Spirax Sarco ABV21i User manual

IM-P405-46 EMM Issue 5 1
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
8. Fault finding
© Copyright 2017
Printed in GB
IM-P405-46
EMM Issue 5
4057650/5
ABV21i and ABV40i
Air Actuated Boiler Blowdown Valves
Installation and Maintenance Instructions

IM-P405-46 EMM Issue 52
1. Safety information
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11)
in compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of
tools and safety equipment must also be complied with.
WARNINGS
Before commencing any dismantling work on a boiler, depressurise, drain,
and vent the boiler to atmosphere.
Pipelines must be adequately isolated, depressurised, and drained. Isolation
valves must be turned on and off gradually to avoid system shocks.
Ball valves can trap pressurised media in the body, so make sure there is no
pressure to the valve body, or any pressure remaining in the body, before
loosening or removing the flange bolts. The actuator must belated both
pneumatically and electrically before any maintenance is carried out.
Do not attempt to service the actuator without first consulting the Installation
and Maintenance Instructions, as the end caps contain springs under pressure.
Failure to follow the instructions could result in injury. The actuator must be
vented before dismantling.
If the valve should seize in the partly open position, the springs in the actuator
will still be partly compressed, and will consequently be storing a large
amount of energy, which could cause injury if released suddenly. If there is
any possibility that this is the case follow the instructions given in the
'Maintenance' section of this booklet - 'Dismantling a seized valve assembly'.
Maximum supply pressure 8 bar g (116 psi g)
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended use / application.
The products listed below comply with the requirements of the European Pressure
Equipment Directive 2014/68/EU and carry the mark when so required.
The products fall within the following Pressure Equipment Directive categories:
Product Group 2
Gases
Group 2
Liquids
ABV21i and ABV40i
DN25 SEP SEP
DN32 SEP SEP
DN40 - DN50
ABV21i 1SEP
ABV40i 1SEP
DN65 1 SEP

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i) The products have been specifically designed for use on steam, compressed air,
water and other industrial fluids that are in Group 2 of the above mentioned
Pressure Equipment Directive. The products' use on other fluids may be possible
but, if this is contemplated, Spirax Sarco should be contacted to confirm the
suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products 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.
v) Remove protection covers from all connections and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.

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1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high / low temperature,
radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and / or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of these products
may reach temperatures of 260 °C (500 °F).
These products are not self-draining. Take due care when dismantling or removing
them from an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost
damage in environments where they may be exposed to temperatures below freezing
point.

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1.15 Safety information - Product specific
Hydraulic locking
Ball valves are prone to lock-up when used on certain heating / cooling applications
where both steam and liquid will pass through the valve. This is caused by liquid
trapped in the ball during closure being heated to create a high hydraulic pressure
inside the ball cavity. To prevent this, during manufacture, a minute hole is drilled
in the ball, so, that in the closed position, any excess pressure will be relieved. Spirax
Sarco ball valves for these applications are clearly marked to allow the valve to be
correctly installed, such that, when closed, the hole is facing the steam source.
1.16 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product
is recyclable and no ecological hazard is anticipated with its disposal providing due
care is taken.
1.17 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on any
hazards and the precautions to be taken due to contamination residues or mechanical
damage which may present a health, safety or environmental risk. This information
must be provided in writing including Health and Safety data sheets relating to any
substances identified as hazardous or potentially hazardous.

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2. General product information
2.1 General description
The Spirax Sarco ABV21i and ABV40i are one piece end entry, reduced bore ball valves
having ISO mounting as standard. They are fitted with a 90°rotary spring return pneumatic
actuator, and a limit switch box. They are used in conjunction with a Spirax Sarco blowdown
timer to provide timed control of bottom blowdown, ensuring that the recommended boiler
blowdown cycles occur with minimum heat loss, avoiding duplication or omission.
The valve is suitable for a maximum pressure of 17.25 bar g @ 208 °C (250 psi g at 406 °F).
A NAMUR (VDI / VDE 3845) solenoid valve is also required, and may be selected from the
Spirax Sarco MV range. Alternatively, an air supply (maximum pressure DN25 8 bar (116 psi),
DN32 to DN65 6 bar (87 psi)) may be connected directly to the actuator port 'A' (¼" BSP), for
applications where it is necessary to install the solenoid valve remote from the actuator.
A standard ¼" BSP 3-way solenoid valve may also be used.
ISO mounting
The integral ISO body mounting allows the valve to be automated without losing seal intregrity,
as the body does not require disassembly.
2.2 Product availability
Valve type Valve size Actuator Switch box
ABV21i and ABV40i
DN25 BVA315S /14 LSB31
DN32 BVA320S /14 LSB31
DN40 BVA325S /14 LSB31
DN50 BVA325S /14 LSB31
DN65 BVA330S /14 LSB31
2.3 Actuator
The actuator uses a rack and pinion system with a quarter-turn operation. A position indicator
is fitted to the top of the pinion shaft, below the switch box. BVA actuators are factory
lubricated, and do not require a lubricated air supply. The air must, however, be dry and clean.
Any other non-corrosive gas can be used as the operating medium.
2.4 Switch box
LSB limit switch boxes are normally used for indicating valve open or valve closed position.
They also allow switching points to be adjustable over the full range of actuators. There is an
open / closed valve position indicator mounted at the end of the switch box axis, at the top
of the cover. LSB's include a stainless steel linkage kit for direct mounting to BVA300 series
actuators.

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3/2
5/2
Fig. 1 ABV21i
Solenoid override screw
Fig. 2
Solenoid valve
MV11 / MV12 / MV11 / MV12
General view
Air inlet port
Use '3/2' adapter plate for this application
Inlet port 'A'
LSB31 limit switch box
BVA300 series pneumatic actuator

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The product must not be used in this region.
Valve
Body design conditions PN40
PMA Maximum allowable pressure 40 bar g @ 120 °C (580 bar g @ 248 °F)
TMA Maximum allowable temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)
Minimum allowable temperature -29 °C (-20 °F)
PMO Maximum operating pressure for
saturated steam service 17.25 bar g @ 208 °C (250 psi g at 406 °F)
TMO Maximum operating temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)
Minimum operating temperature -29 °C (-20 °F)
Note: For lower operating temperatures consult Spirax Sarco
PMX Maximum differential pressure is limited to the PMO
Designed for a maximum cold hydraulic test pressure of: 60 bar g (870 psi g)
Actuator
Maximum ambient temperature 80 °C (176 °F)
Minimum ambient temperature 0 °C (32 °F)
Maximum air supply pressure 8 bar g (116 psi g)
Minimum air supply pressure is dependant on operating conditions
MV series solenoid
Maximum ambient temperature 50 °C (122 °F)
Minimum ambient temperature 0°C (32 °F)
Temperature °C
Pressure bar g
Steam
saturation
curve
2.5 ABV21i - Pressure / temperature limits
Pressure psi g
Temperature °F

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2.6 ABV40i - Pressure / temperature limits
Steam
saturation
curve
Pressure bar g
Temperature °C
Pressure psi g
Temperature °F
The product must not be used in this region.
Valve
Body design conditions ASME 300
PMA Maximum allowable pressure 51 bar g @ 38 °C (739 bar g @ 100 °F)
TMA Maximum allowable temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)
Minimum allowable temperature -29 °C (-20 °F)
PMO Maximum operating pressure for
saturated steam service 17.25 bar g @ 208 °C (250 psi g at 406 °F)
TMO Maximum operating temperature 260 °C @ 0 bar g (500 °F @ 0 psi g)
Minimum operating temperature -29 °C (-20 °F)
Note: For lower operating temperatures consult Spirax Sarco
PMX Maximum differential pressure is limited to the PMO
Designed for a maximum cold hydraulic test pressure of: 76.5 bar g (1 109 psi g)
Actuator
Maximum ambient temperature 80 °C (176 °F)
Minimum ambient temperature 0 °C (32 °F)
Maximum air supply pressure 8 bar g (116 psi g)
Minimum air supply pressure is dependant on operating conditions
MV series solenoid
Maximum ambient temperature 50 °C (122 °F)
Minimum ambient temperature 0°C (32 °F)

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3. Installation
Note: Before actioning any installation read the 'Safety information' in Section 1.
Although the valve has great structural integrity, severe misalignment and/or the pulling
effect of incorrect pipe length will have a detrimental effect on the valve and must be avoided.
Particular attention should be paid to correct pipe alignment such that the inlet pipework and
valve are all on the same axis.
Wherever practicable, valves should be installed where there is adequate space available so
that they can be conveniently operated and maintained.
Before installing a valve, check to ensure that size, pressure rating, materials of construction,
end connections, etc. are suitable for the service conditions of the particular application.
Care must be taken to ensure that all dirt which may have accumulated in the valve during
storage is removed before installation, maintain cleanliness during installation since the
introduction of dirt can result in damage to the valve seats and operating mechanism. To
minimise the danger of abrasive particles damaging the seats, pipeline strainers should be
fitted upstream of the valves.
Install the valve with the actuator uppermost. The preferred position is with the stem vertical.
The air supply to the solenoid valve/actuator must be in 10 mm ( ") minimum diameter pipe.
The air inlet connection is ¼" BSP (G).
Table 1 Maximum air pressure
Valve size Actuator Maximum air pressure
DN25 BVA315S /14 8 bar g (116 psi g)
DN32 BVA320S /14 8 bar g (116 psi g)
DN40 and DN50 BVA325S /14 8 bar g (116 psi g)
DN65 BVA330S /14 8 bar g (116 psi g)
3.1 To fit an MV type solenoid assembly to the valve actuator:
-Turn the spring loaded solenoid override screw anticlockwise to release it for normal
working.
-Fit the screwed location pin from the MV kit in the top centre position above the actuator
ports (see Figure 3). Ensure the pin is screwed far enough into the actuator to allow a
good seal to be made i.e. that it is not holding the solenoid away from the actuator.
-Use the '3/2' adapter plate supplied with the solenoid assembly. Discard the '5/2' plate.
Note: Earlier versions used a double-sided plate. For this type, align the arrow on the
plate with the '3/2' on the valve assembly.
-Fit the solenoid assembly to the actuator using the 2 screws provided in the kit. Do not
overtighten the screws as this could distort the plastic body and prevent proper working.
-Connect the air supply to port 1 (¼" BSP). Note that port 3 is blanked for this application.
The unmarked port near the override screw is not connected in this application.
The solenoid override is operated by using a screwdriver to push the spring loaded plastic
screw inwards and turning it clockwise to lock it in the 'override' position. This bypasses
the solenoid and allows the ABV to be operated without an electricity supply. The screw is
released by turning it anticlockwise.