User Manual - Badger Meter Europa GmbH
Contents
1. ANGLE HIGH PRESSURE VALVE ASSEMBLY 10 000 PSI 1 4 NPT HP 10 Parts and Materials List QUANTITIES ARE FOR ONE 1 UNIT ONLY PART NO arv DESCRIPTION MATERIAL T 527494 00 ANGLE BODY 527609 00 BONNET NOTE 1 NNERVALVE NOTE 1 SEAT 500232 00 UNION NUT 520580 0019 ADAPTOR m 95 12 PACKING 520582 0001 FOLLOWER PFA 520581 00 PACKING GLAND 920583 LOCK NUT 03 SST 520997 CONNECTOR 500 SER 510262 TRAVEL POINTER 500 SER 410009 STEM NUT 300 SER 520986 0002 TRAVEL SCALE 300 SER 400001 0072 SCREW 300 SER 430002 0022 1 FLAT WASHER 300 SER 925025 0001 1 O RING GLAND 316 SST 522761 O RING FOLLOWER TFE 511828 O RING SILICONE RUBBER 520995 0002 PRESS CASE amp YOKE ALUMINUM 510261 0001 DIAPHRAGM BUNA NYLON 9520994 0001 DIAPHRAGM PLATE STEEL ZINC PL O 1 8 NPT 12 11 10 Ic 8 00 8 9 O O A W N N N 39 22 400029 0003 HEX HD RIM SCREW 300 SER SST 1 14 2X 1 4 NPT 23 520996 0002 SPRING CASE ALUMINUM 24 510031 0040 SPRING STEEL N a 520990 0002 SPRING ADJUSTOR 300 SER SST 430002 0037 WASHER 300 SER SST 512416 0002 NAMEPLATE 300 SER SST 400018 0012 DRIVE SCREW 300 SER SST 520991 0001 SPRING SEAT ALUMINUM 520992 TOPWORKS STEM 316 SST 410030 0001 LOCKNUT 300 SER SST 3b INLET N2. psi is reached reduce pressure to zero NEVER TIGHTEN THE PACKING GLAND WHILE THE VALVE IS UNDER PRESSURES HIGHER THAN 500 PSIG AS DAMAGE GALL OR SEIZE MAY OCCUR TO THE THREADS OF THE PACKING GLAND OR BODY DO NOT TEST OVER 10 KSI IMPORTANT Sealing extremely high pressures is difficult at best Although Teflon PFA is more resistant to cold flow creep than pure TFE it is a plastic and possesses some cold flow In addition to the forces applied to the packing by the gland the system pressure also plays a part in sealing the packing against the stem and the packing cavity wall Some packing relaxation is not uncommon Therefore the packing should be tested when the valve is installed The pressure should be raised carefully and in stages to check for leaks If leaks occur the pressure should be lowered to zero the gland turned clockwise 1 16 inch turn then retested Do not attempt to tighten the gland while the valve is under high pressure When packing has been used for any length of time at high pressures and then reduced to lower pressures the packing may leak when the pressure is then re raised to higher pressures If leakage occurs some retightening may be necessary If the valve is disassembled always install new packing Never reuse packing that has been removed from a used valve Page 8 RCV UM 01034 EN 01 August 2014 Packing replacement and or inner valve replacement PACKING REPLACEMENT AND OR INNER VALVE REPLACEM
3. 000 PSI Page iv August 2014 Overview OVERVIEW This manual provides installation operation and maintenance information relating to the HP 10 valve assemblies To insure operator safety and optimum performance these instructions should be read understood and followed All technical bulletins drawings and literature pertaining to this design should be used with this manual Throughout this document numbers in parentheses for example 3 refer to items on the HP 10 drawing on page 10 COMPONENT DESCRIPTIONS Body Bonnet Assembly The HP 10 is available in both Angle or Globe pattern This high pressure design comes with a union bonnet Standard and extended cooling fin bonnets are available The standard alloy is dual certified 316 316L SS but other alloys are available Inner Valve The needle plug and seat inside the body bonnet assembly is the component which modulates the flow through the valve as the actuator strokes NOTE The needle and seat are matched sets and should not be interchanged with other similar components regardless of labeling The inner valve is dual certified 316 316L SS but other alloys are available If these components are gold in color they have been coated with titanium nitride Actuator The actuator sits atop the body bonnet assembly and is connected to the body using a yoke locknut The actuator may be either Air To Open ATO Spring To Close or Air To Close ATC Spring To Open An A
4. A The valve should be adjusted to seat the inner valve at Pneumatic Signal 3 2 psig if ATO and 14 9 psig if ATC Electric Signal 4 1 mA if ATO and 19 9 mA if ATC 5 Reduce the signal to the minimum and conduct seat leak testing If leakage through the valve is excessive Make sure the positioner is adjusted properly causing the valve to be seated at the proper actuator signal Replace the inner valve Packing Adjustment for Hydro Testing 10 000 PSI Valves with Torlon PFA Packing Customer pressures for 10 KSI valves should not exceed 10 000 psig or the lesser of the lowest rated component within the applicable line Factory hydro pressure should not exceed 15 000 psig August 2014 RCV UM 01034 EN 01 Page7 Hydro test procedure packing adjustment HYDRO TEST PROCEDURE PACKING ADJUSTMENT Throughout these instructions numbers in parentheses for example 3 refer to items on the HP 10 drawing on page 10 1 Loosely plug the outlet of test valve and connect the inlet to the hydro pump Stroke valve to 20 5096 open Open upstream valve under low pressure 60 100 psig to vent air until water leaks past the downstream plug Loosen the downstream plug until air is vented then tighten Tighten packing gland 8 until water leakage stops Tighten the packing gland another 1 16 1 8 rotation Slowly engage high pressure pump stopping at 10 000 psig or whenever leakage occurs oN AM PWN When leakage occurs or 10 000
5. D o Angle body shown Globe configuration available N N N 00 No e W O GW Page 10 RCV UM 01034 EN 01 August 2014 Hp 10 globe high pressure valve assembly 10 000 psi 1 4 npt HP 10 GLOBE HIGH PRESSURE VALVE ASSEMBLY 10 000 PSI 1 4 NPT 724 mm M S Y Y 7 SS N D D R 7 TENE SY DA TT a 4 August 2014 RCV UM 01034 EN 01 Page 11 Control Manage Optimize Research Control is a registered trademarks of Badger Meter Inc Other trademarks appearing in this document are the property of their respective entities Due to continuous research product improvements and enhancements Badger Meter reserves the right to change product or system specifications without notice except to the extent an outstanding contractual obligation exists 2014 Badger Meter Inc All rights reserved www badgermeter com The Americas Badger Meter 4545 West Brown Deer Rd PO Box 245036 Milwaukee WI 53224 9536 800 876 3837 414 355 0400 M xico Badger Meter de las Americas S A de C V Pedro Luis Ogaz n N 32 Esq Angelina N 24 Colonia Guadalupe Inn CP 01050 M xico DF M xico 52 55 5662 0882 Europe Middle East and Africa Badger Meter Europa GmbH Nurtinger Str 76 72639 Neuffen Germany 49 7025 9208 0 Europe Middle East Branch Office Badger Meter Eu
6. ENT Throughout these instructions numbers in parentheses for example 3 refer to items on the HP 10 drawing on page 10 1 2 Remove the valve to a suitable workspace If the unit has an Air To Open actuator signal the valve to raise the inner valve off the seat Unthread the inner valve stem from the connector 10 Lay the actuator to the side with the air pressure still on the diaphragm 3 Loosen and remove the yoke lock nut and lift off the actuator 4 Loosen and remove the union nut 4 Separate the bonnet 2 from the body 1 5 With the bonnet and body apart the inner valve can be removed from the bonnet and the seat can be removed from the body 6 Unthread the packing gland 8 and remove from the bonnet 7 Using a brass or aluminum rod up through the bonnet gently tap the lower adaptor 5 until the packing components 10 11 12 13 14 15 16 17 18 19 20 2 22 i 23 24 25 loosen and fall out Notice the order of each of component as it falls out of the packing cavity Clean and inspect the cavity using solvent and a soft brush DO NOT use sandpaper or abrasives Any visible marks can cause leakage If damage to the bore is noticed the bonnet will need to be replaced Use silicone grease or Krytox lubrication on the lower packing adaptor 5 and slide gently to the bottom Using a plastic tweezers lower the first ring into the cavity bore sideways until the ring is p
7. TO actuator closes the valve upon a decreasing instrument signal or loss of signal The ATC actuator opens the valve upon a decreasing instrument signal loss of signal or loss of air supply Packing The packing a series of plastic rings seals the stem of the valve preventing leakage of the process media outside the valve The materials and orientation of the rings can vary from valve to valve Refer to your customer drawing for orientation and material type VALVES OF THIS TYPE ARE TYPICALLY SUPPLIED WITH SOME FORM OF HIGH PRESSURE PROCESS CONNECTION BE SURE TO USE PROPER MATING FITTINGS TO CONNECT THE VALVE TO PROCESS LINES USING MISMATCHED FITTINGS MAY RESULT IN DAMAGE TO THE BODY LEAKAGE OR INJURY TO PERSONNEL UNPACKING Inspect the valve assembly for damage while removing it from the package Notify the shipping service of any damage and retain damaged boxes for inspection August 2014 RCV UM 01034 EN 01 Page 5 Installation INSTALLATION For maintenance and servicing ease select a location for the valve assembly installation that allows for safe access to both sides of the valve 1 Remove any protective plugs or devices from the valve assembly body stem positioner lever and so on 2 Do not remove the black hex pipe plug vent from the actuator housing so to prevent debris from entering the spring side of the housing during operation 3 Make sure all lines are free of debris by flushing with fluid or blowing with
8. ast the threads and entrance Using a 1 8 inch diameter plastic rod tip the ring over so that the concave side is pointing to the bottom of the cavity Using a 5 16 inch diameter plastic rod push the ring to the bottom of the cavity Repeat to install the remaining packing rings Insert the upper packing follower 7 into the cavity on top of the last ring Lubricate the packing gland threads and thread it into the bonnet until it is finger tight At this point a new inner valve set may be installed Insert the inner valve into and through the packing Install the seat into the body Tighten to 10 ft Ib Insert the bonnet into the body Install the union nut over the bonnet and thread onto the body until it is hand tight Stroke the inner valve do not rotate to check for alignment of the inner valve in the seat If dragging occurs do not proceed until the inner valve can be replaced or inspected If the inner valve strokes smoothly tighten the union nut 290 320 ft lb With the actuator still at stroke reinstall the actuator tighten the yoke lock nut and reconnect the inner valve to the actuator stem connector Check and adjust the closed position according to previous instruction Tighten any jam nuts on the stem for positive stops and or position indication Test and adjust packing according to previous instructions August 2014 RCV UM 01034 EN 01 Page 9 Hp 10 angle high pressure valve assembly 10 000 psi 1 4 npt HP 10
9. clean air or other suitable gas before connecting any lines 4 Install suitable isolation valves upstream and downstream of the control valve 5 Due the small size and close clearances of the inner valve proper filtration of the process is recommended If unsure about filter size contact the factory with the valve s serial number and inner valve size 6 Install the valve in the pipeline using mating fittings Never mix fitting types or brands without prior knowledge or experience 7 Ifthe unit is not equipped with a positioner connect the instrument signal line to the port located on the actuator housing Lower port if Air To Open Upper port if Air To Close 8 Use a paste type sealant or clear grease for air connections DO NOT use TFE tape as small pieces of the tape may block the small orifices in the devices 9 If the unit is equipped with a positioner or other devices make those connections according to the instructions for the device e DO NOT EXCEED AIR PRESSURE LIMITS 90 PSIG FOR THE ACTUATOR 40 60 PSIG SHOULD BE SUFFICIENT FOR MOST APPLICATIONS SEE SPECIFIC ACCESSORY MANUAL FOR OTHER DEVICES IF THE UNIT IS EQUIPPED WITH A POSITIONER I P TRANSDUCER REGULATOR IT HAS BEEN PRE ADJUSTED AT THE FACTORY DO NOT ATTEMPT TO READJUST WITHOUT FIRST TESTING THE UNIT WITH THE PRESET SETTINGS REORIENTING THE AIR CONNECTIONS Throughout these instructions numbers in parentheses for example 3 refer to item
10. rope PO Box 341442 Dubai Silicon Oasis Head Quarter Building Wing C Office C209 Dubai UAE 971 4 371 2503 Czech Republic Badger Meter Czech Republic s r o Maf kova 2082 26 621 00 Brno Czech Republic 420 5 41420411 Slovakia Badger Meter Slovakia s r o Racianska 109 B 831 02 Bratislava Slovakia 421 2 44 63 83 01 Asia Pacific Badger Meter 80 Marine Parade Rd 21 06 Parkway Parade Singapore 449269 65 63464836 China Badger Meter 7 1202 99 Hangzhong Road Minhang District Shanghai China 201101 86 21 5763 5412
11. s on the HP 10 drawing on page 10 Use the following procedure if the air connections must be reoriented and if the unit is an Air To Close ATC version 1 Loosen the yoke lock nut 9 until the actuator can turn Orient the unit as desired and retighten the yoke locknut 2 If the unit is an Air To Open ATO version and must be reoriented DO NOT simply rotate the actuator or damage to the inner valve 3 may occur Connect the control air and or electrical signal lines to the I P or positioner so the valve can be stroked Signal the valve to raise the inner valve off the seat 10 30 Once the inner valve is off the seat loosen the yoke locknut and orient the actuator as desired Retighten the yoke locknut De stroke the valve lowering the inner valve to the seated position If the unit is equipped with a positioner or other accessories refer to its instruction for operation and adjustment po ON DAM w When stroking the valve DO NOT remove the airline or electrical signal as the unit may close rapidly possibly damaging the inner valve Page 6 RCV UM 01034 EN 01 August 2014 Operation NOTES Although the valve will operate in any orientation a vertical stem position is preferred for ease of maintenance and adjustment Proper bracing and support is recommended due to the weight of the unit Brackets may be factory ordered or fabricated and attached to one or more of the actuator rim screws OPERATION Before subjec
12. ting the valve to process conditions Verify the stroke function of the unit to make sure the valve is stroking properly in response to the instrument signal Make sure all accessories are functioning properly If the unit is ATO upon an increasing input signal the valve will stroke and increase the flow through the pipeline If the unit is ATC the valve will stroke and decrease the flow through the pipeline Adjusting the Closed Position When in the closed position the inner valve should achieve some level of shut off depending on inner valve size and required tightness Typically linear inner valves sizes K O should achieve ANSI Class IV and P sizes should achieve Class III Seat tightness is pre adjusted at the factory Due to wear or repeated changing of the inner valve seat tightness may need to be adjusted Throughout these instructions numbers in parentheses for example 3 refer to items on the HP 10 drawing on page 10 To adjust the seating position or to achieve maximum tightness use the following method NOTE Application of excess closing force can bend or damage the inner valve stem due to high potential actuator force 1 Stroke the valve to approximately 10 off the seat by signaling the actuator N Turn the spring adjuster 25 clockwise to increase spring preload or counter clockwise to decrease spring preload SA Using the input signal close the valve by decreasing ATO or increasing ATC the signal
13. va RCV Control Valves Type HP 10 10 000 PSI Research Control Research Control ReCo Valves ReCo Valves Badger Meter e RCV UM 01034 EN 01 August 2014 U se r M a n u a Control Valves Type HP 10 10 000 PSI Page ii August 2014 User Manual CONTENTS UII mI clau the de de pl Hee ta bod tie Bok Blea Be dea lan aa e Big m a aha lad Red ue ana ake a ac al ee d 5 Component Descriptions 20 Rh ee u arn 5 Body Bonnet Assembly n ne cae a a da ge Se ge s i RA Ae gh DR dece de ek um ge deg ae Re Ae 5 Inner Valve C 5 ACTUATOI since iod ea s E O ee Ge ay RE tag mata Ghee Se Bod skeen ARA Aa 5 PACKING veria ee EE aa Ege Oded REE PE EEE he e ee ore eee 5 Unpack PPP a SS ee A Bee aa ae A awed det ee e 5 Installation cin eR ko E Rm eee ee be ee eR ee Ee n 6k Re ue 6E CE ee Eo Rc ue Oe C ee 6 Reorienting the Air CONNECTIONS uus e e Roe RR UR RR RR RR Rae RR RR ACE na Raa e Ro VR a S 6 Operation seo bea ee ER OO ORR TDI 7 Adjusting the Closed Position nn 7 Packing Adjustment for Hydro Testing 10 000 PSI Valves with Torlon PFA Packing 7 Hydro Test Procedure Packing Adjustment ee ee eee 8 Packing Replacement and or Inner Valve Replacement 0 0 ee rh 9 HP 10 Angle High Pressure Valve Assembly 10 000 PSI 1 4 NPT ce 10 HP 10 Globe High Pressure Valve Assembly 10 000 PSI 1 4 NPT 1 llle rr 11 August 2014 Page iii Control Valves Type HP 10 10
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