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3.562.5275.200
CTLS Issue 3 - 2019
5953 and 5954 Series Self-Operated Valves
Installation and Maintenance Instructions
1. General Safety information
2. General Product information
3. Installation
4. Maintenance
5. Spare parts
6. Fault finding
© Copyright 2018
E X P E R T I S E
S O L U T I O N S
S U S T A I N A B I L I T Y
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Table of Contents
Related Manuals for Spirax Sarco 5953 Series
Summary of Contents for Spirax Sarco 5953 Series
- Page 1 3.562.5275.200 CTLS Issue 3 - 2019 5953 and 5954 Series Self-Operated Valves Installation and Maintenance Instructions 1. General Safety information 2. General Product information 3. Installation 4. Maintenance 5. Spare parts 6. Fault finding © Copyright 2018 E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y...
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Page 2: General Safety Information
1. General Safety information Safe operation of the unit can only be guaranteed if it is properly installed, commissioned and maintained by a qualified person (see Section 1.11) in compliance with the operating instructions. General installation and safety instructions for pipeline and plant construction, as well as the proper use of tools and safety equipment must also be complied with. Intended use Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended Use/application. The products listed below comply with the requirements of the European Pressure Equipment Directive 2014/68/EU (PED) and carry the mark when so required. The products fall within the following Pressure Equipment Directive categories: Group 1 Group 2 Group 1 Group 1 Unit Connection Gases Gases Liquids Liquids Direct Actuator mod. 595/596 Water pot IT I) The products have been specifically designed for use on steam which is in Group 2 of the above mentioned Pressure Equipment Directive. The product's use on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the product for the application being considered. - Page 3 Pressure systems Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that the system has depressurised even when the pressure gauge indicates zero. Temperature Allow time for temperature to normalise after isolation to avoid the danger of burns and consider whether protective clothing (including safety glasses) is required. Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine Spirax Sarco replacement parts. 1.10 Protective clothing Consider whether you and/or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high / low temperature, radiation, noise, falling objects, and dangers to eyes and face. 1.11 Permits to work All work must be carried out or be supervised by a suitably competent person. Installation and operating personnel should be trained in the correct use of the product according to the Installation and Maintenance Instructions. Where a formal 'permit to work' system is in force it must be complied with. Where there is no such system, it is recommended that a responsible person should know what work is going on and, where necessary, arrange to have an assistant whose primary responsibility...
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Page 4: Returning Products
1.17 Returning products Customers and stockists are reminded that under EC Health, Safety and Environment Law, when returning products to Spirax Sarco they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk. This information must be provided in writing including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous. Caution If the product is not used in the manner specified by these instructions, the protection provided may be impaired. 1.18 Working safely with cast iron products on steam Cast iron products are commonly found on steam and condensate systems. If installed correctly using good steam engineering practices, it is perfectly safe. However, because of its mechanical properties, it is less forgiving compared to other materials such as SG iron or carbon steel. The following are the good engineering practices required to prevent waterhammer and ensure safe working conditions on a steam system. Safe Handling Cast Iron is a brittle material. If the product is dropped during installation and there is any risk of damage the product should not be used unless it is fully inspected and pressure tested by the manufacturer. - Page 5 Steam Mains - Do's ( ) and Dont's ( ): Prevention of tensile stressing Pipe misalignment: Installing products or re-assembling after maintenance: Do not over tighten. Flange bolts should be gradually tightened across Use correct torque figures. diameters to ensure even load and alignment. 3.562.5275.200...
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Page 6: Thermal Expansion
Thermal expansion: Examples showing the use of expansion bellows. It is highly recommended that expert advise is sought from the bellows manufacturer. Guides Axial movement Fixing point Short distance Axial movement Guides Guides Small lateral Large movement Limit lateral rods movement Medium Fixing distance point Small Large Limit rods lateral lateral movement movement Guides 3.562.5275.200... -
Page 7: General Product Information
2. General product information Description Series 5953 e 5954 Pressure Reducing and Relief Valves is a range of direct acting self-powered valve of robust construction, designed to operate under arduous conditions being ideal to control the pressure in water, steam, air and inert gas circuits. A soft-seated PTFE version is available ("G" suffix) for air/gas applications that require tight shut-off (limited to 200 °C). It is recommended that for these applications, a maximum pressure turndown ratio of 10:1 is observed. The valve is controlled by the downstream pressure which acts directly on the diaphragm, opposing the force to which the spring is calibrated. Under stable conditions diaphragm force and spring force are in a state of balance, but an increase or decrease in demand raises or lowers the downstream pressure which in turn acts against the spring to close or open the valve to adjust the flowrate and maintain a constant downstream pressure. Series 5953 and 5954 Valves are periodic maintenance free. Note: When operating a pressure reduction on liquids, it is possible that cavitation occurs. In such situations, it is essential to use control valves which are specifically designed to avoid damages that cavitation may cause both to the valve internal parts and to the components mounted immediately downstream. Fig. 1 - 5953 Reducing Valve Fig. 2 - 5954 Overflow Valve 3.562.5275.200... - Page 8 Valve Body - Technical data Valve Body Technical details with values expressed in bar according to ANSI standards, for valves in ASTM A216 Gr. WCB carbon steel and in ASTM A351 Gr. CF 8M stainless steel. 595-596 Actuators - Technical data 595 Reverse-acting Cast Steel Diaphragm Dimensions 150/250 Available types 596 Direct-acting SG Iron Diaphragm Dimensions 150/250 Body design conditions 595-150 595-250 - Maximum design pressure 15 bar 4,5 bar - Temperatura massima ammissibile 110°C* Minimum design temperature 0°C 0°C Water seal pot - Technical data DN Connection...
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Page 9: Technical Data
Technical data Connections Version Connection to the pipeline Butt weld ” BW Connection to the actuator Screwed ” gas Materials pot housing Carbon steel Pressure / temperature limits Body design condition PN16 PMA - Maximum allowable pressure @ 250°C 15 bar TMA - Maximum allowable temperature @ 15 bar 250°C Minimum allowable temperature 0°C PMO - Maximum operating pressure for saturated steam service 15 bar TMO - Maximum operating temperature* 250°C Minimum operating temperature... -
Page 10: Installation
3. Installation Nota: Before actioning any installation observe the 'Safety information' in Section 1. General information The valve should be installed vertically in a horizontal pipeline. For operating temperatures below 110°C the valve may be installed with the actuator either vertically upwards or vertically downwards (see Fig. 4). For operating on steam or temperatures above 110°Cthe valve must be installed vertically downwards with the spring/actuator below the pipework with a water seal pot fitted on the downstream control signal line to the actuator, a typical installation is shown in Fig. 5. Full attention must be given to correctly install the valve as indicated by the flow direction arrow on the valve body. minimum of 1 m or 15 times the pipe diameter Fig. 4 - Typical installation for downstream temperatures below 110°C, in which the valve can also be installed with the actuator upwards. minimum of 1 m or 15 times the pipe diameter IT Water seal pot Fig. -
Page 11: Isolating Valves
Pressure control pipe The valve actuator signal connection must be piped directly to the downstream side. To provide a good control signal the downstream sensing point should be positioned a minimum of 1 metre or 15 pipe diameters away from the valve or change in pipework direction on either side. It is recommended that the actuator signal pipe should be 8 mm diameter copper or stainless steel of 1 m minimum length. Preventing dirt Before installing the valve the system pipework should be flushed out to remove any residual dirt or scale that may be present. The valve should be protected by a pipeline strainer of the same size as the upstream pipework. For steam and air applications the strainer should be installed on its side to prevent the accumulation of water. Removal of condensate For steam installations a separator should be installed on the upstream side of the valve fitted with a suitable steam trap. Pressure gauges To assist in commissioning the valve and monitoring operating conditions it is essential to fit pressure gauges on both upstream and downstream sides of the valve. Safety valve It is recommended that a suitable safety valve is installed on the downstream side of the valve to protect downstream equipment from excessive pressure. The valve should be set to lift at a pressure below the safe working pressure of the downstream equipment and sized to pass the full capacity, should it fail in the fully open position. The safety valve outlet pipework should discharge to a protect and safe place. Isolating valves It is recommended that manually operated isolating valves are installed upstream and downstream of the pressure reducing valve station to provide means of isolation for cleaning and maintenance. Water seal pot If fitted, the water seal pot must be charged with water prior to the valve being put into service. Remove the water seal pot filling plug and fully charge the vessel with soft water. Replace the filling plug. -
Page 12: Product Specific - Safety Information
4. Maintenance Nota: Before actioning any maintenance program observe the 'Safety information', Section 1. Product specific - Safety Information This product should not be dismantled without first releasing the compression on the control spring. General information The valve is maintenance free, but it is recommended that the valve is dismantled every 12 to 18 months for routine inspection of the component parts. Items showing signs of wear should be replaced. Details of available spares are given in Section 5. Prior to routine inspection or fitting spare components, firstly ensure the reducing valve is isolated and that the upstream and downstream pressures are reduced to zero, rotating spring adjuster (9) to reduce spring(s) compression to zero. The downstream pressure signal pipe should be disconnected from the actuator. Note: This product contains PTFE/steel composite brushes. The precautions laid down in Section 1.15 should be taken. - Page 13 How to renew the actuator diaphragm and the sealing washer (Fig. 6) - Before replacing spare parts, separate the actuator from the valve - Rotate the spring adjuster (9) to fully discharge the spring (12). - Remove bolts and nuts (15, 16), the cover (20) and the diaphragm (19) from the actuator. - Fit the new diaphragm (19). - Replace the cover (20) of the actuator. - Replace bolts and nuts (15, 16). - Fix the actuator assembly to the valve by tightening the actuator mounting ring - Reconnect the line of the pulse inlet. - Before operating the valve, water seal pot should be filled with water (when installed). - Re-commission the valve. Fig. 6 - Actuator Mod. 595 3.562.5275.200...
- Page 14 4.3.1 How to renew or change the control spring(s) (Fig. 6) - Rotate the spring adjuster (9) to fully discharge the compression of the spring (12). - Disconnect the downstream pressure signal piping. - Undo the actuator mounting nuts and separate the actuator from the valve. - Remove bolts and nuts (c), the cover (d) and the diaphragm (e) from the actuator. - Undo the locking screw (g) and remove the diaphragm plate (f). - Replace the spring and reassemble in reverse order the plate, and the locking screw. - Reassemble the diaphragm, cover, screws and nuts. - Adjust the stroke of the valve and reconnect the inlet pulse piping. - Re-commission the valve. 3.562.5275.200...
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Page 15: Spare Parts
5. Spare parts Parts List Note: When placing an order for spare parts please clearly specify the full product description as found on the label of the valve body, as this will ensure that the correct spare parts are supplied. Part. N. Description Upper diaphragm casing Diaphragm plate Diaphragm casing bolts and nuts Diaphragm Diaphragm rod Lower diaphragm casing Spring adjusting ring nut Spring adjusting screw Actuator Counter spring Hexagon socket cap screw (except 592 type) Yoke Travel indicator plate Fixing or travel stop bolts Stem hexagon locknut Travel disc hexagon locknut (for Industrial valves only Travel indicator disc (for industrial valves series only) Stem Stuffing box nut Yoke Nutlock Stuffing box packing assembly Body nuts Lantern (except series 25 and cast iron valves) Plug fixing pin (where fitted) Bonnet Valve Plug Body gaskets Valve body Seat ring/s Guide bushing (where fitted) Blind bottom flange Body studs Lower plug locknuts... - Page 16 ¼" NPT air connection Fig. 7 - Model 592 diaphragm pneumatic actuator reverse acting NPT air connection ½" NPT (pressure control pipe) Fig. 8 - Model 595 diaphragm pneumatic actuator size 250 for self-regulating valves 3.562.5275.200...
- Page 17 Fig. 9 - Model 3 double seated valve body direct acting Fig. 10 - Model 4 double seated valve body reverse acting 3.562.5275.200...
- Page 18 Fig. 11 - Stuffing box assembly with teflon/ graphite rings Fig. 12 - Stuffing box assembly with graphite rings 3.562.5275.200...
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Page 19: Fault Finding
6. Fault finding Before investigating any fault ensure that both upstream and downstream isolating valves are shut. Symptom Possible cause Remedy 1. Blockage of the pressure 1. Disconnect the pressure signal pipe or coupling. signal pipe from the actuator coupling and blow through the pipe and coupling to clear obstruction. 2. Leakage across actuator 2. Remove the actuator Downstream pressure diaphragm or actuator housing and inspect the increases above it’s 'set' diaphragm clamp gasket. - Page 20 SERVICE For technical support, please contact our local Sales Engineer or our Head Office directly: Spirax Sarco S.r.l. - Technical Assistance Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Italy Tel.: (+39) 0362 4917 257 - (+39) 0362 4917 211 - Fax: (+39) 0362 4917 315 E-mail: support@it.spiraxsarco.com LOSS OF GUARANTEE Total or partial disregard of above instructions involves loss of any rights to guarantee. Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307 3.562.5275.200...
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