Spirax Sarco PV4 User manual

IM-IBR-P174-01-EN-ISS1 CMGT 1
IM-IBR-P174-01-EN-ISS1
CMGT (India)
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2018
Printed in India
PV4 and PV6
Piston Valves
Installation and Maintenance Instructions

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1. Safety information
Safe operation of these products can only be guaranteed if they are 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.
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 Indian Boiler
Regulations, 1950
i) The PV4 has been specifically designed for use on steam, air or condensate.
The PV4 and PV6 range have been designed for use on steam, air and water /
condensate. 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) A number of products are supplied for the intention of the end user (or agent
thereof) modifying the flange configuration from that supplied. It is the
responsibility of the organisation carrying out the modification to do so in
accordance with the internationally recognised flange standards and to ensure
that the design rating and operation of the product are not compromised. Spirax
Sarco will not be held responsible for any unapproved modification or
consequential liability resulting in failure to observe these requirements.
iv) Determine the correct installation situation and direction of fluid flow.
v) 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.
vi) 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.

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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.
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 the 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.

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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 some products
may reach temperatures in excess of 425 °C (797 °F) for PV4 and 538 °C (1000 °F)
for PV6.
Many products are not self-draining. Take due care when dismantling or removing
the product 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.
1.15 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.
1.16 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
Fig. 1 PV with screwed connections
2.1 General description
The PV4 and PV6 are piston isolation valves that have been designed for use on steam,
condensate and other liquid sytems.
Available types:
Screwed, butt weld
and socket weld
connections
PV4 Carbon steel body /bonnet and stainless steel internals
PV6 Stainless steel body / bonnet and internals
Standards
This product fully complies with the requirements of the Indian Boiler Regulations, 1950.
Note: All certification/ inspection requirements must be stated at the time of order placement.
Note: For further data regarding the PV range see Technical Information sheet TI-IBR-
P174-02-EN-ISS1.

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Date code
Fig. 2 Name plate
2.2 Sizes and pipe connections
½", ¾", 1", 1¼", 1½" and 2"
Butt welded ends to EN 12627:1999BW - ASME B16.25
Screwed BSP (BS 21 / DIN 2999) or NPT to (ASME B1.20.1)
Socket weld ends to ASME B 16.11
Product
material
type
Maximum
allowable
pressure
Maximum
allowable
temperature
Minimum
allowable
temperature
Connection type
to appear here
(see Table 1)
Pressure class
Æ20 area to
be clear of
engraving
Date code to appear here

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2.3 PV4 Pressure / temperature limits
The product must not be used in this region.
A - BScrewed, socket weld and butt weld
Body design conditions API Class 800
PMA Maximum allowable pressure 136 bar g @ 38 °C (1 972.5 psi g @ 100 °F)
TMA Maximum allowable temperature 425 °C @ 76 bar g (797 °F @ 1 102 psi g)
Minimum allowable temperature -29 °C (-20 °F)
PMO Maximum operating pressure for
saturated steam service 101 bar g (1 465 psi g)
TMO Maximum operating temperature 425 °C @ 76 bar g (797 °F @ 1 102 psi g)
Minimum operating temperature -29 °C (-20 °F)
Note: For lower operating temperatures consult Spirax Sarco
Designed for a maximum cold hydraulic test pressure: 204 bar g (2 958.8 psi g)
Pressure bar g
Steam
saturation
curve
Temperature °C
B
A
Pressure psi g
Temperature °F

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2.4 PV6 Pressure / temperature limits
The product must not be used in this region.
A - BScrewed, socket weld and butt weld
Body design conditions API Class 800
PMA Maximum allowable pressure 132 bar g @ 0 °C (1 914.5 psi g @ 32 °F)
TMA Maximum allowable temperature 538 °C @ 67 bar g (1 000.4 °F @ 971.7 psi g)
Minimum allowable temperature -29 °C (-20 °F)
PMO Maximum operating pressure for
saturated steam service 84 bar g (1 218 psi g)
TMO Maximum operating temperature 538 °C @ 67 bar g (1 000.4 °F @ 971.7 psi g)
Minimum operating temperature -29 °C (-20 °F)
Note: For lower operating temperatures consult Spirax Sarco
Designed for a maximum cold hydraulic test pressure: 198 bar g (2 871.8 psi g)
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Pressure bar g
Temperature °C
Steam
saturation
curve
A
B

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Note: Before actioning any installation observe the 'Safety information' in Section 1.
3. Installation
The valve can be installed
from the vertical to the
horizontal plane.
The valve can be installed
in vertical pipework.
The preferred orientation
for installation.
Fig. 3 Correct orientation for installation

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Fig. 4 Incorrect orientation for installation
3.1 Install the valve in the direction of flow given by the arrow on the body. The preferred
position is with the spindle vertical. The valve can be installed from the vertical to the
horizontal plane (see Figure 3 opposite). Do not mount the valve upside down
(Figure 4).
3.2 Wherever practicable, valves should be installed where there is adequate space
available so that they can be conveniently operated and maintained.
3.3 Before installing a valve, check to ensure that the size, pressure rating, materials of
construction, end connections, etc. are suitable for the service conditions of the
particular application. Remove any plastic plugs from the ports.
3.4 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.
3.5 When a socket weld valve is being installed the welding should be carried out to an
approved procedure to a recognised standard. During welding the valve should be in
the open position to allow maximum heat dissipation.
3.6 Ensure that the discharged flow is directed to a safe place.

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Note: Before actioning any maintenance programme observe the 'Safety information'
in Section 1.
6.1 General information
As with all mechanical devices, regular maintenance is the most efficient means of ensuring
continued operational efficiency.
Regular scheduled inspection of all valves is essential especially on valves which are operated
only occasionally. With a piston valve, the bonnet must be tightened down to prevent stem
gland seal leaks. Applying the recommended torque (see Table 1) to nut (10) will ensure any
steam leaks are avoided.
The piston valve is designed for either bonnet assembly replacement which includes all the
necessary internal parts, or simple in-line replacement of the upper and lower sealing rings.
Note: The valve spindle should be periodically checked (typically 12 months) to ensure
adequate grease is present to ensure efficient valve operation. Grease such as 'Never Seize'
is recommended. When fitted on high temperature applications or where severe weather
conditions prevail, the grease should be checked more regularly.
6. Maintenance
4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests
on any alarms or protective devices.
The Spirax Sarco PV4 and PV6 piston valves are operated manually by a handwheel.
Special care must be taken to ensure that the movement is made in the correct direction;
Anticlockwise to open - Clockwise to close.
To open the valve fully, turn the handwheel until the shaft is raised to the maximum position,
then turn the handwheel clockwise a ¼turn to remove any backlash. This is to prevent the
possibility of attempting to force open a valve, which is already fully open, resulting in damage
to the stem or other components.
Due to the unique design of the piston valve it is fully closed as soon as the piston engages
into the lower sealing rings. Therefore there is no need to continue closing the valve until the
spindle movement stops.
Note: The valve spindle should be periodically checked (typically 12 months) to ensure
adequate grease is present to ensure efficient valve operation. Grease such as 'Never Seize'
is recommended. When fitted on high temperature applications or where severe weather
conditions prevail, the grease should be checked more regularly.
Important: The use of a valve key is therefore not recommended or required. If the handwheel
is overtightened, damage to the valve internals may occur.
5. Operation

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6.2 How to replace the bonnet assembly and sealing rings:
-Close the piston valve.
-Remove the 2 x bonnet nuts (10) and 2 x washers (13).
-Withdraw the bonnet (2) complete with the piston (6).
-Remove the upper sealing rings (4), lantern bush (5) and lower sealing ring (3).
-Ensure the inside surfaces of
the valve are clean.
-Refit the new lower sealing
ring (2), lantern bush (4) and
the upper sealing ring (3).
-Refit the bonnet (2) complete
with the piston (6) and tighten
the bonnet nuts (10) to the
recommended torque (see
Table 1).
Fig. 5 PV4 (screwed) shown
10
6
2
4
13
5
3
Table 1 Recommended tightening torques
Item Size or
mm N m (lbf ft)
10
½"13 A / F 12 (9)
¾"13 A / F 9(7)
1" 13 A / F 9(7)
1¼" 17 A / F 30 (22)
1½"22 A / F 35 (26)
2" 26 A / F 70 (52)
Caution: The torque of the studs is calculated to optimise the use of the product. An
excessive torque can damage the valve internals (particulary if the product is open). The
studs of valve can be retightened to extend the life of it, but only when it is closed and not
more than the recommended torque.

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7. Spare parts
Spare parts are available as indicated below. No other parts are supplied as spares.
Available spares
Set of sealing rings 3and 4
Bonnet assembly 2,3,4,5,6,7,8 and 11
How to order spares
Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of valve.
Example: 1 - Bonnet assembly for a ½" Spirax Sarco PV4 (screwed) piston valve.
Fig. 6 PV4 and PV6 (screwed) shown
6
2
4
5
3
7
8 + 11

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