stem guide sleeve 1
23 Packing 1
11.2 Actuator spare parts.
Figure number Part name Number of parts
44 Grooved nut 1
54 Ball bearing 1
55 Sealing ring 1
58 Needle bearing 1
74 Diaphragm 1
12. OPERATION SAFETY CONDITIONS
The following rules must be adhered to in order to ensure operation safety:
- the valve can be detached from a pipeline or parts coming into contact with a medium
can be dismantled not before the user ensures that these elements are no longer under
the medium pressure.;
- the actuator springs are under tension and, when removing the diaphragm plate (39),
hold it by hand until the springs are completely relaxed.
- other operating hazards are marked with “!” in this document.

Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022) 9
13. PRODUCT DISPOSAL
After the product life is over, it must be dismantled and its components must be grouped
according to their materials, i.e. metal components (non-ferrous metals, acid-resistant and
carbon steels), rubber components (diaphragms, seals) and plastic components (plat
seals and packing, electric components, plugs). Recycled materials must be reused in line
with general rules regulating individual groups of materials.
The product does not contain materials whose disposal is harmful for the environment.
14. FIGURES
14.1. Designations and names of valve parts.
Figure number Part name
number of
pcs. Figure number Part name
number of
pcs.
1 Body 1 16 Pressure sleeve 1
2 Bridge 1 17 Distance sleeve 1
4 Plug 1 18 Lubricating sleeve 1
6 Seat 1 20 Conical pin 1
8 Plug screw 1 21 Cylindrical pin 1
10 Shaft 1 23 Packing 5(10)
12 Plug guiding sleeve 1 27 Spring washer 2
13 Stem guiding sleeve 1 28 Stud bolt 2
15 Pressure lever 1 29 Nut 2
14.2. Designations and names of actuator parts.
Number
in Fig. Part name
Number
of
pieces
Number
in Fig. Part name
Number
of
pieces
3 Connecting rod 1 54 Ball bearing 1
5 Top housing 1 55 Sealing ring 1
7 Body 1 56 Spring ring 2
9 Yoke 1 57 Spring ring 2
11 Bearing sleeve 1 58 Needle bearing 1
14A Front plate with nameplate 1 59 Washer 1
14B Front plate (plexiglass) 1 60 Cap 1
19 Stroke indicator 1 61 Cylindrical head screw 4
22 Faceplate seal 1 62 Pin 1
24 Safety plate 1 63 Pipe plug 1
25 Security plate seal 1 64 Cap 2
26 Connector unit 1 65 Cap 2
26C Seat screw 4 66 Cap 1
30 Screw 6 67 Cap 3
31 Nut 6 68 Cap 2
32 Washer 6 69 Cap 2
33 Spring washer 10 70 Bonnet 1
34 Seat screw 4 71 Sliding sleeve 2
35 Cross hole screw 2 72 Bearing pin 1
36 Low nut 2 73A Spring I 1

10 Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022)
37 Seat screw 3 73B Spring II 1
38 Lever 1 74 Diaphragm 1
39 Diaphragm plate 1 75 Cheese head screw 1
40 Spring washer 3 76 Stud bolt 1
41 Nut 2 77 Fork pin 1
42 Nut with flexible insert 1 78 Fork 1
43 Washer 2 79 Groove pin with a round head 1
44 Grooved nut 1 101 Wheel 1
45 Plug 4 103 Counter lever 1
46 Plug 4 150 Manual drive screw 1
47 Tapered head screw 4 151 Ring 1
48 Washer 2 152 Ball 1
49 Pressure screw with seat 1 153 Ring 1
50 Pressure screw with seat 1 154 Screw 4
51 Cylindrical head screw 1 155 Spring washer 4
52 Spring housing 1 156 Washer 4
53 Sliding bearing 2 157 Nut 4

Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022) 11
Fig. 1 Valve and actuator cross-section

12 Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022)
Fig. 2 Actuator cross-section
hole for external adjustment
of the positioner
stroke limiter
external stroke limiter
manual drive
(on request)

Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022) 13
Fig. 3 View of BR 99-2 positioner
14.2 Positioner part designation and name.
Figure number Part name Number of parts
4 Lever 1
6 Cam 1
20 Spring 1
30 Screw 1
31 Washer 1
36 Spring ring 1

14 Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022)
13. ADDITIONAL REQUIREMENTS RESULTING FROM EQUIPMENT OPERATION IN
EXPLOSIVE ATMOSPHERES, AS PER 2014/34/EC (ATEX) DIRECTIVE
13.1. Design requirements
The valves type "BR33" with pneumatic rotary actuators type 99 have been designed in
line with the requirements applicable to equipment operating in explosive atmospheres,
for Group II, Category 2, as per PN-EN 13463-1; 2002, with particular consideration of:
- ensuring operation in line with technical parameters defined by the manufacturer and
high level of protection,
- - operation in rooms where explosive atmospheres caused by mixtures of air with gases,
mists, vapours or dust-air mixtures are likely to occur,
- providing explosion protection measures ensuring a high degree of protection, even in
the event of frequent problems and faults.
13.2. Application requirements
The valves "BR33" with pneumatic rotary actuators type 99 made with marking (Ex) can
be used for operation in the following zones, as per PN-EN 1127-1; 1997:
a) Zone 1 for gases/vapours including locations in which explosive atmosphere may
sometimes occur during standard operation; the Zone may encompass, e.g.:
- direct vicinity of Zone “0”;
- direct vicinity of locations where raw materials are supplied or elements are filled
and emptied;
- direct vicinity of equipment vulnerable to damage or insufficiently protected
seals.
b) Zone 2 for gases / vapours covering places where the explosive atmosphere does not
occur during normal operation or in case of occurrence takes a short time.
This Zone may include, e.g. the vicinity of Zone “0” and “1”.
c) Zone 21 for dust including locations in which explosive atmospheres in the form of a
flammable dust cloud in the air may sometimes occur during standard operation and may
include, e.g. locations in the direct vicinity of facilities where the dust is loaded/unloaded
and locations with dust layers which, during standard operation, may create flammable
mixtures of dust with air, within explosive concentration limits.
d) Zone 22 for dust including locations in which explosive atmosphere in a form of
flammable dust cloud in the air does not occur during standard operation or it occurs for
limited periods of time. This Zone may include, e.g. locations in the direct vicinity of
equipment where dust may accumulate or be released.
e) In case the explosive atmosphere comprises acetylene, carbon disulphide, hydrogen,
hydrogen sulphide or ethyl oxide, the actuator non-pressure (spring-actuated) chamber
must be connected by means of piping with non-explosive atmosphere in order to eliminate

Control valves type BR33 (Z33) Edition BR33(Z33)/11/2022) 15
the risk of explosion caused by mechanically induced sparking, e.g. in case the spring
breaks.
13.3. Repair and maintenance requirements
While performing inspections, repairs and maintenance activities in explosive
atmospheres, ensure safety conditions relating to the used tools and zones in which they
can be utilised in line with EN 1127-7, Annex A.

Manufacturer & Distributor:
ZAKŁADY AUTOMATYKI „POLNA” SA
ul. Obozowa 23 37 - 700 Przemyśl
Phone: [phone]; Fax: [phone]
Edition BR33 (Z33)/11/2022