PRESSURE REDUCING AND SUSTAINING VALVE

E2115-02

OPERATING & MAINTENANCE

MANUAL

Via L.Galvani 6 tel. 0039 0461 248311 ISI SRL

38105 Lavis TN fax 0039 0461 247024
Italy
 OPERATION CONTROL of the main valve is returned to the
pressure reducing pilot (4).
The pressure reducing/sustaining valve E2115-02
(SCH002) is controlled by a normally open
diaphragm actuated, two way, spring loaded, MOUNTING
adjustable pressure reducing control pilot (4), set
to maintain a constant outlet pressure from the The mounting principle of a regulating valve is
main valve and by normally closed diaphragm shown in the SCH 450 (at the end of this
actuated, two way, spring loaded adjustable procedure); the choice of the proper "by-pass"
pressure discharging control pilot (5), set to alternative must be taking into consideration the
maintain a minimum pressure at valve inlet, which following points:
is open when upstream pressure is above the
setting point. a) Can the main transport/feeding line be put
As long as the inlet pressure is higher than the out of service during some hours (corresponding
value of the prescribed minimum value, the main to the requested time for maintening the MAIN
valve (1) is controlled by the pressure reducing VALVE), without generating problem for the
pilot (4); the set point of the downstream reduced exploitation of the system? In particular, it must be
pressure, which is sensed under the pilot noted that an empty system may required several
diaphragm, is adjustable within the indicated days to be vented properly.
spring range of the pilot.
b) Has the downstream zone of the system to be
As downstream pressure increases, the protected against any risk of pressure surge
diaphragm pushes against the spring, allowing the (quick closing of heavy demands, closing time of
pilot poppet loaded by an auxiliary spring to be pressure reducing valve)?
pulled towards its closed position, restricting the In order to get the best accuracy from the
flow through the pilot (4) and modulating the main pressure reducing/sustaining valve operation, the
valve towards a closed position. preset values for the reduced downstream
pressure and the minimum upstream pressure
The closing speed can be adjusted by the should be included in the indicated range of the
independent flow regulator "CLOSING SPEED" pilot valves. If it is very near of the extreme limits
located in the lockable central control "TUP-93". of the range, it would then be advisable to replace
the spring by the correct one.
As downstream pressure decreases, the control
pilot 4) throttles towards open, modulating the Available 263 APN 263 SS PV20C
main valve towards open. ranges (brassNi) (SS-316) (BZ/biNi)
press.red. press.red. Press.sustain.
The opening speed can be adjusted by the 0,1 - 2,0 X X X
independent flow regulator "OPENING SPEED" 1,4 - 12,0 X X X
located in the lockable central control "TUP-93". 7,0 - 21,0 - X X

Valve inlet pressure can drop as upstream or

downstream demands increase. When there is a
decrease of upstream pressure to the sustaining
set-point of pilot (5), this one throttles towards
closed, modulating the main valve towards closed
an appropriate amount to maintain the desired
upstream pressure, regardless the drop of
pressure at the outlet of the valve (eventually may
become null).
The set-point of the pressure sustaining pilot (5),
which is sensed under the pilot diaphragm through
a sensing line connected to the inlet of the
lockable central control "TUP-93" (unfiltered
intake), is adjustable within the indicated spring
range of the pilot.
As upstream pressure rises above the sustaining
set-point, the control pilot (5) throttles open:
E2115-02AUG00 PRESSURE REDUCING AND SUSTAINING VALVE
FM 0800
Rel 1.2 ISI PROPERTY INFORMATION
Should installation require the main valve stem to
be horizontal (cover pointed sideways),
manufacturer should be consulted concerning
valves of DN 200 mm and larger.
NOTE:
All sizes on request are available with a
additional venting cover device ( venting cock
installed at the top of the cover ) to permit a
simple escaping of air during the first
commissioning.
INSTALLATION-START UP see.sch002
- Before the installation of the regulating valve
(and respective strainer), it is recommended to
flush the upstream line, in order to clear it of slags
and other debris.
2
Note: An efficient flushing should be made with a
fluid velocity of at leat 1,5 m/s during several
hours!
- Install the valve so that the FLOW ARROW
marked on the valve body matches flow through
the line.
UPSTREAM DOWNSTREAM
- Close upstream and downstream isolation
valves
- Preset the central control "TUP-93":
A) reaction speed (RS) (normally preset in
factory), should be located on: 2,5
B) opening speed (OS) = 2
C) closing speed (CS) = 6
- Open isolating cocks 2 A-B and maintain
closed the 2C, of control circuit-
If not included in the order, install two pressure
gauges (one for each side) by utilizing the gauge
holder ball valves (9).
The isolating valves ( before the Y strainer
and after the pressure reducer) are in closed
position.
START UP OF AN AUTOMATIC CONTROL
VALVE REQUIRES THAT PROPER
PROCEDURES BE FOLLOWED. TIME MUST
BE ALLOWED FOR THE VALVE TO REACT
TO ADJUSTMENTS AND THE SYSTEM TO
STABILIZE. THE OBJECTIVE OF THE
FOLLOWING PROCEDURE IS TO BRING THE
VALVE INTO SERVICE IN A CONTROLLED
MANNER.
A) SETTING THE PRESSURE REDUCING
CONTROL
STEP 1
On pressure sustaining pilot (5), loose lock nut
and turn the setting screw counterclockwise
(OUT), until the screw is practically unloaded,
which will allow the pilot (5) to stay OPEN during
the pressure reducing set-up procedure.
STEP 2
On pressure reducing pilot (4), loose lock nut and
turn the setting screw counterclockwise (OUT),
until the screw is practically unloaded. This is
simulating the lowest setting value of the range,
from which the commissioner will have to
E2115-02AUG00 PRESSURE REDUCING AND SUSTAINING VALVE
FM 0800
Rel 1.2 ISI PROPERTY INFORMATION
gradually increase the pressure, up to the
prescribed one.
STEP 3
Adjust the central control "TUP-93" as prescribed
above.
STEP 4
Open upstream isolation valve SLOWLY of
one/two turns, in order to allow a controlled
filling of the regulating
valve, which is going to close (2C closed). Vent air
of cover through the safety venting cock mounted
on the valve position indicator E50 (8).
STEP 5
Open completely upstream isolating valve. Check
downstream pressure gauge. If during the step 4
the main chambre with air wasn't able to close
very fast, the downstream pressure could be the
same that inlet. Take out the downstream
pressure ( throught the manometer gauge holder
ball valve 9 downstream side) until to rich the 0
value .
Open the 2C and wait few second in terms to
check the downstream pressure to 0 value.
Turn the reducing control adjusting screw
CLOCKWISE (IN) to increase the pressure at the
prescribed value. Slowly 180 degree for time and
wait the pressure stabilized on the new value step
by step.
STEP 7
When the desired pressure is reached, gradually
open the downstream isolating valve.
It is recommended to fill the downstream system
with a low flow, in order to avoid any surge due to
the presence of air in the system, which should be
vented through the venting device installed at the
outlet of the regulating valve, as well as through
the one(s) installed in the system itself.
STEP 8
Allow the system to stabilize. OPEN then
completely the downstream isolation valve.
STEP 9
Fine-tune the pressure reducing pilot valve to the
set point:
SCREW CLOCKWISE (IN) ----> increases the
outlet pressure
SCREW COUNTERCLOCKWISE (OUT) ---->
decreases the outlet pressure
3
Then lock the setting screw by its locking nut!
STEP 10: "(TUP 93)"
The opening speed adjustment restricts the
control flow out of the main valve control chamber.
If recovery of pressure is too slow pre-setting of
the
flow regulator at value (2) upon increased
downstream demand, increase the adjustment of
the regulator progressively up to (3) or even higher
setting, if requested, which will increase the rate of
opening.
If recovery of downstream pressure is too quick,
as indicated by a rapid increase in pressure,
possibly higher than the desired set-point,
decrease the adjustment of the regulator
progressively up to (0,5) at the maximum. Do not
close the regulator completely on (0), since the
opening speed would then become too long!
STEP 11: "(TUP-93)"
The closing speed adjustment restricts the control
flow into the main valve control chamber,
controlling the valve closing speed.
Its maximum pre-setting (6) is insuring the highest
closing speed possible, in order to avoid any
downstream pressure increase, when the demand
is decreasing. If however the too quick closing is
generating surge in the upstream system, then
decrease the adjustment of the regulator
progressively down to (5) or any lower value. Do
not decrease more than value (1), in order to still
insure a proper closing of the valve.
SETTING THE SUSTAINING CONTROL
STEP 1
This procedure requires the lowering of the valve
inlet pressure!
STEP 2
Leave downstream isolation valve full open and
close the upstream isolation valve until the inlet
pressure drops to or below the desired setting.
STEP 3
Turn the sustaining pilot screw clockwise (IN) until
the inlet pressure begins to increase, or
counterclockwise (OUT) to decrease, stopping at
the desired pressure.
STEP 4
Allow pressure to stabilize.
STEP 5
Fine-tune the pressure sustaining pilot valve to the
set point:
E2115-02AUG00 PRESSURE REDUCING AND SUSTAINING VALVE
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Rel 1.2 ISI PROPERTY INFORMATION
SCREW CLOCKWISE(IN) ----> increases the
inlet pressure
SCREW COUNTERCLOCKWISE (OUT) ---->
decreases the inlet pressure
Then lock the setting screw by its locking nut!
STEP 6
Open upstream isolation valve to return to normal
operation.
TROUBLE SHOOTING
Downstream pressure value equalizes upstream
value.
First of all verify if this problem arises from
leakage inside the main valve (1), seal problem of
quad-ring on inox sealing seat (SCH016 pos. 4
and 15), or failure of diaphragm (SCH016 pos.
17), or it is caused by a small leakage from the
pilot (4) (SCH002).
To identify the part subject to intervention, act as
follows:
1. Close downstream isolating valve. It is not
possible to verify shortly possible causes
without this isolation. Flow rate must be at 0 l/s
value. Follow drawing SCH002 and close ball
valve (2C). Upstream and downstream gauges
will show the same value of static pressure.
2. Discharge the part of the line on main valve
upstream up to reach an upstream pressure
value of 0 bars. This operation may be carried
out by the gauge holder ball valve with drain
hole or through the device installed on
upstream between main valve (1) and isolating
valve.
3. After releasing close the ball valve or the other
device. Wait a little time verifying that the
gauge does not reach again any pressure
value over 0 bar. Shut off control circuit by the
ball valve (2C) forcing main valve (1) to close.
Downstream gauge will show a 0 pressure
value thanks to main valve (1) bubble
tightness. In the opposite case, if downstream
pressure value comes to the upstream one,
disassemble main valve (1) and replace or the
quad-ring or the diaphragm. It is advisable to
have always at your disposal a main valve (1)
spare gaskets set so to put in service the valve
autonomously and with no waste of time.
During reassembling of cover and main body,
fasten softly (without forcing) the nuts of stud
bolts and centering pins between body and
cover. The connections of control circuit on the
cover will indicate the right position.
4
In absence of losses and with a downstream
gauge showing a 0 value, act as follows:
1. Loosen the protection of pilot (4) adjusting
screw;
2. Loosen completely pilot (4) adjusting screw
and turn it counterclockwise up to release
completely the inner spring;
3. Open again ball valve (2C). Downstream
pressure value can remain at 0 or it can rise up
to the minimum allowed by pilot control range
(standard pilot: 1,4 bar).
If the pressure on downstream gauge comes to
higher values, the breakdown is caused by the
pilot. In this case act as follows:
1. Close ball valves (2 A-B-C), see drawing
SCH014-A;
2. Remove bottom plug (pos. 14) avoiding to lose
the spring (pos. 16) between bottom plug and
shutter. This spring is essential for pilot
working;
3. Extract, by using tweezers, the shutter (pos.
18) e check seal zone characterized by a 45
rubber cone. Eliminate possible foreign matters
that can create leakage even at 0 value. It is
advisable to have always at your disposal for
such services a pilot (4) full set of gaskets;
4. Reassemble the pilot (4) by slipping the shutter
stem into the proper guide, the spring and the
pertinent plug ;
5. Open ball valves (2 A-B-C);
6. Release downstream pressure by the proper
device or through the gauge holder ball valves;
7. After releasing close the ball valves or the
other device. Wait a little time verifying that the
downstream pressure reported by the gauge
remains at 0 or at the most comes to the
minimum pressure adjustable according to the
type of pilot.
If downstream pressure value equalizes the
upstream one we suggest to contact our
Customer Service.
Hunting
Verify the position of speed regulators on control
unit TUP-93 (pos. 3). Hunting may be reduced by
regulating the two speeds with completely different
values.
For example:
In case of standard regulations (OS=2, CS=6)
there is no hunting;
OS=3, CS=3, the possibility of hunting is higher
for a valve under particular working conditions
with low flow.
Lack of regulation
E2115-02AUG00 PRESSURE REDUCING AND SUSTAINING VALVE
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Rel 1.2 ISI PROPERTY INFORMATION
Verify perfect closing of position indicator drain
cock. In the opposite case the valve does not
work. In control chamber pressure value is 0.
Make sure also ball valves (2 A-B-C) are in open
position.
Pilot dripping (4) (5)
The diaphragm of pressure control pilot is
damaged. Lets start replacing it.
When downstream demand rises, downstream
pressure decreases to unacceptable values
Verify that Reaction Speed (RS) value is exactly
2,5. In case of regulations at lower or different
values repeat adjusting as previously explained
(see INSTALLATION). If after regulations the inlet
pressure can come to a value near the one of
outlet pressure (for example P1=4, P2=3.5) lead
reaction speed at value 3. Then adjust again the
pilot (4). Due to this fact the valve regulates up to
reach the pressure loss value of the valve.
Recommended spare parts:
Full set of gaskets for E2001;
Full set of gaskets for 263 (specify the model:
263AP in nickel plated brass or 263 SS in
stainless steel).
Full set of gasket for PV20C.
MAINTENANCE
If the valve has been installed as per enclosed
drawing, the quality of constructive materials
should produce no wear of the internal
components. However we are recommending:
AFTER 6 MONTHS OF SERVICE:
Control and clean the filter on TUP-93 (see
SCH017). The results of this inspection will permit
to fix the frequency of such control.
NOTE: A plugged screen will prevent any flow of
control fluid into the pilot circuit, which will put the
main valve progressively out of control.
AFTER 12/18 MONTHS OF SERVICE:
- Control and clean the TUP-93 (3) screen.
- Take the main valve (1) apart, by removing first
the complete pilot circuit.
- Then unscrew the stud nuts and remove the
cover and internal diaphragm assembly.
- Check for any eventual damage of the QUAD-
RING and the diaphragm.
5
- Clean thoroughly the internal part of the valve,
grease slightly the stem at both guided locations
(water grease, non toxic !!).
- Assemble main valve (1) and pilot circuit.
- Put the valve back into service.

This control should then allow to determine the

cycle of the requested maintenance, since it is
taking into consideration the true service
conditions of the valve.

STORAGE

The valves from ND 40 to ND 200 are packed in

special cardboard boxes. Outside the carton are
clearly pointed out:
- The arrow indicating the position of the valve;
- The name of the customer;
- The code of the valve;
- The number of order confirmation.
The valve is protected by two hardening foam
cushions, carefully coated by a thermal plate. This
kind of packing if properly stored avoids all the
damages originated from transport, unloading,
and handling before installation. Avoid to store it
under the rain for more than 24 hours!
Open the upper side of the carton and remove the
upper cushion. Do not lift the valve by utilizing the
pilot, the pilot circuit, or the position indicator. For
any kind of handling we recommend to utilize
proper eyebolts.

For any further information contact our

Customer Service, indicating all data as per
inox plate on main valve body. Give full
detailed informations about working
conditions, the type of problem, and report the
adjusting values (OS-CS-RS).

E2115-02AUG00 PRESSURE REDUCING AND SUSTAINING VALVE 6

FM 0800
Rel 1.2 ISI PROPERTY INFORMATION