VALSTEAM ADCA PS130 User manual

VA L STEAM
ADCA
We reserve the right to change the design and material of this product without notice.
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22
PS130
INSTALLATION AND MAINTENANCE INSTRUCTIONS
SANITARY PRESSURE
SUSTAINING VALVE

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22
GENERAL INFORMATION
• These instructions must be carefully read before performing any work involving
VALSTEAM ADCA products. Failure to observe these instructions may result in
hazardous situations.
• These instructions describe the entire life cycle of the product. Keep them in a
location that is accessible to every user and make these instructions available to
every new owner of the product.
• Current regional and plant safety regulations must be considered and followed
during installation, operation, and maintenance work.
• The images shown in these instructions are for illustration purposes only.
• For the problems that cannot be solved with the help of these instructions, please
contact VALSTEAM ADCA or its representative.
VALSTEAM ADCA ENGINEERING S.A
Zona Ind. da Guia
Pav.14 - Brejo
3105-467 Guia, Pombal
PORTUGAL
[email protected]
We reserve the right to change the design and material of this product without notice.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22
CONTENT
1. SAFETY INFORMATION 4
1.1. Explanation of symbols 4
1.2. Intended use 4
1.3. Qualication of personnel 5
1.4. Personal protective equipment 5
1.5. The system 5
1.6. ATEX 6
1.7. General safety notes 6
2. PRODUCT INFORMATION 8
2.1. Principle of operation 8
2.2. Certication 9
2.3. Product identication 10
2.4. Technical data 10
2.5. Factory assembly and cleaning 10
3. TRANSPORT, STORAGE AND PACKAGING 11
4. INSTALLATION 12
4.1. Preparation for installation 13
4.2. Installation procedure 14
5. START-UP 14
5.1. Preparation for start-up 14
5.2. Start-up procedure 15
6. OPERATION 16
7. SHUTDOWN 16
7.1. Shutdown procedure 16
8. PARTS LIST 17
9. MAINTENANCE 19
9.1. Maintenance procedure 19
9.2. Replacing the diaphragms and plug assembly 19
9.3. Tightening torques 20
10. TROUBLESHOOTING 20
11. DISPOSAL 21
12. RETURNING PRODUCTS 21

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 4
1. SAFETY INFORMATION
1.1. Explanation of symbols
Hazardous situation which, if not avoided by applying the correct preventive
measures, will result in fatal or serious injury and/or considerable damage to
property.
DANGER
Hazardous situation which, if not avoided by applying the correct preventive
measures, could result in fatal or serious injury and/or considerable damage
to property.
WARNING
Hazardous situation which, if not avoided by applying the correct preventive
measures, could result in moderately severe or minor injury.
CAUTION
Situation which, if not avoided, can result in property damage or product
malfunction.
NOTICE
Indicates additional information, tips and recommendations.
NOTE
1.2. Intended use
Refer to the markings on the device, such as nameplate and laser markings, Information
Sheet (IS) and these Installation and Maintenance Instructions (IMI) to check that the
product was designed for the intended use and meets the specications used for sizing
and selection. This includes checking application, material suitability, process medium,
pressure and temperature as well as their respective limiting values.
VALSTEAM ADCA does not assume any responsibility for damage resulting from
inappropriate use of the product, damage caused by external stresses or any other
external factors. Correct installation of the product is the full responsibility of the contractor.
Inappropriate use of the product is any use other than the one described in this chapter.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 5
Inappropriate use also includes:
• Use of spare parts which are not genuine;
• Performance of maintenance work not described in these instructions;
• Use outside the limits dened by the accessories connected to the product.
• Unauthorized modications to the product.
If the product is to be used for an application or with a uid other than the one it was
designed for, contact VALSTEAM ADCA.
1.3. Qualication of personnel
Handling, installation, operation and maintenance work must be carried out by fully
trained and qualied personnel, capable of judging the work which they are assigned
to perform and recognizing potentially hazardous situations. They should be trained to
properly use this product according to these Installation and Maintenance Instructions.
Where a formal “Permits to Work” system is implemented in the plant it must be complied
with.
1.4. Personal protective equipment
Personal protective equipment should always be worn during work in order to protect
against hazards posed by e.g. the process medium, dangerous temperatures, noise,
falling or projected objects, working at height. These equipment includes a helmet, safety
glasses, safety harness, protective clothes, safety shoes, hearing protection, etc.
Always assess whether you or others in your vicinity require any protective
equipment. When in doubt check with the plant’s health & safety responsible
personnel for details on required protective equipment.
NOTE
1.5. The system
The complete system should be assessed as well as every action (e.g. closing of shut-
o󰀨 valves, disconnection of the power supply) to ensure this will not bring additional risk
to personnel or property.
Dangerous actions that can result in a hazardous situation include isolation of protective
devices such as safety valve, vents, vacuum relief valves, disconnection of electric safety
devices, sensors and alarms.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 6
1.6. ATEX
If the product is in the scope of the ATEX 2014/34/EU directive and as such bears the Ex
marking, consult its specic Additional Instructions for use in Potentially Explosive Areas
(IMI EX). In such cases, handling, installation, operation and maintenance work must
only be performed by personnel qualied and authorized to work in potentially explosive
areas.
1.7. General safety notes
RISK OF BURSTING IN PRESSURE EQUIPMENT
Valves, ancillaries and pipelines are pressure equipment. Working above
their operating limits or improper opening can lead to component bursting.
• Observe the maximum operating limits of the product and check if they are
lower than those of the system in which it is being installed. Check the product
Information Sheet (IS).
• Install a safety device.
• Before starting any work on the product, depressurize it and cool or heat it up
to ambient temperature. This also applies to the line in which it is tted.
• Drain the process medium from the product and all the relevant plant sections.
DANGER
RISK OF BURNS
Depending on the operating conditions, products and pipelines may get very
hot or cold and cause burn injuries.
• Do not touch the product while it is hot or cold, allowing it rstly to cool down
or heat up.
• Wear protective clothing and safety gloves during working operation.
• Thermally insulate tubes and product’s as a preventive measure.
RISK OF INJURY CAUSED BY FLUID ATTACK ON PRODUCTS
MATERIALS
The product must only be used with mediums that do not attack the materials
of the product (body, gaskets, seals). Otherwise, leaks may occur, and hot
and/or hazardous uid can escape.
• Do not use the product with mediums other than the ones it was designed for.
Check section 1.2 - Intended Use.
• Prevent medium contamination.
WARNING

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 7
RISK OF INJURY CAUSED BY UNDER TIGHTENED PRODUCT OR
ITS COMPONENTS
Excessively low tightening torques may cause medium to escape or and/or
components to be projected at high speed which may result in a hazardous
situation depending on the medium, chemical properties and/or its operating
conditions.
• Do not loosen any screw while the equipment is pressurized.
• Observe the specied tightening torques on these Installation and Maintenance
Instructions. If the relevant torque value is not mentioned contact VALSTEAM
ADCA.
RISK OF HEARING LOSS
Depending on the operating conditions, the product may generate loud
noises.
• Wear hearing protection when in the vicinity of the product.
RISK OF INJURY AS A RESULT OF ILLEGIBLE INFORMATION
Important information written in the product nameplate, markings and warning
signs may wear overtime or get illegible due to e.g. dirt accumulation, resulting
in hazardous situations and personal injury or property damage.
• Keep nameplates, markings and warning signs in a legible state, replacing
when illegible, missing or damaged.
RISK OF INJURY DUE TO VENTING IN SPRING LOADED
REGULATORS
Spring loaded regulators with self-relieving option and without captured vent
will vent the medium to the atmosphere through the cover.
• When working with hazardous uids in regulators with self-relieving option
make sure it is also tted with captured vent/leakage line connection directed
to a safe place.
WARNING
RISK OF INJURY DUE TO RESIDUAL PROCESS MEDIUM
Direct contact with dangerous process medium may lead to personal injury,
e.g. smoke inhalation and chemical burns.
• Drain the process medium from the product and all the relevant plant sections.
• Wear protective clothing, safety gloves, mask, and eye protection.
CAUTION

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 8
RISK OF INJURY DUE TO IMPROPER HANDLING
Manual handling (e.g. lifting, carrying, pushing, pulling) of large and/or heavy
products may result in personal injury.
• Assess the risk associated with the handling task.
• Use adequate handling methods and appropriate auxiliary handling equipment.
CAUTION
RISK OF PRODUCT DAMAGE DUE TO EXCESSIVELY HIGH
TIGHTENING TORQUES
High tightening torques may lead to premature wearing of product components.
• Observe the specied tightening torques on these Installation and Maintenance
Instructions. If the relevant torque value is not mentioned contact VALSTEAM
ADCA.
NOTICE
2. PRODUCT INFORMATION
The ADCAPure PS130 is a direct acting, diaphragm sensing pressure sustaining valve.
This spring-loaded regulator is designed for use with clean air, nitrogen, carbon dioxide,
oxygen, argon and other gases or liquids compatible with the construction materials and
valve design. This model is available with ASME BPE, DIN and ISO clamp ferrules or
tube weld (ETO) ends connections.
2.1. Principle of operation
The function of a pressure sustaining
valve, also commonly referred to as a back
pressure regulator, is to limit and control
upstream pressure of a medium to a specic
adjusted set point. The regulator will open in
case of excessive upstream pressure and
close when the pressure drops below the
set point.
During start-up the upstream pressure
(P1) is immediately supplied to the
sensing chamber. Here it acts below the
diaphragms (15, 16) applying a force Fs
that pushes the plug (5) upwards, opening
the valve and admitting process medium
to the downstream pipework, increasing
P2
FS
FS
FL
P1
21
26
15
5
Fig. 1
16

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 9
downstream pressure (P2).
Clockwise rotation of the adjustment knob (26) allows setting of the desired set pressure,
by compressing the adjustment spring (21) and increases the loading force FL. When
the loading force exceeds the counteracting force Fs, the valve closes.
When upstream pressure (P1) rises, the force it applies on the lower side of the diaphragm
increases. The valve opens as a result, exhausting the excess pressure above the set
point after which the plug will reseat and the valve will close once again.
A pressure sustaining valve is not a shut-o󰀨 device and as such there is
almost always a small amount of leakage between seat and plug. For this
reason, a shut-o󰀨 valve should be used downstream of the regulator when
isolation is required.
NOTE
A pressure sustaining valve is not by any means a safety relief valve. A safety
relief valve is a safety device designed to protect system and personnel
from overpressure via rapid exhaust of pressure as it “pops-up” wide open.
A pressure sustaining valve on the other hand senses upstream pressure
changes and reacts porportionally by closing or opening.
NOTE
2.2. Certication
This product has been specically designed for use with liquids and gases which are
in Group 2 of the European PED – 2014/68/EU Pressure Equipment Directive and it
complies with its requirements.
PS130 – CE MARKING – GROUP 2 (PED – European Directive)
PN 16 Category
All sizes SEP
If the product falls within category SEP it must not be CE marked, unless
other directives are applicable.
NOTE
This product is not in the scope of the ATEX 2014/34/EU directive as it does not have its
own potential ignition source. Personnel responsible for the plant installation must assess
the risks caused by static electricity and take the necessary precautionary measures to
prevent static charge. These measures include e.g. connection of the product to the
equipotential bonding system.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 10
The product has been designed in accordance with ASME BPE and EHEDG guidelines.
The product surface nishing conditions and non-metallic material approvals such as
FDA and USP CL. VI are detailed in the ADCAPure specic inspection certicate.
Refer to IS PV20.00 Technical Information Sheet - ADCAPure for further information.
2.3. Product identication
The following items are indicated on the product nameplate or directly on its body:
• Manufacturer
• Product model (e.g. PS130)
• Pressure rating (e.g. PN 16) or maximum allowable pressure (e.g. Pmax = 16 bar)
• Nominal size (e.g. TC 1/2" BPE)
• Min. operating temperature (e.g. Tmin = -10 ºC)
• Max. operating temperature (e.g. Tmax = 150 ºC)
• Flow direction (indicated by an arrow)
• Serial number and year of manufacturing (e.g. Reg.:17483/19)
• CE Marking (when applicable – see section 2.2 – Certication)
• EX Marking (when applicable e.g. EX h IIB T6…T3 Gb – see section 2.2 –
Certication)
2.4. Technical data
For technical data including dimensions, materials, limiting conditions and versions refer
to the product respective Information Sheet (IS).
2.5. Factory assembly and cleaning
Assembly of the product is performed in a certied clean room according to ISO 14644-1
and all its components are cleaned and, when admissible, degreased and passivated.
Such operations are performed in accordance with certied procedures and rigorous
control.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 11
3. TRANSPORT, STORAGE AND PACKAGING
RISK DUE TO FALLING LOADS
Loads may tip or fall over resulting in demage to property, serious injury or
death.
• Use suitable equipment when moving or lifting suspended loads.
• Make sure no one is standing below the suspended load.
WARNING
RISK OF INJURY DUE TO IMPROPER HANDLING
Manual handling (e.g. lifting, carrying, pushing, pulling) of large and/or heavy
products may result in personal injury such as back injury.
• Assess the risk associated with the handling task.
• Use adequate handling methods and appropriate auxiliary handling equipment.
CAUTION
RISK OF PRODUCT DAMAGE DUE TO IMPROPER STORAGE
• Do not remove any packaging or protective covers until immediately before
installation at the site.
• Store the product in a solid base in a dry, cool and dust-free environment.
• Until its installation, protect it from the weather, dirt, corrosive atmospheres and
other harmful inuences.
RISK OF PRODUCT DAMAGE DUE TO LONG TERM STORAGE
Some product components may deteriorate with time (e.g. valve packings,
seals).
• Do not store the product for more than 12 months.
• If for any reason the product must be stored for longer periods of time contact
VALSTEAM ADCA.
NOTICE
The product is end capped and sealed with recyclable thermo shrinkable plastic lm
inside the clean room where it was assembled to prevent contamination as it leaves the
clean environment. The product is stored in a cardboard box as it leaves VALSTEAM
ADCA. Avoid removing packaging, covers and sealings until immediately before installing
the product at the site.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 12
If the transport packaging has any shipping damage contact VALSTEAM
ADCA or its representative.
NOTE
Before storing and transporting the product protect it from impacts and mechanical
damage, paying special care with sealing surfaces and other fragile parts.
4. INSTALLATION
Before performing any installation work, refer to section 1 – Safety information.
RISK OF INJURY DUE TO INSUFFICIENT SUPPORT
DURING INSTALLATION
Insu󰀩cient support of the product during installation may cause it to fall and
cause personal injury.
• Ensure the product is safely held in place during installation.
• Wear protective safety shoes.
WARNING
RISK OF INJURY AND PRODUCT MALFUNCTION DUE TO
PRESSURIZED SPRING CHAMBER
Plugging or isolating the captured vent/leakage line connection in a self-
relieving regulator will result in pressurization of the spring chamber, altering
the regulator set pressure and causing medium to escape and/or components
to be projected at high speed during disassembly.
• The captured vent/leakage line connection must be kept depressurized.
CAUTION
RISK OF PRODUCT DAMAGE DUE TO STRESS
The product is not intended to withstand external stresses that may be
inducted by the system to which it is being connected to.
• Make sure that the connected pipe does not subject the body to any stress
(forces or torques) during installation and operation.
• Do not use the product as an elevation point.
NOTICE

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 13
4.1. Preparation for installation
Before installation, make sure the following conditions are met:
• The installation area has easy access and the device is to be installed in a position
where operation and maintenance work can be performed safely.
• The product will be installed with proper support and free of any stresses that can
be induced by the system due to e.g. thermal pipe expansions / contractions during
CIP/SIP. The necessary precautions are recommended during system design.
• The pipeline where the product will be installed is designed in such a way that it
takes into account the weight of the product. The pipeline may require support on
both sides next to the product, particularly if its size and weight are considerable
and especially if vibrations are to be expected in the system.
• Consider good hydraulic ow control to avoid pressure surges and avoid dead legs
on pipeline branches.
• The product is not damaged.
• Make sure all the necessary materials and tools are readily available during
installation work.
• Referring to this Installation and Maintenance Instructions (IMI), Information Sheet
(IS) and nameplate, check that the product is suitable for the intended installation:
temperature, medium, pressure, etc. – see section 1.2 – Intended use.
• Check that there are no foreign bodies inside the pipelines and ancillaries, ushing
may be necessary. These should be thoroughly cleaned.
• A lter may be necessary to install upstream of the regulator in some applications,
protecting it from solid particles.
• A shut-o󰀨 valve is installed upstream and downstream of the regulator to facilitate
start-up, maintenance and troubleshooting. A bypass line is recommended as it
additionally prevent system shutdown during maintenance procedures, in which
case a manual valve should be tted to allow regulation of downstream pressure.
• The pressure regulator will not be thermally insulated.
• A pressure gauge is installed both upstream and downstream of the regulator for
monitorization, set point adjustment and troubleshooting.
• In steam applications (not recommended for the PS130), it should be dry and free
of impurities. A humidity separator with an appropriate trapping set trap is strongly
recommended.
Assembly Drawings (AD) with assembly details and parts lists are available
on request.
NOTE

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 14
4.2. Installation procedure
1. Remove plastic lm and other packaging, as well as the protective covers which
are placed on clamps or ETO connections. Make sure the regulator is free from
foreign matter.
2. Handle the regulator carefully to prevent damage to its surface nish.
3. The regulator recommended installation position is horizontal with the adjustment
knob pointing upwards. Other installation positions may increase wear and shorten
its service lifetime.
4. The regulator has an arrow or inlet/outlet designations, be sure that it is installed in
the appropriate direction according to uid ow.
5. When a clamp ferrule version is being installed, use appropriate gaskets. Sanitary
clamps must respect the system operating limit conditions.
6. When an ETO version is being installed, the welding should be carried out by
qualied personnel following an appropriate orbital welding procedure.
7. For dome-loaded regulators, connect the control pressure line to the dome chamber
threaded port using suitable ttings and tubing.
5. START-UP
Before performing the start-up procedure, refer to section 1 – Safety information.
The start-up procedure must be followed every time the product is put back into service.
5.1. Preparation for start-up
Before starting up, make sure the following conditions are met:
• All works on the system have been completed.
• All the necessary safety devices have been installed.
• When required, warning notices are used to alert others that the system is starting
up.
• The product is correctly installed – see section 4 – Installation.
• Referring to these Installation and Maintenance Instructions (IMI), Information Sheet
(IS) and nameplate, check that the product is suitable for the intended installation:
temperature, medium, pressure, temperature, etc. – see section 1.2 – Intended
use.
• A safety check was performed by qualied personnel. Checking for leaks, structural
damage and integrity of system components.
• The adjustment spring is completely relaxed. If not, release tension by turning the
adjustment knob (26) counterclockwise.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 15
• The supply pressure is greater than the required set pressure but does not exceed
the pressure rating of the regulator.
RISK OF PRODUCT DAMAGE DUE TO CONTAMINATION
The plant operator is responsible for cleaning the pipelines in the plant as
well as keeping the product well maintained. At start-up, the presence of
small particles in the medium (dirt, scale, weld splatters, etc.) may damage
the product or cause malfunction.
• Flush pipelines before start-up.
• Clean protection varnishes from pipes and anges, leftover paint, graphite,
grease, etc.
• Use a pipeline strainer or a lter.
NOTICE
5.2. Start-up procedure
1. Slowly open the downstream shut-o󰀨 valve to prevent sudden surges of pressure
that can damage the regulator.
2. Operation is performed by turning the adjustment knob (19) clockwise to increase
set pressure and counterclockwise to decrease set pressure.
3. Partially open the upstream shut-o󰀨 valve to allow the regulator to sense the inlet
pressure with minimal ow.
4. Close the upstream shut-o󰀨 valve and verify the set pressure with the aid of the
upstream pressure gauge.
5. Turn the adjustment knob (19) to adjust the set pressure and repeat steps 3 and 4
as necessary. Make sure the nal adjustment is made in the direction of increasing
pressure (clockwise rotation of the adjustment knob) to obtain the most accurate
set pressure.
6. Adjust the system supply pressure to its normal working value and continue to
slowly open the upstream shut-o󰀨 valve.
7. Check for any leaks.
8. Check the pressure regulator to ensure it is operating correctly.
24 hours after system start-up, it is recommended to check pipe connection
for leaks and retighten when necessary. Clean strainers/lters to avoid
blocking.
NOTE

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 16
6. OPERATION
Before operating the product refer to section 1 – Safety information.
Immediately after completing the start-up procedure, the product is ready for operation.
7. SHUTDOWN
Before performing the shutdown procedure, refer to section 1 – Safety information.
7.1. Shutdown procedure
1. Switch of the system and secure it so it cannot be turned on by unauthorized
personnel.
2. Fully close the upstream shut-o󰀨 valve, to stop the process medium from owing
through the pressure regulator.
3. Allow medium to cool down and completely drain it from the pipeline and pressure
regulator.
4. Make sure the pipeline and pressure regulator are not under pressure and are at a
safe temperature.
5. Fully close the downstream shut-o󰀨 valve.
6. If the pressure regulator won’t be put back in operation for a long period of time
relax the regulating spring or disconnect the loading control pressure supply.
7. If the pressure regulator is to be removed from the pipeline – see section 3 -
Transport, storage and packaging.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 17
8. PARTS LIST
30
29 26
27
28
22
23
2
24
19
21
17
18
16
15
5
6
12
1
4
3
25
20
Fig. 2

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 18
Fig. 3 - Leakage line/captured vent option.
33
31
3435
32
36
POS.
Nº DESIGNATION SPARE PARTS
1Valve body
2Cover
3Bottom cover
4O-ring X
5Plug X
6Valve head X
12 Retainer X
15 Lower diaphragm X
16 Upper diaphragm X
17 Washer
18 Plate
19 Nut
20 Serrated washer X
21 Adjustment spring X
22 Spring guide
POS.
Nº DESIGNATION SPARE PARTS
23 Adjustment screw
24 Washer
25 Bolt
26 Adjustment knob
27 O-ring
28 Bearing
29 Shaft ring
30 Cover nut
31 * Leakage line/captured vent ring
32 * O-ring X
33 * O-ring
34 * Bolt
35 * O-ring
36 * Compression tting
* Only for versions with leakage line option.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 19
9. MAINTENANCE
Before performing a maintenance procedure, refer to section 1 – Safety information.
The product requires maintenance to ensure that it operates correctly and safely
throughout its lifetime. Maintenance work should be performed in a planned manner
at periodic intervals. These intervals must be dened by the operator according to the
service conditions.
9.1. Maintenance procedure
1. Make sure all the necessary materials and tools are readily available during
maintenance work.
2. Perform the shutdown procedure – see section 7 – Shutdown.
3. Perform the maintenance procedure – see the following sections.
4. Put the product back into operation – see section 5 – Start-up.
9.2. Replacing the diaphragms and plug assembly
1. Completely relax the adjustment spring (21) or disconnect control pressure supply.
If the valve is removed from the line, x the valve body (1) in a vise with soft jaws,
with the cover (2) pointing upwards.
2. Unscrew the cover (2), remove the O-ring (32), if any, and adjustment spring (21).
3. Remove washer (17) and the diaphragm/plug assembly (5, 6, 12, 15, 16, 18, 19,
20).
4. Thoroughly clean the inside of the valve body (1) and cover (2).
5. Disassemble the diaphragm/plug assembly by holding the plug (5) in a vise and
unscrewing the nut (19).
6. Renew the serrated lock washer (20), upper diaphragm (16), lower diaphragm (15)
and plug assembly (5, 6, 12).
7. Clean reusable parts and reassemble the diaphragm assembly (5, 6, 12, 15, 16,
18, 19, 20). Hold the plug (5) in a vise and tighten the nut (19) until the lower
diaphragm (15) just starts to deform.
8. Place the diaphragm assembly (5, 6, 12, 15, 16, 18, 19, 20) onto the body (1)
followed by the washer (17). Fit the O-ring (32) if any, and adjustment spring (21).
9. Apply a suitable lubricant on the cover (2) thread and screw it into the valve body
(1) tightening with the recommended torque – see section 9.3 – Tightening torques.

VA L STEAM
ADCA
Produced in accordance with Sound Engineering Practices of the European PED - Pressure Equipment Directive. IMI PS130.08 E 00.22 20
9.3. Tightening torques
POS. Nº DESIGNATION TORQUE (Nm)
2 Cover 150
3 Bottom cover 35
10. TROUBLESHOOTING
Before applying any corrective measure, refer to section 1 – Safety information.
If the malfunction cannot be solved with the help of the following table, contact VALSTEAM
ADCA or its representative.
Malfunction Possible cause Corrective measure
Leakage between seat
and plug before the
adjusted set pressure has
been reached.
Seat and/or plug is worn or damaged.
• Replace plug assembly - see sections 9.2.
• Inspect seat conditions and if damaged
contact VALSTEAM ADCA.
Foreign matter is stuck between seat
and plug.
• Remove foreign matter and replace plug if
necessary - see sections 9.2.
• Consider installing a lter upstream of the
regulator.
Bypass valve is leaking. • Check, clean and replace the bypass valve
if necessary.
The regulator is blocked
(no ow allowed through
the regulator).
The valve head (6) is stuck to the seat. • Replace plug assembly - see sections 9.2.
The set pressure has been accidentaly
altered. • Readjust set pressure.
Set pressure cannot be
reached.
The adjustment spring regulating range
is incorrect. • Replace the adjustment spring.
The inlet upstream pressure to the
regulator is not high enough.
• Ensure that the upstream pressure to
the regulator is equal or greater than the
required set pressure at minimum and
maximum consumption scenarios.
Leakage between body
and cover.
The lower diaphragm (15) is damaged. • Replace damaged diaphragms – see
sections 9.2.
Cover (2) tightening torque is too low.
• Tighten cover (2) with the recommended
torque – see sections 9.3 – Tightening
torques.
The regulator is hunting
or chattering.
The ow rate through the regulator is
too low. The regulator is oversized.
• Check valve sizing and if necessary, install
a smaller regulator.
• Contact VALSTEAM ADCA.
The reducing ratio is too high.
• Install a second regulator in series (two-
stage reduction).
• Contact VALSTEAM ADCA.
The upstream pressure
rises too much when
ow rate reduces to
a static condition (no
consumption).
Flow rate through the regulator is too
high.
• When occurring during start-up, allow
downstream system to pressurize slowly to
prevent demage to the regulator.
• Check valve sizing and if necessary, install
a larger regulator or a second regulator in
parallel.
• Contact VALSTEAM ADCA.