GF NeoFlow DN200, Operating Instructions Manual

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CONTENTS
1 PRODUCT DESCRIPTION ....................................................................................................... 6
1.1 Intended Use ............................................................................................................................ 6
1.2 EC Manufacturer's declaration .................................................................................................. 6
1.3 PRESSURE REDUCING VALVE (PRV) CONFIGURATION................................................................. 7
1.3.1 METHOD OF OPERATION ...........................................................................................................................7
1.3.2 P&ID ...........................................................................................................................................................7
1.4 PRESSURE RATINGS & PERFORMANCE ...................................................................................... 8
1.5 FLANGE & SIZING DATA ............................................................................................................ 8
1.6 NAMEPLATE INFORMATION ...................................................................................................... 9
1.7 BILL OF MATERIALS – PRESSURE REDUCING ASSEMBLY............................................................ 10
1.8 BILL OF MATERIALS – VALVE BODY .......................................................................................... 12
1.9 BILL OF MATERIALS – CONTROL BLOCK .................................................................................... 14
1.10 BILL OF MATERIALS – PRESSURE REDUCING PILOT (PR1) .......................................................... 15
1.11 BILL OF MATERIALS – SPEED CONTROL .................................................................................... 16
1.11.1 SEAL KITS ..................................................................................................................................................17
1.11.2 PRESSURE SENSE PORTS ..........................................................................................................................17
1.11.3 PRESSURE CONTROLLER COMPATIBILITY .................................................................................................18
1.12 RECOMMENDED TOOLS AND CONSUMABLES .......................................................................... 18
1.12.1 INSTALLATION/MAINTENANCE TOOLS ....................................................................................................18
1.12.2 LUBRICATION & THREAD SEALANT ..........................................................................................................18
2 INSTALLATION ................................................................................................................... 19
2.1 TRANSPORT AND HANDLING .................................................................................................. 20
2.2 SITE SELECTION....................................................................................................................... 21
2.2.1 BYPASS LINE .............................................................................................................................................21
2.2.2 PERMITTED VALVE ORIENTATIONS ..........................................................................................................23
2.2.3 PERMITTED SPATIAL DIMENSIONS...........................................................................................................24
2.3 PILOT SPRING OPTIONS .......................................................................................................... 25
2.4 VALVE INSTALLATION ............................................................................................................. 26
2.5 VALVE BOLT TORQUES ............................................................................................................ 29
2.6 FLANGE ADAPTORS................................................................................................................. 29
3 COMMISSIONING ............................................................................................................... 30
3.1 NeoFlow EXTERNAL COMPONENTS ......................................................................................... 30
3.2 SETTING SPEED CONTROL VALVE ............................................................................................. 31
3.3 INITIAL PRESSURISING ............................................................................................................ 32
3.4 SETTING PRV DOWNSTREAM PRESSURE .................................................................................. 34
3.4.1 WITH HYDRANT ........................................................................................................................................34
3.5 ADJUSTING THE SPEED CONTROL ............................................................................................ 36
4 MAINTENANCE .................................................................................................................. 37
4.1 DEPRESSURISING CONTROL SYSTEM ....................................................................................... 38
4.2 LIVE STRAINER & CONTROL SYSTEM FLUSHING........................................................................ 39
4.3 VALVE REMOVAL .................................................................................................................... 41
4.4 CONTROL SYSTEM REMOVAL .................................................................................................. 43
4.5 CONTROL SYSTEM SERVICING ................................................................................................. 44
4.5.1 CONTROL BLOCK ......................................................................................................................................44
4.5.2 PRV PILOT .................................................................................................................................................45
4.6 MAIN BODY ............................................................................................................................ 47
4.6.1 SHUT-OFF SEAL SERVICING ......................................................................................................................50
5 TROUBLESHOOTING ........................................................................................................... 52
5.1 DIAGNOSTICS ......................................................................................................................... 52