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Emerson Daniel 788DVC, User Manual

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Emerson Daniel 788DVC User Manual Download Page 79

3. Install the indicator guard on the indicator adaptor and secure it with the

lockwashers and screws. Replace the two jack-out screws.

9.4.3

AP cylinder reassembly

Procedure

1. Protect the cup-seals against damage or distortion of any kind.
2. Install cup-seals with the closed ends facing “in”.
3. Cup-seal installation:

•

Place the inside edge of the bottom seal in the deep recess of the piston body
(below the seal’s resting position) and carefully pull seal into position. Adjust
cup-seal position into its proper location.

•

Ensure that the closed ends of the top cup-seal face “in” (back-to-back).

Retrofit a control valve

Applications requiring aggressive products need control valve modification. Use the
following specific valve retrofitting procedure for these petroleum blending operations.

Upgrade existing AP units supplied prior to September, 1992

Three O-rings are supplied as a separate kit to upgrade existing valves, which have the
original AP option (received prior to September 1992).

Procedure

1. Follow the procedures described in 

Disassemble/Assemble the control valve

 for

general disassembly and 

AP cylinder reassembly

 for aggressive products cylinder

reassembly.

2. Replace O-rings as required.
3. Complete the cylinder assembly by installing the piston and all the component

parts through the top of the cylinder housing.

Important

Do not attempt to install the piston through the seat area. This will destroy the
spring-loaded Teflon cup-seals.

4. For ease of installation, secure cylinder assembly to cylinder heads using hand

pressure or arbor press.

 

WARNING

DISASSEMBLY HAZARD
When performing any disassembly procedure caution is required as the cylinder

head is bolted to a spring loaded cylinder assembly. Service should only be

performed by trained and qualified service personnel.
Failure to follow these instructions could result in death, serious injury or damage

to the equipment.

User manual 

Planned maintenance

P/N 3-9008-556

October 2019

User manual 

79

Summary of Contents for Daniel 788DVC

Page 1: ...User manual P N 3 9008 556 Rev AF October 2019 Daniel Model 788DVC Digital Control Valve NPS 2 through 8 Class 150 300 ...

Page 2: ...2 ...

Page 3: ...m Return Material Authorization RMA A Return Material Authorization RMA number must be obtained prior to returning any equipment for any reason Access and fill in the RMA form for Daniel products clicking on the link below http go emersonprocess com RMAOnlineForm Signal words and symbols Pay special attention to the following signal words safety alert symbols and statements Safety alert symbol Thi...

Page 4: ...is a statement the user needs to know and consider Tip Tip provides information or suggestions for improved efficiency or best results Note Note is general by the way content not essential to the main flow of information 4 ...

Page 5: ...rts and work procedures specified in this manual Product owners Purchasers Use the correct product for the environment and pressures present See technical data or product specifications for limitations If you are unsure discuss your needs with your Daniel representative Inform and train all personnel in the proper installation operation and maintenance of this product To ensure safe and proper per...

Page 6: ...and an instruction or do not feel comfortable following the instructions contact your Daniel representative for clarification or assistance Install this product as specified in the INSTALLATION section of this manual per applicable local and national codes Follow all instructions during the installation operation and maintenance of this product Ensure that all connections to pressure and electrica...

Page 7: ...BILITY FOR PROPER SELECTION USE AND MAINTENANCE OF ANY DANIEL PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END USER TO THE BEST OF DANIEL S KNOWLEDGE THE INFORMATION HEREIN IS COMPLETE AND ACCURATE DANIEL MAKES NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND IN NO EVENT SHALL DANIEL BE LIAB...

Page 8: ... storage or handling or any other cause not the fault of Daniel are not covered by this limited warranty and shall be at Buyer s expense Daniel shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by Daniel All costs of dismantling reinstallation and freight and the time and expenses of Daniel s personnel and rep...

Page 9: ... Chapter 5 Installation prerequisites 65 5 1 Pre start checks 65 5 2 Torque information 65 5 3 Torque values flanges 66 5 4 Torque pattern sequences 66 5 5 Tools required for control valve installation 66 Chapter 6 Installation procedure 67 6 1 External components assembly 67 Chapter 7 Testing the product 69 7 1 Commission the control valve 69 Chapter 8 Operation parameters 71 8 1 Control valve no...

Page 10: ...1 Recommended spare parts 85 Chapter 12 Decommission 89 12 1 Shut down the control valve 89 12 2 Shipment of the control valve 89 Appendix A Needle valve 91 A 1 Disassembly and assembly 91 A 2 Needle valve 92 A 3 Order spare parts 93 Contents User manual October 2019 P N 3 9008 556 x Model 788DVC Digital Control Valve ...

Page 11: ...ons No diaphragms or stuffing boxes 45 body design assures high capacity Positive shut off Uniform speed of response Linear control O ring plus metal to metal seat Pilots and other optional accessories enable the valve to perform a variety of control functions such as back pressure control regulating rate of flow pressure relief surge control etc 1 2 2 Control valve applications The Daniel Model 7...

Page 12: ... of reducing the rate of flow on on startup and before final shut off of a predetermined delivery This minimizes surges of pressure and line shock and ensures 1 4 gallon shut off sizes 2 inch 8 inch of the preset volume The total system generally consists of three pieces of equipment 1 a flow meter 2 an electronic preset with digital control and 3 a digital electric control valve The electronic pr...

Page 13: ...d position Open control position The normally closed solenoid is closed The normally open solenoid is closed Y port P3 to Z port P2 is closed X port P1 to Y port P3 is closed The product cannot flow to or from the top of the piston The piston is hydraulically locked in position until the electronics preset commands the valve to open or close as required to maintain the desired high flow rate or lo...

Page 14: ...is closed off by the normally open solenoid The pressure on the bottom of the piston P1 is greater than the pressure at P3 plus the spring force P1 minus P2 is equal to or greater than the spring force Therefore P1 pressure pushes the piston open No flow control is required See below Introduction User manual October 2019 P N 3 9008 556 14 Model 788DVC Digital Control Valve ...

Page 15: ...Figure 1 3 Open position no control User manual Introduction P N 3 9008 556 October 2019 User manual 15 ...

Page 16: ...1 1 Part description for a Series 788DVC Control Valve NPS 2 Item number Description Part number Quantity 2 inch 1 Cylinder Standard 520471 690 1 2 O ring Buna N 1500399 1 EPR 1500399 005 FFKM 1500399 075 NBR Low swell 1500399 120 CR 1500399 116 FKM 1500399 022 FKM GFLT 1500399 027 FKM V1289 1500399 029 Introduction User manual October 2019 P N 3 9008 556 16 Model 788DVC Digital Control Valve ...

Page 17: ...GFLT 152073 027 FKM V1289 152073 029 7 O ring Buna N 157000 2 EPR 157000 005 FFKM 157000 075 NBR Low swell 157000 120 CR 157000 116 FKM 157000 022 FKM GFLT 157000 027 FKM V1289 157000 029 8 Retaining ring 1500408 1 9 Washer 540032 1 10 Retaining ring 156488 1 11 Spring Light blue 530031 1 Medium bronze 530029 12 O ring Buna N 157029 1 EPR 157029 005 FFKM 157029 075 NBR Low swell 157029 120 CR 1570...

Page 18: ...et 1500409 1 24 Indicator housing 540082 690 1 25 Indicator top 540084 690 1 26 Screw 151469 1 27 Bal seal 159775 2 28 Piston seal retainer 520027 690 2 29 External retaining ring 156576 2 31 Nuts 151546 M 4 32 Valve body class 150 521001M 1 class 300 523001M DIN PN 16 521001 016M DIN PN 40 523001 040M 33 Studs 151309M 4 34 Pipe plug 154721 2 38 Cap plug 154774 1 39 O ring Buna N 157012 1 EPR 1570...

Page 19: ...89 500 1 44 Indicator guard 540082 400 1 45 Lock washer 152119 2 46 Screws 150727 2 47 Indicator adapter 540081 500M 1 48 Cap plug 154774 1 50 Set Screw 150975 1 A Cylinder assembly class 150 and 300 Without indicator Buna N 520075 690 1 EPR 520075 697 1 FFKM 520075 695 1 NBR Low swell 520075 696 1 CR 520075 693 1 FKM 520075 692 1 FKM GFLT 520075 69G 1 FKM V1289 520075 69M 1 With visual indicator ...

Page 20: ... Part description for a Series 788DVC Control Valve NPS 3 Item number Description Part number Quantity 3 inch 1 Cylinder Standard 530471 690 1 High pressure 536471 690 1 2 O ring Buna N 1500480 1 EPR 1500480 005 FFKM 1500480 075 NBR Low swell 1500480 120 CR 1500480 116 FKM 1500480 022 FKM GFLT 1500480 027 FKM V1289 1500480 029 3 Seat ring Standard 530026 690 1 High pressure 536024 610 4 Piston Sta...

Page 21: ...5 022 FKM GFLT 152095 027 FKM V1289 152095 029 8 Retaining ring 1500408 1 9 Washer 540032 1 10 Retaining ring 156488 1 11 Spring Light blue 540031 1 Medium bronze 540029 12 O ring Buna N 159575 1 EPR 159575 005 FFKM 159575 075 NBR Low swell 159575 120 CR 159575 116 FKM 159575 022 FKM GFLT 159575 027 FKM V1289 159575 029 13 Cylinder head Standard 530056 510 M 1 16 Screw 151012 6 17 Jack out screws ...

Page 22: ... 31 Nuts 151547M 4 32 Valve body class 150 531001M 1 class 300 533001M DIN PN 16 531001 016M DIN PN 40 533001 040M 33 Studs 151305M 4 34 Pipe plug 154721 2 38 Cap plug 154774 1 39 O ring Buna N 157012 1 EPR 157012 005 FFKM 157012 075 NBR Low swell 157012 120 CR 157012 116 FKM 157012 022 FKM GFLT 157012 027 FKM V1289 157012 029 40 Seal retainer 540188 500 1 41 O ring Buna N 152096 1 EPR 152096 005 ...

Page 23: ...t Screw 150975 1 A Cylinder assembly class 150 and 300 Without indicator Buna N 530075 690 1 EPR 530075 697 1 FFKM 530075 695 1 NBR Low swell 530075 696 1 CR 530075 693 1 FKM 530075 692 1 FKM GFLT 530075 69G 1 FKM V1289 530075 69M 1 With visual indicator Buna N 530575 690 1 EPR 530575 697 1 FFKM 530575 695 1 NBR Low swell 530575 696 1 CR 530575 693 1 FKM 530575 692 1 FKM GFLT 530575 69G 1 FKM V128...

Page 24: ...rd 540471 690 1 High pressure 546471 690 2 O ring Buna N 152080 1 EPR 152080 005 FFKM 152080 075 NBR Low swell 152080 120 CR 152080 116 FKM 152080 022 FKM GFLT 152080 027 FKM V1289 152080 029 3 Seat ring 540026 690 1 4 Piston Standard 540024 690 1 AP option 540024 693 5 O ring Buna N 152078 1 EPR 152078 005 FFKM 152078 075 NBR Low swell 152078 120 CR 152078 116 FKM 152078 022 FKM GFLT 152078 027 F...

Page 25: ... N 157032 1 EPR 157032 005 FFKM 157032 075 NBR Low swell 157032 120 CR 157032 116 FKM 157032 022 FKM GFLT 152078 027 FKM V1289 152078 029 13 Cylinder head Standard 540056 510M 1 16 Screw 151012 6 17 Jack out screws 150695 2 18 Indicator stem visual 540183 690 1 Indicator stem micro switch 540183 691 19 Magnet 1500410 2 20 Retaining ring 153946 1 21 Indicator adapter 540081 690M 1 22 Cap plug 15476...

Page 26: ...157012 005 FFKM 157012 075 NBR Low swell 157012 120 CR 157012 116 FKM 157012 022 FKM GFLT 157012 027 FKM V1289 157012 029 40 Seal retainer 540188 500 1 41 O ring Buna N 152096 1 EPR 152096 005 FFKM 152096 075 NBR Low swell 152096 120 CR 152096 116 FKM 152096 022 FKM GFLT 152096 027 FKM V1289 152096 029 42 Backup ring 157172 2 43 Upper bearing 540189 500 1 44 Indicator guard 540082 400 1 45 Lock wa...

Page 27: ...CR 540075 693 1 FKM 540075 692 1 FKM GFLT 540075 69G 1 FKM V1289 540075 69M 1 With visual indicator Buna N 540575 690 1 EPR 540575 697 1 FFKM 540575 695 1 NBR Low swell 540575 696 1 CR 540575 693 1 FKM 540575 692 1 FKM GFLT 540575 69G 1 FKM V1289 540575 69M 1 With standard indicator Buna N 540175 690 1 EPR 540175 697 1 FFKM 540175 695 1 NBR Low swell 540175 696 1 CR 540175 693 1 FKM 540175 692 1 F...

Page 28: ...3 Seat ring 560026 690 1 4 Piston Standard 560024 690 1 AP option 560024 693 5 O ring Buna N 157002 1 EPR 157002 005 FFKM 157002 075 NBR Low swell 157002 120 CR 157002 116 FKM 157002 022 FKM GFLT 157002 027 FKM V1289 157002 029 6 Backup ring 157185 2 7 O ring Buna N 152079 2 EPR 152079 005 FFKM 152079 075 NBR Low swell 152079 120 CR 152079 116 FKM 152079 022 FKM GFLT 152079 027 FKM V1289 152079 02...

Page 29: ...0056 510 M 1 16 Screw 151012 8 17 Jack out screws 150695 2 18 Indicator stem visual 560183 690 1 Indicator stem micro switch 560183 691 19 Magnet 1500410 2 20 Retaining ring 153946 1 21 Indicator adapter 540081 690M 1 22 Cap plug 154769 1 23 Ring magnet 1500409 1 24 Indicator housing 540082 690 1 25 Indicator top 540084 690 1 26 Screw 151469 1 27 Bal seal 159716 2 31 Nuts 151553M 8 32 Valve body c...

Page 30: ...52096 005 FFKM 152096 075 NBR Low swell 152096 120 CR 152096 116 FKM 152096 022 FKM GFLT 152096 027 FKM V1289 152096 029 42 Backup ring 157172 2 43 Upper bearing 540189 500 1 44 Indicator guard 540082 400 1 45 Lock washer 152119 2 46 Screws 150727 2 47 Indicator adapter 540081 500M 1 48 Cap plug 154774 1 50 Set Screw 150975 1 A Cylinder assembly class 150 and 300 Without indicator Buna N 560075 69...

Page 31: ...1 FKM V1289 560575 69M 1 With standard indicator Buna N 560175 690 1 EPR 560175 697 1 FFKM 560175 695 1 NBR Low swell 560175 696 1 CR 560175 693 1 FKM 560175 692 1 FKM GFLT 560175 69G 1 FKM V1289 560175 69M 1 Table 1 5 Part description for a Series 788DVC Control Valve NPS 8 Item number Description Part number Quantity 8 inch 1 Cylinder Standard 580471 500 1 High pressure 586471 500 1 2 O ring Bun...

Page 32: ...FFKM 157005 075 NBR Low swell 157005 120 CR 157005 116 FKM 157005 022 FKM GFLT 157005 027 FKM V1289 157005 029 6 Backup ring 157198 2 7 O ring Buna N 157004 2 EPR 157004 005 FFKM 157004 075 Low swell NBR 157004 120 CR 157004 116 FKM 157004 022 FKM GFLT 157004 027 FKM V1289 157004 029 11 Spring Light blue 580031 1 Medium bronze 580029 12 O ring Buna N 157074 1 EPR 157074 005 FFKM 157074 075 NBR Low...

Page 33: ...s 151558M 4 32 Valve body class 150 581008M 1 class 300 583001M DIN PN 16 581001 016M DIN PN 40 583001 040M 33 Studs 151335M 4 34 Pipe plug 154704 2 38 Cap plug 154774 1 39 O ring Buna N 157012 1 EPR 157012 005 FFKM 157012 075 NBR Low swell 157012 120 CR 157012 116 FKM 157012 022 FKM GFLT 157012 027 FKM V1289 157012 029 40 Seal retainer 540188 500 1 41 O ring Buna N 152096 152096 1 EPR 152096 005 ...

Page 34: ... 154774 1 50 Set Screw 150975 019 1 A Cylinder assembly class 150 and 300 Without indicator Buna N 580075 690 1 EPR 580075 697 1 FFKM 580075 695 1 NBR Low swell 580075 696 1 CR 580075 693 1 FKM 580075 692 1 FKM GFLT 580075 69G 1 FKM V1289 580075 69M 1 With standard indicator Buna N 580175 690 1 EPR 580175 697 1 FFKM 580175 695 1 NBR Low swell 580175 696 1 CR 580175 693 1 FKM 580175 692 1 FKM GFLT ...

Page 35: ...Normall y open FKM 150 UL 458815 012 458815 022 275 456910 X12 456910 X22 456910 X42 456910 X72 456910 X82 456910 X92 740 456910 X12 456910 X22 456910 X42 456910 X72 456910 X82 456910 X92 NBR 150 275 456910 X10 456910 X20 456910 X40 456910 X70 456910 X80 740 456910 X10 456910 X20 456910 X40 456910 X70 456910 X80 CR 150 275 456910 X13 456910 X23 740 456910 X13 456910 X23 EPR 150 275 456910 X17 4569...

Page 36: ...15 026 275 740 FKM 150 Atex 458815 512 458815 522 275 456910 XA2 456910 XB2 456910 XE2 456910 XF2 456910 X92 740 456910 XA2 456910 XB2 456910 XE2 456910 XF2 456910 X92 FFKM 150 458815 515 458815 525 275 456910 XA5 456910 XB5 740 456910 XA5 456910 XB5 FKM For LPG Service 150 458815 529 458815 529 275 458815 529 458815 529 740 Normall y open FKM 150 UL 458800 012 458800 022 275 456960 X12 456960 X22...

Page 37: ...456960 X43 456960 X83 EPR 150 275 456960 X17 456960 X27 456960 X47 740 456960 X17 456960 X27 456960 X47 FFKM 150 458800 015 458800 025 275 456960 X15 456960 X25 456960 X85 740 456960 X15 456960 X25 456960 X85 FKM For LPG Service 150 458800 019 458800 029 458800 039 458800 079 458800 089 458800 099 275 458800 019 458800 029 458800 039 458800 079 458800 089 458800 099 740 FKM 150 Atex 458800 512 458...

Page 38: ...5 456960 XB5 740 456960 XA5 456960 XB5 FKM For LPG Service 150 458800 529 458800 529 275 458800 529 458800 529 740 WARNING EQUIPMENT HAZARD When the process fluid is liquid ammonia use this equipment ONLY with CR elastomers Consult a Daniel representative for assistance Failure to comply may result in death or serious injury Introduction User manual October 2019 P N 3 9008 556 38 Model 788DVC Digi...

Page 39: ...ilot used with the 788DVC Control Valve Item Number Description Part Number Quantity 1 O ring NBR 152071 1 O ring EPR 152071 005 1 O ring FFKM 152071 075 1 O ring NBR Low swell 152071 120 1 O ring CR 152071 116 1 O ring FKM 152071 022 1 User manual Introduction P N 3 9008 556 October 2019 User manual 39 ...

Page 40: ...075 1 O ring NBR Low swell 157024 120 1 O ring CR 157024 116 1 O ring FKM 157024 022 1 O ring FKM GFLT 157024 027 1 O ring FKM V1289 157024 029 1 4 O ring NBR 157034 1 O ring EPR 157034 005 1 O ring FFKM 157034 075 1 O ring NBR Low swell 157034 120 1 O ring CR 157034 116 1 O ring FKM 157034 022 1 O ring FKM GFLT 157034 027 1 O ring FKM V1289 157034 029 1 5 Plug 157138 024M 1 6 Seat 455016 1 7 Pilo...

Page 41: ... 007 1 Manual Cage Assembly NBR Low swell 455525 008 1 Manual Cage Assembly FKM GFLT 455525 00G 1 Manual Cage Assembly FKM V1289 455525 00M 1 Table 1 8 Voltages for the 1710 456910 pilot Type Elastomer Voltage 110VAC 220VAC 440VAC 12VDC 24VDC 48VDC Red Hat I CSA FKM 456810 0 12 456810 0 22 456810 0 42 456810 0 72 456810 0 82 456810 0 92 NBR 456810 0 10 456810 0 20 456810 0 40 456810 0 70 456810 0 ...

Page 42: ... E2 456810 0 F2 456810 0 92 FFKM 456810 0 A5 456810 0 B5 WARNING EQUIPMENT HAZARD When the process fluid is liquid ammonia use this equipment ONLY with CR elastomers Consult a Daniel representative for assistance Failure to comply may result in death or serious injury Introduction User manual October 2019 P N 3 9008 556 42 Model 788DVC Digital Control Valve ...

Page 43: ...ilot used with the 788DVC Control Valve Item Number Description Part Number Quantity 1 O ring NBR 152071 1 O ring EPR 152071 005 1 O ring FFKM 152071 075 1 O ring NBR Low swell 152071 120 1 O ring CR 152071 116 1 O ring FKM 152071 022 1 User manual Introduction P N 3 9008 556 October 2019 User manual 43 ...

Page 44: ...075 1 O ring NBR Low swell 157024 120 1 O ring CR 157024 116 1 O ring FKM 157024 022 1 O ring FKM GFLT 157024 027 1 O ring FKM V1289 157024 029 1 4 O ring NBR 157034 1 O ring EPR 157034 005 1 O ring FFKM 157034 075 1 O ring NBR Low swell 157034 120 1 O ring CR 157034 116 1 O ring FKM 157034 022 1 O ring FKM GFLT 157034 027 1 O ring FKM V1289 157034 029 1 5 Plug 157138 024M 1 6 Seat 455016 1 7 Pilo...

Page 45: ...075 1 O ring NBR Low swell 152067 120 1 O ring CR 152067 116 1 O ring FKM 152067 022 1 O ring FKM GFLT 152067 027 1 O ring FKM V1289 152067 029 1 13 GLYD RING 157160 1 14 POPPET SHAFT ASSEMBLY 456952 1 15 Spring 456957 1 16 Washer 478922 1 Table 1 10 Voltages for the 1711 456960 pilot Type Elastomer Voltage 110VAC 220VAC 440VAC 12VDC 24VDC 48VDC Red Hat I CSA FKM 478935 0 12 478935 0 22 478935 0 4...

Page 46: ...rs Consult a Daniel representative for assistance Failure to comply may result in death or serious injury 1 3 Agency certifications for control valves Models 788DVC Digital The following product agency certifications are applicable to the Daniel Control Valves Table 1 11 Agency certifications for control valves Certification type Description Pressure equipment PED Process temperature Standard temp...

Page 47: ... continued Certification type Description INMETRO certification Electrical Certificate number UL BR 19 1331X INMETRO marking Ex mb IIB T4 Gb 16 1 W Ex mb IIB T3 Gb 20 1W 15 C Tamb 50 C User manual Introduction P N 3 9008 556 October 2019 User manual 47 ...

Page 48: ...Introduction User manual October 2019 P N 3 9008 556 48 Model 788DVC Digital Control Valve ...

Page 49: ...hemicals ie benzene toluene xylenes cumene olefins pyrolysis gasoline Natural gas liquids Viscosity limits on valves with pilots Maximum viscosity for valves with pilots is 440 Cst due to response time of high viscosity pilot Differential pressure The maximum allowable differential pressure across a control valve is 5 102 kPa 740 psi Consult factory for location of first shut down valve Atmospheri...

Page 50: ...d Seat ring Class 150 and 300 NPS 2 6 Stainless steel NPS 8 Nickel coated steel O Rings Standard FKM Optional CR EPR FKM V1289 NBR FFKM FKM GLT For other material contact the factory External hook up Class 150 and 300 NPS 2 6 Carbon steel Stainless steel 10 mm 0 375 NPS 8 Carbon steel Stainless steel 13 mm 0 5 Other internal parts Stainless steel Valve capacity Cv is a capacity coefficient that de...

Page 51: ...rom external fire Mass fluid in process and test conditions WARNING FUNCTIONAL AND ENVIRONMENTAL HAZARD Evaluate the functional and environmental conditions prior to installing a control valve Install the control valve in a well designed piping system Failure to comply may result in death or serious injury from pipe failure 2 1 2 Environmental conditions WARNING EQUIPMENT HAZARD Never use this equ...

Page 52: ...ons locate the control valve to an area that has fewer than 10 buildings intended for human occupancy within an area that extends 200 meters 220 yards radially from the control valve Reference Class 1 Location U S DOT CFR Title 49 Part 192 5 Closed poorly ventilated areas Install the control valve in a well ventilated area not less than one meter approximately three feet from source of ignition or...

Page 53: ...I ratings or flanges consult the factory engineers For maximum working pressures at intermediate temperatures refer to ANSI B16 5 WARNING FLANGE SIZE HAZARD Customers must choose the appropriate size material of the flange for their piping requirements Choosing an incorrect flange may cause a pressure leak resulting in death or serious injury 2 2 2 Requirements and limitations for installation NOT...

Page 54: ...e this equipment for any purpose other than its intended use Failure to comply may result in death serious personal injury and or property damage Operating conditions and specifications User manual October 2019 P N 3 9008 556 54 Model 788DVC Digital Control Valve ...

Page 55: ...ght and volume table for the control valve Approximate Size 150 lb ANSI 300 lb ANSI 150 300 lb ANSI lbs Kg lbs Kg Cubic feet Cubic meters 2 55 25 60 27 1 66 0 047 3 95 43 105 48 2 36 0 067 4 115 52 140 64 2 51 0 071 6 210 95 250 113 4 84 0 137 8 400 181 465 211 8 94 0 253 User manual Operating conditions and specifications P N 3 9008 556 October 2019 User manual 55 ...

Page 56: ... 279 mm 210 mm 3 11 11 9 12 8 3 4 279 mm 333 mm 229 mm 305 mm 222 mm 4 13 13 9 12 1 2 9 330 mm 368 mm 229 mm 318 mm 229 mm 6 17 17 12 15 3 4 11 432 mm 454 mm 305 mm 400 mm 279 mm 8 22 25 22 25 15 17 5 11 75 565 mm 591 mm 381 mm 445 mm 298 mm Operating conditions and specifications User manual October 2019 P N 3 9008 556 56 Model 788DVC Digital Control Valve ...

Page 57: ...mer facility Procedure 1 Remove the control valve from the shipping container 2 Inspect the control valve for damage 3 See Installation procedure 3 2 Store the control valve 3 2 1 Rust inhibitor Apply light oil or rust inhibitor on surfaces that are in contact with the environment 3 2 2 Pack the control valve Procedure 1 Use stretch wrap not adhesive to attach the correct size flange cover to the ...

Page 58: ...he storage temperature limits are 20 ºC to 60 ºC 68 ºF to140 ºF Shelf life for elastomers Inspect O rings for wear or damage during disassembly of the cover and right before assembling the unit Replace damaged elastomer Viton has an unlimited shelf life Inspect stored equipment Examine the internal surfaces and flange faces of the control valve at least once every three months Repack the control v...

Page 59: ...us injury or equipment damage CAUTION FORKLIFT HAZARD Do not insert the forks of a forklift into the bore when moving the control valve Inserting the forks may cause the meter to become unstable resulting in serious injury or equipment damage Table 4 1 Lifting and installation conditions Conditions Description Ventilation and lightning Install the control valve in a well lit and ventilated locatio...

Page 60: ...igging and lifting should lift valves Prior to use visually inspect the slings for any signs of abrasion or other damage Refer to the sling manufacturer for inspection procedures specific to the sling you are using Never attempt to lift the valve by wrapping slings around the visual indicator position indicator pilots needle valves accessories or tubing Never attempt to lift the valve using only o...

Page 61: ...ed when calculating the load rating CAUTION SLING HAZARD Never allow the slings to come in contact with the visual indicator position indicator pilots needle valves accessories or tubing Use a spreader bar on the sling to prevent contact Failure to comply may cause equipment damage User manual Prepare the control valve for use P N 3 9008 556 October 2019 User manual 61 ...

Page 62: ...Failure to comply may result in death or serious injury 4 3 Configure the control valve The factory configures Daniel control valve internal components Inspect the internal components before installation 4 3 1 Orientation and position of the control valve Flow direction NOTICE Comply with local government regulations and company requirements NOTICE Flush lines to remove welding bead pipe scale etc...

Page 63: ...mendations NOTICE When installing the control valve ensure that the bolts conform to the requirements of ASME B16 5 paragraph 5 3 and to the material requirements of ASME B16 5 Table 1B Gaskets must conform to the requirements of ASME B16 20 The design of the control valve has not been assessed for the effects of traffic wind or earthquake loading User manual Prepare the control valve for use P N ...

Page 64: ...ents connected to the control valve are not under stress Important Provide fire prevention measures and equipment per local regulations Prepare the control valve for use User manual October 2019 P N 3 9008 556 64 Model 788DVC Digital Control Valve ...

Page 65: ...setting on an air wrench 4 Use the correct tightening sequence for the bolt flanges 5 Follow your company s internal flange installation procedures Important Ensure that piping or other attachments connected to the control valve are not under stress Important Provide fire prevention measures and equipment per local regulations Flanges with 4 and 8 bolts First round 30 of final torque flange sequen...

Page 66: ... 2 8 5 11 3 9 6 12 8 1 5 3 7 2 6 4 8 1 7 4 10 2 8 5 11 3 9 6 12 The position of the number 1 screw determines the position of the clockwise rotation of the subsequent screws 5 5 Tools required for control valve installation Flange installation tools Follow all best practice procedures when installing or removing flanges Control valve components The control valve does not have pre installation requ...

Page 67: ...selection Bolt material selection Description ASTM SA 193 Grade B7 63 5 mm 2 5 in High strength low alloy steel ASTM SA 193 Grade B7M 63 5 mm 2 5 in Controlled strength low alloy steel ASTM SA 320 Grade L7 63 5 mm 2 5 in High strength low alloy low temperature steel ASTM SA 320 Grade L7M 63 5 mm 2 5 in Controlled hardness low temperature steel ASTM SA 449 25 4 mm 1 0 in Quenched and tempered steel...

Page 68: ...rage Remove each nut and bolt as a pair Thread the matching nut back onto the bolt Stack them in a fashion that will not cause thread damage Reuse of stud bolts and nuts The reuse of threaded fasteners is permitted on Daniel control valves under the following conditions Fasteners are clean free of corrosion paint thread damage cracks teeth marks caused by wrenches or other signs of damage Fastener...

Page 69: ...dures have been followed and that flange connections are leak free 2 Evaluate the system setup to ensure that all components are in the correct operating sequence 3 Evaluate the system setup to ensure that all components are in the correct sequence for accurate product measurement Some components are isolation valves strainers flow straighteners turbine meters downstream sections etc User manual T...

Page 70: ...Testing the product User manual October 2019 P N 3 9008 556 70 Model 788DVC Digital Control Valve ...

Page 71: ...s Opening speed control Device installed in the Y port of the valve to control opening speed Thermal relief It is the pressure differential safety device use to eliminate excessive pressures caused by thermal expansion Block or isolation valve for X Y Z ports Manual override Device used to by pass the pilot module Valve position indicator Limit switches The sequential switches convert the mechanic...

Page 72: ...ION EQUIPMENT DAMAGE Read the entire recommended procedure for all installation operations and maintenance procedures before attempting to install or disassemble the valve Disassembly of this cylinder assembly is different from previous Daniel Control Valves and requires strict adherence to the procedures outlined in this manual Failure to read and comply with these procedures could result in dama...

Page 73: ...ools required for mechanical components Flange installation tools Follow all best practice procedures when installing or removing flanges Control valve components The control valve does not have pre installation requirements If installation is required for maintenance purposes use the following tools Socket wrench Adjustable wrench T handle or extended Allen wrench Arbor press may be needed for 4 ...

Page 74: ...ss to immobilize the cylinder head This is to prevent sudden spring pressure from being released and causing injury or damage CAUTION SPRING PRESSURE HAZARD Follow the instructions in Step 5 Failure to comply may cause release of spring pressure resulting in serious injury or equipment damage 6 Use an Allen wrench to remove the screws that secure the cylinder head to the cylinder and then graduall...

Page 75: ...coil housing cover Solenoid coil may now be removed NOTICE The models 1710 and 1711 normally closed pilot have a retaining ring holding the coil in place which must be removed before coil can be removed 3 Rotate the hex head nut below solenoid base assembly counterclockwise to separate solenoid base assembly from pilot body 4 Remove cage assembly consisting of plunger valve cage ans poppet shaft a...

Page 76: ...equipment 9 4 Mechanical assembly 9 4 1 Valve torque specifications Table 9 1 Valve cylinder head to body stud nut torque specifications Valve size in Flange rating lbs Num bolts Min torque lbs ft 2 150 6 6 300 6 15 3 150 6 15 300 6 40 4 150 8 13 300 8 35 6 150 8 18 300 8 46 8 150 10 51 300 10 132 Table 9 2 Valve cylinder head to cylinder socket head screws torque specifications NPS Class Socket h...

Page 77: ...s down on the piston to force the seat ring into position against the lip in the cylinder 5 Remove the piston from the cylinder 6 With the piston in a vertical position nose end down place the O ring into the groove on the piston If the valve is a high pressure model the piston will require PTFE backup rings on either side of the O ring 7 Place the indicator stem retaining ring into the counter bo...

Page 78: ...o wiggle the indicator stem a little to get it into position When the indicator stem is in position you will not be able to pull it out 2 Place the magnets onto the indicator stem and retain the magnets by placing the retaining ring on the indicator stem 3 Coat the threads of the indicator adapter with pipe sealant and place the indicator adapter over the indicator stem and screw it into the cylin...

Page 79: ...rate kit to upgrade existing valves which have the original AP option received prior to September 1992 Procedure 1 Follow the procedures described in Disassemble Assemble the control valve for general disassembly and AP cylinder reassembly for aggressive products cylinder reassembly 2 Replace O rings as required 3 Complete the cylinder assembly by installing the piston and all the component parts ...

Page 80: ... piping or other attachments connected to the control valve are not under stress Important Provide fire prevention measures and equipment per local regulations 9 5 Planned maintenance tasks Table 9 3 Planned maintenance tasks Task Recommended action Inspect Implement a periodic inspection program to ensure all parts are free from damage during its use due to process ambient or other abnormal condi...

Page 81: ...on in the internal components at least once a year Follow internal procedures for corrosion The valve was designed without corrosion allowance Periodically inspect the valve s metal parts for corrosion and erosion and inspect the seals and O rings for wear and chemical damage Lubricant information High viscosity silicone oil with a temperature range of 54 C to 204 C 65 F to 400 F Proper lubricatio...

Page 82: ...Planned maintenance User manual October 2019 P N 3 9008 556 82 Model 788DVC Digital Control Valve ...

Page 83: ...ollen O rings Disassemble valve and replace O rings Check compatibility of O rings with product Pilot malfunction Consult pilot manual 710 711 Control Valve pilot Valve opens too slowly Valve inlet pressure below normal Check strainer and pump for obstruction Swollen O rings Disassemble valve and replace O rings Check compatibility of O rings with product Check X port sensitivity control needle va...

Page 84: ...w Procedure 1 Inspect all bolts used to secure the control valve in line to ensure that proper mounting procedures have been followed and that flange connections are leak free 2 Evaluate the system setup to ensure that all components are in the correct operating sequence 3 Evaluate the system setup to ensure that all components are in the correct sequence for accurate product measurement Some comp...

Page 85: ...FKM W520055 6 92 W520155 6 92 W520555 6 92 FKM GFLT W520055 6 9G W520155 6 9G W520555 6 9G FKM V1289 W520055 6 9M W520155 6 9M W520555 6 9M 3 150 300 Buna N W530055 6 90 W530155 6 90 W530555 6 90 EPR W530055 6 97 W530155 6 97 W530555 6 97 FFKM W530055 6 95 W530155 6 95 W530555 6 95 Aggressive Products W530055 6 96 W530155 6 96 W530555 6 96 CR W530055 6 93 W530155 6 93 W530555 6 93 FKM W530055 6 92...

Page 86: ...M 6 150 300 Buna N W560055 6 90 W560155 6 90 W560555 6 90 EPR W560055 6 97 W560155 6 97 W560555 6 97 FFKM W560055 6 95 W560155 6 95 W560555 6 95 Aggressive Products W560055 6 96 W560155 6 96 W560555 6 96 CR W560055 6 93 W560155 6 93 W560555 6 93 FKM W560055 6 92 W560155 6 92 W560555 6 92 FKM GFLT W560055 6 9G W560155 6 9G W560555 6 9G FKM V1289 W560055 6 9M W560155 6 9M W560555 6 9M 8 150 300 Buna...

Page 87: ...0 621 456800 612 456800 621 456800 612 456800 621 456800 612 456800 621 1 Solenoid N O 110 50 120 60 220 50 240 60 456815 012 456815 022 456815 012 456815 022 456815 012 456815 022 456815 012 456815 022 456815 012 456815 022 1 Needle valve 460385 522 460385 522 460385 522 460385 522 460385 522 Strainer assembly 530245 530245 530245 530245 530245 2 Order spare parts Contact Flow Lifecycle Services ...

Page 88: ...Spare parts User manual October 2019 P N 3 9008 556 88 Model 788DVC Digital Control Valve ...

Page 89: ...use high pressure fluids to leak resulting in death or serious injury Procedure 1 Ensure that the valve is free of contaminants 2 Drain the valve of liquids 3 Clean the valve components 4 Label all parts or place parts in labeled containers during disassembly 5 Do not use metal clamping devices in direct contact with control valve parts or surfaces 12 2 Shipment of the control valve Refer to Flow ...

Page 90: ...Decommission User manual October 2019 P N 3 9008 556 90 Model 788DVC Digital Control Valve ...

Page 91: ...tment stem by turning it counterclockwise 3 For pilots used on crude oil gasoline diesel fuel or other general liquid hydrocarbon service apply a light oil or general purpose grease to all O rings to prevent cutting and to facilitate assembly Use a light oil only for Butane and Propane service Tools required Retaining ring pliers Ratchet wrench Pin removal tool Needle nose pliers User manual Needl...

Page 92: ...067 116 1 O ring FKM 152067 022 1 O ring FKM GFLT 152067 027 1 O ring FKM V1289 152067 029 1 2 NPS 2 6 Pilot Body Carbon Steel 460386 500M 1 NPS 2 6 Pilot Body 303 Stainless Steel 460386 600M 1 NPS 8 Pilot Body Carbon Steel 460386 551M 1 NPS 8 Pilot Body 303 Stainless Steel 460386 651M 1 3 NPS 2 6 Adjusment Stem 460683M 1 NPS 8 Adjusment Stem 460683 001M 1 Needle valve User manual October 2019 P N...

Page 93: ...iption Part Number Quantity 4 Retainer 460684M 1 5 Cap 460686 1 A 3 Order spare parts Provide the following information when ordering parts Daniel valve serial number Part number Part description Quantity User manual Needle valve P N 3 9008 556 October 2019 User manual 93 ...

Page 94: ...bai UAE T 971 4 811 8100 Asia Pacific Singapore T 65 6777 8211 2019 Daniel Measurement and Control Inc All rights reserved Unauthorized duplication in whole or part is prohibited Printed in the USA Daniel Measurement and Control Inc Daniel is an Emerson Process Management business unit The Daniel name and logo are trademarks of Daniel Industries Inc The Emerson logo is a trademark and service mark...

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