PreVent BR12b Manuel utilisateur

BR12b Instruction Manual

Manual BR12b Version 1.2 19.11.2019

Contents: Page

Introduction 2

1. Functional principle 3

2. Installation 3

3. Operating conditions 3

4. Operability, maintenance and repair 4

- standard construction

4.1. Stuffing box 4

4.2. Valve seat and plug 5

5. Operability, maintenance and repair 6

- models with extended or bellows bonnel

5.1. Stuffing box 6

5.2. Valve seat and plug 7

5.3. Changing the bellows 7

6. Model with pneumatic P/R actuator 8

6.1. Changing the operating mode of the actuator 9

6.2. Replacing a diaphragm 10

7. Model with pneumatic P1/R1 actuator 11

7.1. Changing the operating mode of the actuator 12

7.2. Changing the control air range for P1/R1 14

pneumatic actuator

8. Other actuators 14

9. Diagrams / Spare part lists 15

10. Contacting us 20

To ensure trouble-free and safe operation of the valve, it is essential to be familiar with the contents of this

BR12b Instruction Manual, and also with the general instructions for installation and operation, before installing

and operating the valve.

Failure to observe or comply with these operating instructions will invalidate the manufacturer’s guarantee and

liability. The manufacturer’s general conditions of sales and terms of delivery shall apply unless otherwise stat-

ed.

Manual BR12b Version 1.2 19.11.2019

1. FUNCTIONAL PRINCIPLE

The valve regulates mass-flow by a linear movement of the valve stem, which may be operated pneu-

matically, electrically or manually. As the stroke of the valve alters, the openings in the cage can be re-

leased or covered.This directly influences the amount of fluid flowing through the valve.

2. INSTALLATION

The valve may be mounted in any position; however, for valves of DN 80 size and above, vertical instal-

lation with the actuator mounted above is preferred. For valves with extended construction, bellows, or

drives weighing more than 50 kg, a suitable support or suspension mounting should be provided for the

actuator, otherwise its own weight might cause wear and leakage at the stuffing box.

3. OPERATING CONDITIONS

Regulator valves should be operated under conditions that take into account the size and nature of the

construction and the type of material. To ensure trouble-free operation over the whole operational life-

time, the regulator valve and its accessories should be regularly inspected and maintained.

Normal operating conditions:

With pneumatic actuator

Ambient temperature from - 25 to + 80°C, with

silicone diaphragm of -40 °C to +80 °C

Relative humidity up to 98 %.

The control and feed air supplies must contain no mechanical impurities, oil or corrosive substances, cop-

per or aluminium alloys, and must be dehumidified such that the dew-point corresponds to a temperature

that is at least 10 °C lower than the operating temperature of the position controller and the positioning

drive.

With electrical actuator

In accordance with the manufacturer’s instructions.

With hand-operated actuator of type NN

Ambient temperature from - 25 to + 80°C

Relative humidity up to 98 %.

Manual BR12b Version 1.2 19.11.2019

4. OPERABILITY, MAINTENANCE AND REPAIR - STANDARD CONSTRUCTION

The operability of the regulator valve during use is based on maintaining an appropriate flow characteristic and

not exceeding the permitted leakage level for the valve.

To ensure long-term correct and safe operation of the valve, it is essential to carry out regular recorded inspec-

tions. Valves that operate continuously should be checked at least every 6 months. Valves that operate discon-

tinuously should be checked at least every 12 months.

If it is necessary to carry out maintenance or repair work on the regulator valve, it should be carried out as fol-

lows:

4.1. Stuffing box

A key criterion for operability is external seal-tightness, which is provided by the stuffing box.

The stuffing box to be used is normally pre-specified based on the operating conditions.

With normal stuffing box, the tightness of the seal is achieved by tightening the sealing nut or the lantern ring.

WARNING:

When the valve is supplied, the stuffing box nut is only hand-tightened. Before putting the valve into

service, it is essential to tighten the sealing sufficiently to achieve an adequate contact pressure, thus

ensuring a secure external seal, but without blocking the valve spindle.

If self-adjusting stuffing box used, the constant contact pressure is provided by a stainless steel spring. For this

reason, the stuffing box nut should be screwed in up to the stop.

To change the stuffing box, proceed as follows:

Before changing the stuffing box, ensure that the valve is not under pressure and is not contaminated

1. Loosen the upper part (bonnel) of the valve by opening the body nuts (21) between the body and the top

of the valve.

2. Lift the upper part of the valve out of the body, along with the valve stem and the valve plug. Loosen the

lantern ring (16) by slackening the nuts (18), and withdraw the valve stem and valve plug from the upper

part of the valve.

3. Remove all parts of the stuffing box (35, 36, 37, 38, 39) from the packing space using suitable tools, and

carefully clean out the packing space.

4. Fit a new body gasket (9) and seating seal (10) carefully clean the surfaces of the seal in the body and on

the upper part.

5. Insert the valve stem and the valve plug into the upper part of the valve.

6. Carefully locate the upper part of the valve on the valve body and fasten it in place with the nuts (21).

7. Carefully fit the new stuffing box parts over the valve stem and into the packing space, taking care to get

everything in the correct order (insert the parts in reverse order to the order in which they were taken out).

8. Fit on the lantern ring and secure it with the nuts (18).

9. Connect the actuator and the valve solidly back together.

Manual BR12b Version 1.2 19.11.2019

4.2. Replacement of the valve seat and the valve plug

If it is necessary to change the valve seat and valve stem due to a change in the operating conditions or due to

wear and tear, proceed as follows:

Before making the change, ensure that the valve is not under pressure and is not contaminated.

Replacing the valve plug

1. Loosen the upper part (bonnel) of the valve by opening the body nuts (21) between the body and the top

of the valve.

2. Lift the upper part of the valve out of the body, along with the valve stem and the valve plug. Disconnect

the drive stem from the valve stem. Remove control cage (6) and if present remove throttle cages I (7)

and II (8).

3. Undo the stuffing box by loosening the nuts (18) on the lantern ring (16) and withdraw the valve stem and

piston cone (4a/4b) from the upper part of the valve.

4. Knock out the dowel pin (20) using a punch, and unscrew the valve plug; screw a new plug on to the stem

(3), drill it and knock in a dowel to secure it in place again.

5. Push the stem with its new plug into the upper part (bonnel) of the valve.

6. To seal the valve, also remove the seat (5), fit a new seat gasket (10) and replace the seat again.

7. If present replace the throttle cage I (7) and throttle cage II (8) and also the control cage (6) on the valve

seat. Carefully place the bonnet of the valve onto the valve body and fasten it down with the nuts (21).

8. Pre-tension the stuffing box by tightening the nuts (18) on the lantern ring (16).

9. Re-connect the actuator and the valve.

Replacing the seat

1. Loosen the upper part (bonnel) of the valve by opening the body nuts (21) between the body and the

top of the valve. Remove the control cage (6) and if present remove the throttle cage I (7) and the throt-

tle cage II (8).

2. Since the valve seat (5) is only clamped in place, it can normally be removed without using any special

tools.

3. Fit a new seat gasket (10) and a new valve seat (5). Replace the control cage and if present replace the

throttle cage I and the throttle cage II on the seat.

4. Re-assemble the valve as when changing the valve plug, see 4.2 above (items 7-9).

Manual BR12b Version 1.2 19.11.2019

5. OPERABILITY, MAINTENANCE AND REPAIR – MODELS WITH EXTENDED OR BELLOWS CON-

STRUCTION

The regulator valve’s operability during use is based on maintaining an appropriate flow characteristic and not

exceeding the permitted leakage level for the valve.

To ensure long-term correct and safe operation of the valve, it is essential to carry out regular recorded inspec-

tions. Valves that operate continuously should be checked at least every 6 months. Valves that operate discon-

tinuously should be checked at least every 12 months.

If it is necessary to carry out maintenance or repair work on the regulator valve, it should be carried out as fol-

lows:

5.1. Stuffing box

A key criterion for operability is external seal-tightness, which is provided by the stuffing box.

The stuffing box to be used is normally pre-specified based on the operating conditions.

With normal stuffing box, the tightness of the seal is achieved by tightening the nuts (18) on the lantern ring

(16).

WARNING:

When the valve is supplied, the stuffing box is only hand-tightened. Before putting the valve into ser-

vice, it is essential to tighten the sealing via the nuts (18), sufficiently to achieve an adequate contact

pressure, thus ensuring a secure external seal, but without blocking the valve stem.

If self-adjusting stuffing box are used, the constant contact pressure is provided by a stainless steel spring. For

this reason, the stuffing box nuts (18) should be screwed in up to the stop.

For models with extended and bellows construction, the stuffing box is changed as described in item 4 above.

Manual BR12b Version 1.2 19.11.2019

5.2. Replacement of the valve seat and the valve plug

If it is necessary to change the valve seat and valve plug due to a change in the operating conditions or due to

wear and tear, proceed as follows:

Before making the change, ensure that the valve is not under pressure and is not contaminated.

In order to achieve a better seal when changing the valve seat and valve block, we recommend lapping the seat

and the block with a fine abrasive paste.

Replacing the valve plug

The procedure is identical to that described for models of normal construction; however, please note:

To avoid damage in the models with metal bellows (the version with extension bonnel does not have a bellows),

take care that no torque is applied to the bellows when unscrewing the valve plug and screwing it back in. We

recommend applying an opposing torque to the valve stem.

Replacing the seat

Exactly as described in item 4.2 above.

5.3. Replacing the bellows

1. Loosen the upper part of the valve by opening the body nuts (19) between the body and the bonnel of the

valve.

2. Lift the upper part of the valve out of the body, along with the bellows (25), upper bonnel (2C), valve

stem and valve plug. Disconnect the actuator stem from the valve stem. Remove the control cage (6)

and if present remove the throttle cage I (7) and the throttle cage II (8).

3. Loosen the gasket on the upper bonnel cover. Unfasten the connecting nuts (33) on the bellows, and take

off the upper bonnel (2C).

4. Unscrew the fastening nut (29) from the upper part of the bellows (27).

5. Withdraw the bellows (27) from the bellows bonnel, along with the valve stem.

6. Dismantle the valve plug (4a; 4b) from the bellows as described in item 5.2.

7. Clean the surfaces of the gaskets on the connecting piece.

8. Screw the valve plug back onto the new valve stem with bellows as described and dowel in place.

9. WARNING

Take great care that no torque is applied to the bellows when unscrewing the valve plug and

screwing it back in.

10. Fit a new bellows gasket (26) and insert the bellows from below into the bellows bonnel. Replace the

securing nut (27) and tighten it. Fit a new body gasket (29), replace the upper bonnel gasket, and fasten it

to the bellows bonnel (23) using the connecting nuts (31).

11. Pre-tension the stuffing box by tightening the nuts (16) on the lantern ring (14).

12. Fit a new gasket (8) and a new valve seat (5). Replace the clamping cage or perforated cage on the seat.

13. Re-assemble the valve as when changing the valve plug, see 4.2 above (items 7-9).

Manual BR12b Version 1.2 19.11.2019

6. PNEUMATIC P/R DRIVE

(For drawing numbers, see BR11 manual)

When the pressure rises in the actuator pressure chamber, a force is applied to the diaphragm in the actuator

unit. If this force exceeds the spring force of the springs in the second chamber, the springs are compressed

and the actuator stem starts to travel out or in, according to the function. If the pressure continues to increase,

once the maximum spring force is reached the springs will be pressed against the end-stop and the actuator will

stop. Thus, a single actuating pneumatic drive can reach a defined position in proportion to the air pressure.

The size of the drive is based on the cm

surface of the diaphragm.

Drive

size

Stroke

Spring range (kPa)

–

100

–

200

–

120

–

240

–

140

120

–

280

180

How

many

spring

total

com-

pres-

sion

(mm)

How

many

spring

total

com-

pres-

sion

(mm)

How

many

spring

total

com-

pres-

sion

(mm)

How

many

spring

total

com-

pres-

sion

(mm)

How

many

spring

total

com-

pres-

sion

(mm)

How

many

spring

total

com-

pres-

sion

(mm)

How

many

springs

total

com-

pres-

sion

(mm)

250 20 - 6 - - 6 - 6 6 6 - -

400 20 - 6 - - 6 - 6 6 6 - -

6 0 8 - 6 - 10 6 10 10+10

6 10+10

12 10+10

1000

8 - 6 - 9,5 6 9,5

9,5+

9,5 6

9,5+

9,5 12

9,5+

9,5

50 - 6 - 12,5 6 12,5

12,5+

12,5 6

12,5+

12,5 12

12,5+

12,5

6 - 6 - 16 6 16 16+16

6 16+16

12 16+16

Spring range and drive sizes for pneumatic drives of type P/R

P type drive: Single acting diaphragm actuator.

Safe position NO (open on loss of pressure)

When pressure rises in the upper chamber, the actuator stem travels out.

R type drive: Single acting diaphragm actuator.

Safe position NC (closed on loss of pressure)

When pressure rises in the lower chamber, the actuator stem travels in.

Manual BR12b Version 1.2 19.11.2019

6.1. Changing the operating mode of the drive

No additional components are required in order to alter the direction of operation of type P/R pneumatic actua-

tor.

Changing P to R and vice versa

1. Disconnect the valve from the actuator.

2. Ensure that no air pressure is applied to the actuator.

3. Remove the top cover of the actuator, taking care that the tensioning nuts (long nuts) (82) are un-

screwed to the ends – in accordance with the notes on the warning label,

The further steps in the procedure depend on the current operating mode of the actuator before it is

changed.

To change the actuator function from P to R, proceed as follows:

4. Undo the special nuts (34) from the bolts on the actuator.

5. Remove the diaphragm with its diaphragm plate, spacer ring, washer and spacer cover (or spacer co-

vers for drive sizes 630 and 1000).

6. Remove the springs (31) from the lower cover.

7. Turn the diaphragm together with all the parts as listed above through 180 degrees, and fit the dia-

phragm back over the actuator stem.

8. Screw the special nuts (34) on to the actuator bolts, thus compressing the whole of the above group of

components.

9. Place the springs on the diaphragm plate so that they fit in the guide cut-outs and their ends are aligned

with the axis of the bolts.

10. Place the top cover over the springs and initially tighten the tensioning nuts (82).

11. Compress the springs evenly until the upper part of the drive end-stop is pressed against the lower part,

then insert the rest of the bolts and screw on the nuts.

Manual BR12b Version 1.2 19.11.2019

To change the drive function from R to P, proceed as follows:

4. Remove the springs (31) from the diaphragm plate (28).

5. Undo the special nuts (34) from the bolts on the actuator.

6. Remove the diaphragm with its diaphragm plate, spacer ring, washer and spacer cover (or spacer co-

vers for drive sizes 630 and 1000).

7. Place the springs in the designated locations in the lower cover.

8. Turn the diaphragm together with all the parts as listed above through 180 degrees, and fit the dia-

phragm back over the drive bolts, so that the 6 mm diameter opening on the base and the nut on the

edge of the diaphragm plate are axially aligned with one of the openings on the edge of the diaphragm.

9. Screw the special nuts (34) on to the actuator stem, thus compressing the whole of the above group of

components.

10. Place the springs on the diaphragm plate (28) so that they fit in the guide cut-outs. To check that the

springs are in the correct position, rotate the diaphragm (to the position of the notch on the nut at the

edge of the diaphragm plate) until the 6 mm opening on the base is visible. By sighting through the

opening, check that there is a spring in place on the underside.

11. Place the top cover over the springs and initially tighten the tensioning nuts (82).

12. Compress the springs evenly until the upper part of the drive end-stop is pressed against the lower part,

then insert the rest of the bolts and screw on the nuts.

6.2. Changing the diaphragm

Should it be necessary to change a diaphragm, the actuator should be dismantled as described in item 6.1.

Instead of putting the actuator back together in reverse order, it should simply be re-assembled in its original

order after changing the diaphragm.

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