Mankenberg RP Series Manuel utilisateur

Original operating manual

Pilot-controlled pressure regulators

Originalbetriebsanleitung

pilotgesteuerte Druckregelventile

RP-4.X.22 Stand 01.08.2022 www.mankenberg.com

Table of contents EN

1 Introduction................................................................................................................................................. 6

2 Intended use ............................................................................................................................................... 6

3 Marking of the fitting.................................................................................................................................. 8

4 Safety instructions ..................................................................................................................................... 8

4.1 General precaution .............................................................................................................................. 8

4.2 Special safety instructions for the plant operator................................................................................. 8

4.3 Special hazards ................................................................................................................................... 9

5 Transport and storage ............................................................................................................................... 10

6 Installation................................................................................................................................................... 11

6.1 General notes ...................................................................................................................................... 11

6.2 Installation preparations....................................................................................................................... 11

6.3 Installation steps .................................................................................................................................. 13

7 Pressure testing the pipeline section....................................................................................................... 14

8 Initial start-up.............................................................................................................................................. 15

9 Normal operation........................................................................................................................................ 16

10 Maintenance................................................................................................................................................ 17

11 Troubleshooting help................................................................................................................................. 18

12 Information on REACH and RoHS ............................................................................................................ 20

12.1 Declaration on the REACH Regulation 1907/2006.............................................................................. 20

12.2 Declaration on the RoHS Directive 2011/65/EU .................................................................................. 20

13 Further information .................................................................................................................................... 20

14 Know How ................................................................................................................................................... 20

14.1 Tusk ..................................................................................................................................................... 20

14.2 Selecting valve type and nominal diameter ......................................................................................... 21

14.3 Selecting rated pressure and valve material........................................................................................ 21

14.4 Selecting the setting range .................................................................................................................. 21

14.5 Selecting elastomer materials.............................................................................................................. 21

14.6 Flow velocity ........................................................................................................................................ 21

14.7 Sense line (control line) ....................................................................................................................... 21

14.8 Protecting your system ........................................................................................................................ 21

14.9 Protecting the backpressure regulator................................................................................................. 22

14.10 Valve seat leakage .............................................................................................................................. 22

14.11 Cut-off.................................................................................................................................................. 22

14.12 Stellited seat and cone ........................................................................................................................ 22

14.13 Leakage line ........................................................................................................................................ 22

14.14 Mounting position................................................................................................................................. 22

14.15 Start-up................................................................................................................................................ 22

14.16 Steam operation .................................................................................................................................. 23

14.17 Setting the pressure............................................................................................................................. 23

14.18 Maintenance ........................................................................................................................................ 23

14.19 Valves free of oil and grease or silicone.............................................................................................. 23

RP-4.X.22 Stand 01.08.2022 www.mankenberg.com

Inhaltsverzeichnis DE

1 Einleitung .................................................................................................................................................... 24

2 Bestimmungsgemäße Verwendung.......................................................................................................... 24

3 Kennzeichnung der Armatur ..................................................................................................................... 26

4 Sicherheitshinweise................................................................................................................................... 26

4.1 Allgemeiner Sicherheitshinweis ........................................................................................................... 26

4.2 Spezielle Sicherheitshinweise für den Betreiber.................................................................................. 26

4.3 Besondere Gefahren ........................................................................................................................... 27

5 Transport und Lagerung............................................................................................................................ 28

6 Einbau.......................................................................................................................................................... 29

6.1 Allgemeines ......................................................................................................................................... 29

6.2 Vorbereitung zum Einbau .................................................................................................................... 29

6.3 Schritte beim Einbau............................................................................................................................ 31

7 Druckprüfung des Rohrleitungsabschnitts ............................................................................................. 32

8 Erste Inbetriebnahme................................................................................................................................. 33

9 Normalbetrieb ............................................................................................................................................. 34

10 Wartung....................................................................................................................................................... 35

11 Hilfe bei Störungen..................................................................................................................................... 36

12 REACH- und RoHS-Auskunft .................................................................................................................... 38

12.1 Erklärung zur REACH-Verordnung 1907/2006.................................................................................... 38

12.2 Erklärung zur RoHS-Richtlinie 2011/65/EU ......................................................................................... 38

13 Weitere Informationen................................................................................................................................ 38

14 Know-How................................................................................................................................................... 38

14.1 Funktion ............................................................................................................................................... 38

14.2 Auswahl von Ventiltyp und Nennweite................................................................................................. 39

14.3 Auswahl von Nenndruck und Werkstoff............................................................................................... 39

14.4 Auswahl des Einstellbereichs .............................................................................................................. 39

14.5 Auswahl der Elastomere...................................................................................................................... 39

14.6 Strömungsgeschwindigkeit .................................................................................................................. 39

14.7 Steuerleitung........................................................................................................................................ 39

14.8 Absicherung Ihres Systems ................................................................................................................. 40

14.9 Schutz des Überströmventils ............................................................................................................... 40

14.10 Sitzdichtheit ......................................................................................................................................... 40

14.11 Absperrung .......................................................................................................................................... 40

14.12 Panzerung ........................................................................................................................................... 40

14.13 Leckleitung........................................................................................................................................... 40

14.14 Einbaulage........................................................................................................................................... 40

14.15 Inbetriebnahme.................................................................................................................................... 40

14.16 Betrieb mit Dampf................................................................................................................................ 41

14.17 Einstellung des Drucks ........................................................................................................................ 41

14.18 Wartung ............................................................................................................................................... 41

14.19 Öl- und fett- bzw. silikonfreie Geräte ................................................................................................... 41

RP-4.X.22 Stand 01.08.2022 www.mankenberg.com

Original operating manual

Pilot-controlled pressure regulators RP

RP-4.X.221 Issue 01.08.2022 www.mankenberg.com

1 Introduction

This manual is intended to assist users of a MANKENBERG pilot-controlled pressure-reducing or overflow valve

during installation, operation and maintenance. Read the manual thoroughly before installing or putting this

valve into service.

caution

Failure to follow the following instructions – particularly the cautionary and warning

notes – may lead to hazards and may invalidate the manufacturer's warranty.

MENKENBERG is at your servíce for any assistance and queries. See section Further

information [}20] for the addresses. Technical information is also available at

www.mankenberg.de.

Technische Informationen auch unter www.mankenberg.de

2 Intended use

A pilot-controlled MANKENBERG pressure-reducing valve DM.. is a device that is intended exclusively for

automatically regulating the outlet pressure of the medium (without any additional electrical/pneumatic energy)

after it has been installed in a pipeline system:

The force of the outlet pressure acts on a pilot valve. This controls the main valve so that if the outlet pressure

falls below the target value, the main valve opens further (or entirely) until the target value has been re-

established. If the outlet pressure rises above the target value, the main valve reduces or closes.

The pilot valve is integrated onto the main valve together with a restrictor assembly. The restrictor assembly

contains 2 or 3 restrictors for optimizing the regulation characteristics and 1 strainer. The desired target value

for the setting range must be set on the adjusting screw of the pilot valve.

A pilot-controlled MANKENBERG backpressure regulator UV.. is a device that is intended exclusively for

automatically regulating the inlet pressure of the medium (without any additional electrical/pneumatic energy)

after it has been installed in a pipeline system:

The force of the inlet pressure acts on a pilot valve. This controls the main valve so that if the inlet pressure falls

below the target value, the main valve is reduced (or closed) until the target value has been re-established. If

the inlet pressure increases above the target value, the main valve opens.

The pilot valve is integrated onto the main valve together with a restrictor assembly. The restrictor assembly

contains 2 or 3 restrictors for optimizing the regulation characteristics and 1 strainer. The desired target value

for the setting range must be set on the adjusting screw of the pilot valve.

note

A pilot-controlled pressure-reducing or backpressure regulator does not begin to operate until

Δp > 2bar; the valve does not react if the difference from the target value is lower thanthis. If

the control function is to operate at a lower differential pressure, special models or normal

pressure-reducing and overflow valves should be used.

note

A pilot-controlled pressure-reducing or backpressure regulator is not a safety valve. A suitable

valve must be present in the pipe section to limit any excess pressure.

note

After installation, the pilot valve must be adjusted to the desired inlet or outlet pressure. The

pressure gauges needed for this must not be mounted directly on the valve and are therefore

not included in the supply schedule. Suitable pressure display devices are needed on the plant

side.

MANKENBERG planning documents are available to give users precise assistance in selecting and designing

the appropriate fitting, e.g.:

In the section

<DM: Regulating valves for pressure>

Original operating manual

Pilot-controlled pressure regulators RP

RP-4.X.221 Issue 01.08.2022 www.mankenberg.com

<Know-how on pressure-reducing valves / backpressure regulators>

with technical data and tables of the setting ranges and the dimensions.

danger of

fatalities

These valves are no shut-off elements ensuring a tight closing of the valve. In accordance with

DIN EN 60534-4 and/or ANSI FCI 70-2 they may feature a leakage rate in closed position in

compliance with the leakage classes II – V:

Leakage class II (metal sealing double seat cone) = 0.5% Kvs values

Leakage class III (metal sealing cone) = 0,1 % Kvs values

Leakage class IV (PTFE seal cone) = 0,01 % Kvs values

Leakage class V (soft seal cone) = 1,8 x 10-5 x Δp x D* [l/h]

*D = seat diameter

Consequently, according to DIN EN ISO 2503 and DIN EN ISO 7291, a safety valve has to be

installed on the control side, which is dimensioned and adjusted in such a way that the lower

one of both pressure indications as mentioned below is relevant as response pressure:

- 1.5 times the maximum set pressure and/or (P out) of the valve (see nameplate), whichever

is the lowest

- PS out (see nameplate)

The response pressure of the safety valve should be abt. 40 % above the max. set pressure of

the pressure control valve.

Contrarily to the Pressure Equipment Directive, Annex 1, Paragraph 7.3, the short-term

maximum excess pressure is limited to 5 % of the max. allowable pressure (see above).

Failure to observe this regulation means danger to life and limb and may cause damage

to the pressure-regulating valve.

caution

Pressure-regulating valves are generally supplied with an open bonnet to facilitate

maintenance.

Valves with a sealed bonnet and leakage line connection can be supplied for toxic or

hazardous media. In this case the user must make sure that a suitable leakage line is installed.

caution

Service life

The valve is designed for quasi-static operation. 1000 full load variations between 0 bar and

PS max (PN or MAWP) are permitted, based on the entire service life of the pressure vessel;

see No. 1.4 AD 2000 sheet S 1.

Relevant pressure surges or dynamic loads are not permissible. The estimated service life is

approx. 5 years.

MANKENBERG valves are supplied as standard for screw-mounted or flange-mounted pipeline/tank

connections – also for special connections if required.

The upper limit of the permitted operating data is permanently marked on each fitting supplied.

In the following sections the two valve types DM and UV are combined under the heading of “Fitting” or

“Pressure-regulating valves” apart from a few sections that only apply to the valve types mentioned.

Original operating manual

Pilot-controlled pressure regulators RP

RP-4.X.221 Issue 01.08.2022 www.mankenberg.com

3 Marking of the fitting

Each fitting bears the following markings as a minimum:

For Marking Remark

Manufacturer MANKENBERG See section Further information [}20] for the

address

Fitting design Pressure-reducing + type or

Backpressure regulator + type

Design name as per accompanying

MANKENBERG data sheet

Nominal diameter e.g. DN or G and numerical

value

Numerical value for DN in [mm], for G in [inches]

Nominal pressure PN or Class and numerical

value

Zahlenwert für PN in [bar], für Class in [lbs/square

inch]

Numerical value for PN in [bar], for Class in [lbs/

square inch]. Unless otherwise indicated, all data

give the overpressure above atmospheric.

If 2 numerical values are given, these apply to the

inlet and outlet pressure.

Pressure range Pressure range and numerical

values

Max. permitted

temp.

Temperature and numerical

value

Temperatures above 50 °C entail a reduced

pressure resistance. This must be considered for

the corresponding material in accordance with the

DIN EN 1092 standard

Body material e.g. CrNiMo steel CrNiMo steel = high-alloy austenitic steel

Flow direction Indicated by an arrow

The markings (in the case of fittings made of deep-drawn stainless steel, they are etched into the body) should

neither be covered nor painted over, so that the fitting remains identifiable.

4 Safety instructions

4.1 General precaution

The same safety regulations apply to a fitting as to the system into which it is installed. These instructions only

give those safety recommendations that have to be additionally observed for the fitting.

4.2 Special safety instructions for the plant operator

The following requirements for the intended use of a fitting are not the responsibility of the manufacturer but

have to be guaranteed by the user:

» he fitting may only be employed for the purpose described in section Intended use [}6].

» The operator must ensure that the valve is only used with media for which both the valve and sealing

material are suitable.

» Only competent specialist personnel may install, operate and service the fitting. Competent as defined in

these instructions refers to persons who, because of their training, specialist knowledge and professional

experience, are capable of correctly assessing and properly executing the work with which they are

entrusted and of recognizing and rectifying hazards.

Original operating manual

Pilot-controlled pressure regulators RP

RP-4.X.221 Issue 01.08.2022 www.mankenberg.com

» The pipeline system must be properly designed and installed so that the fitting can be mounted and

operated without any tension.

» The fitting must be properly installed in the correct mounting position.

» The recommended installation, as described in the relevant MANKENBERG data sheet <DM 8...> or <UV

8...>, must be used for the pipeline section into which the pilot-controlled pressure-regulating valve is

installed. All control and/or leakage lines that are required on the pressure-regulating valve must be laid

properly, in accordance with the accompanying MANKENBERG data sheet.

» A pressure-regulating valve with an open spring must be installed in such a way that it presents no risk of

crushing to the operating personnel.

» The usual flow rates should not be exceeded in the pipeline section during continuous operation, and

abnormal operating conditions such as vibrations, unusually high flow rates, etc. should be avoided or – if

unavoidable – clarified with the manufacturer in advance.

» The prevailing operating conditions must comply with the limits of the design data stated in the

MANKENBERG order confirmation.

» The corrosion protection for the fitting must be adapted to the local environmental conditions.

» The fitting must not be coated with thermal insulation.

Detailed notes are provided on some of these prerequisites in the following sections.

4.3 Special hazards

danger of

fatalities

Before a fitting is removed from the system or before a fitting is dismantled but partially

remains in place, the pressure in the system on both the inlet and outlet side must be

completely reduced so that there is no uncontrolled flow of the medium out of the system.

In the case of toxic or hazardous media, the system must be completely drained before the

fitting is removed.

Caution is required with residues that might continue flowing.

danger of

being

crushed

Only valves with open spring:

It is necessary to ensure on site, by an appropriate installation or by providing safety devices

and/or positioning a clearly visible warning sign in accordance with the regulations of EN 292

(formerly accident prevention regulations), that effective protection is afforded against

objects catching on an exposed spring in the pressure-regulating valve.

If required, MANKENBERG will assist in selecting a suitable type with closed bonnet.

danger of

fatalities

If a pressure-regulating valve has to be dismantled:

The following must be observed at all costs:

First release the tension fully on the spring by turning the setting screw on the spring module

anticlockwise. When doing so, be sure to follow the notes in section Initial start-up

[}15]!

Then either seal off the two shut-off valves installed before and after the fitting in accordance

with the MANKENBERG installation recommendation and vent the pressure-regulating valve

or remove the pressure from the section of the system and then remove the fitting from the

pipeline.

caution

If a fitting is removed from a system with a toxic medium and is taken out of the plant:

it must be properly decontaminated before repair.

Original operating manual

Pilot-controlled pressure regulators RP

RP-4.X.221 Issue 01.08.2022 www.mankenberg.com

5 Transport and storage

A fitting must be handled, transported and stored with care:

» The fitting must be transported and stored in its protective packaging until it is installed.

caution

The fitting has moving internal parts.

Even packaged fittings should be transported smoothly without any shocks.

caution

In the case of a fitting that can no longer be transported by hand, the lifting gear must be

attached to a suitable position on the housing (branches).

Under no circumstances may the lifting gear be affixed to any attachments (adjusting

screw, handwheel or accessories).

caution

Pilot-controlled pressure-regulating valves in a sandwich design with slotted discs, in

particular, are especially sensitive to transport damage and dirt.

Die The protective packaging on the body must not be damaged during transport and

storage.

» When the fitting is stored prior to installation, it should be kept in closed rooms and protected against

harmful influences such as dirt, moisture and frost.

» In special cases, the fitting is supplied free of oil, grease or silicone and is marked accordingly. A fitting such

as this must not come into contact with oil/grease/silicone during storage and handling (particularly when

subsequently unpacked).

» A MANKENBERG fitting generally has functional and/or sealing parts made of elastomer materials. These

cannot be stored for an unlimited period.

note

ISO 2230 describes the storage conditions for elastomers in detail and specifies the

permissible storage period.

Functional and sealing parts must be replaced well before the storage period expires.

They are available from MANKENBERG as a “service set”. See also section Troubleshooting

help [}18].

note

MANKENBERG fittings of small and medium nominal diameters are largely made of stainless

steel (high-alloy CrNiMo steel).

If, under exceptional circumstances, fittings are stored in a unpacked state, they must be

protected against ferritic dust to avoid corrosion.

note

The fitting is generally not capable of standing alone:

The spring module may have a greater weight/volume than the basic body with its pipe

connections.

Handle with care so that the fitting does not tip over during transport/storage..

» Pressure-regulating valves are generally supplied with a slackened spring. The spring must not be

pretensioned by means of the adjusting screw until after it has been installed, during initial start-up.

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