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4.6.1

SHUT-OFF SEAL SERVICING

If the shut-off seal needs servicing, it can be accessed by removing the inlet screws. This can be

performed with the control system still on the valve.

a. Remove the inlet screws using a Torx-Plus screwdriver head. Remove the inlet strainer

and inlet piece to reveal the shut off seal.

b. Remove the shut off seal and inspect for any cracks or signs of wear.

c. Before replacing the seal check both the face on the casing and inlet for any debris.

Summary of Contents for NeoFlow DN200

Page 1: ...Operating instructions NeoFlow Pressure Reducing Valve DN200 DN300...

Page 2: ...durability It is subject to modification Our General Terms of Sales apply Observe instruction manual The instruction manual is part of the product and an important element within the safety concept R...

Page 3: ...ENANCE 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 SP...

Page 4: ...R OF MAINTENANCE ACTIVITIES CAN BE COMPLETED DURING LIVE OPERATION THESE ARE OUTLINED IN SECION 4 FAILURE TO FOLLOW THE PROCESSES IN THIS MANUAL MAY INVALIDATE THE PRODUCT WARRANTY PLEASE CONTACT GF P...

Page 5: ...Terpolymer GCR GCR Tech Pressure Controller HWN Halma Pressure Controller P ID Piping and Instrumentation Diagram PCS Control Space Pressure PN Pressure Nominal PRV Pressure Reducing Valve SS Stainles...

Page 6: ...n the medium can affect the function of the NeoFlow pressure reducing valve For this reason use is only recommended with an upstream strainer 1 2 EC MANUFACTURER S DECLARATION The manufacturer Georg F...

Page 7: ...D OF OPERATION Item Description 1 Upstream inlet 2 Downstream outlet 3 Control block 4 Pilot supply 5 Pilot outlet connection 1 3 2 P ID Item Description 1 Pressure reducing pilot 2 Strainer 3 Restric...

Page 8: ...Drop 0 1 bar With medium temperature 20 C 20 C on request Pilot dependent Flow rate size dependent 1 5 FLANGE SIZING DATA Dimension Nominal Pipe Diameter Flange compatibility Kv m3 hr Cv USGal min DN...

Page 9: ...al size DN DN0200 DN300 Allowable pressure PS 16 Bar g 20 C Allowable incidental pressure 1 1 x PS Continuous Operating temperature range 20 C 20 C on request Flow coefficient Cv See Pressure Rating P...

Page 10: ...10 1 7 BILL OF MATERIALS PRESSURE REDUCING ASSEMBLY...

Page 11: ...l 2 7 Tameson R1 4 to G1 4 Unequal tee 2 8 Nero R3 8 R1 4 Reducing nipple 1 9 Nero R1 4 barrel nipple 2 10 Vee Lok R1 4 to 10mm tube straight 3 11 Vee Lok R1 4 to 10mm tube elbow 1 12 Accu G1 4 Plug 5...

Page 12: ...12 1 8 BILL OF MATERIALS VALVE BODY...

Page 13: ...ion valve handle 1 109 M20 x 1 5 to G1 4 Bulkhead 4 110 Spring 1 111 Geann G3 8 quarter turn ceramic cartridge valve 1 112 Core seal 1 113 Primary shaft seal 1 114 Inlet 1 115 BS110 Control space seal...

Page 14: ...14 1 9 BILL OF MATERIALS CONTROL BLOCK Item No Description Quantity 201 Control Block 1 203 60 Mesh Strainer 1 204 Control block strainer plug 1 205 BS119 Strainer 1...

Page 15: ...1 4 Pilot base plug 1 309 Pilot setpoint bolt 60mm 1 310 PR1 Pilot Nameplate Sticker 1 311 Pilot Primary Spring 1 312 Pilot Actuator Spring 1 313 Pilot Diaphragm Bolt 1 314 Pilot base seal 1 315 Pilot...

Page 16: ...ption Quantity 501 Control block mount 1 502 CAM Restrictor 1 503 Speed control schematic plate 1 504 CAM Damper seal 1 505 Bossard pan head Torx screw 2 2 x 5mm 2 506 3 x 24mm ISO2338 Parallel dowel...

Page 17: ...1008 DN250 173021009 DN300 173021010 1 11 2 PRESSURE SENSE PORTS Logging equipment and pressure gauges can be attached on the upstream downstream and PCS Control Space Pressure control loop ports Pres...

Page 18: ...ll set Flat head screwdrivers Torque wrenches Allen hex keys full set ball ended 1 12 2 LUBRICATION THREAD SEALANT Lubrication The manufacturer approved lubricant for all static seals is any generic W...

Page 19: ...e instruction manual is part of the product and an important component within the safety concept Non observance may lead to severe injuries Read and observe instruction manual Always have instruction...

Page 20: ...at room temperature and out of direct sunlight at all times WARNING DO NOT LIFT via the external control system i e the pilot pilot bracket or feed tubes Damage to these components through improper li...

Page 21: ...nd an upstream flow meter are also recommended 2 2 1 BYPASS LINE For existing installations with bypass lines GF Piping Systems recommends the configuration shown below Isolation valves 1 and 6 must b...

Page 22: ...Recommended 3 Flow Meter 4 NeoFlow Pressure reducing valve 5 Downstream Hydrant Recommended 6 Downstream Isolation Valve 7 Upstream Bypass Isolation Valve 8 Bypass Valve Location 9 Bypass Downstream...

Page 23: ...23 2 2 2 PERMITTED VALVE ORIENTATIONS Horizontal Orientation Vertical Orientation...

Page 24: ...mble the valve see table below WARNING All pipework MUST be securely fastened to the ground or other solid object before the installation is commissioned to constrain the valve adequately VALVE SIZE A...

Page 25: ...dication Washer It is recommended that the pilot spring is selected so that the maximum setpoint pressure is near to the upper limit of its pressure range e g for 7 bar setpoint pressure a black sprin...

Page 26: ...a hydrant open the outlet shut off valve only slightly to be able to control the pressure WARNING Leaking flange connection Danger of injury and or damage to property due to leaking flange connections...

Page 27: ...27 a Fit gaskets and place four stud bolts in the bottom 4 bolt holes b Apply grease to the ends of the bolts and add retaining washers and nuts loosely c Place valve in the centre of the bolt circle...

Page 28: ...28 d Insert remaining bolts and tighten four studs in a cross pattern to their designated torques see section 2 5 Repeat with remaining four studs and re tighten all eight...

Page 29: ...APTORS a Follow steps a d from section 2 4 within the user specified flange adaptors b Place flange adaptor valve assembly into the pipeline and slide the retaining collars onto the pipework ensuring...

Page 30: ...EPS IN THE COMISSIONING PROCESS ARE FOLLOWED IN SEQUENCE 3 1 NEOFLOW EXTERNAL COMPONENTS Item Description BV1 Upstream Control loop Ball Valve BV2 Downstream Control loop Ball Valve CS Control Space I...

Page 31: ...ed control valve alters the response time and stability of the valve GF Piping Systems recommend setting the speed control valve to the positions stated in the table below Size Recommended Speed Contr...

Page 32: ...sure inlet and outlet isolation valves A and O and hydrant H are closed b Open BV1 BV2 control loop ball valves and CS control space isolation valve before pressurisation c Fully open the adjusting sc...

Page 33: ...g valve with black colour coding of the pilot valve spring is 3 bar Caution Use of an incompatible NeoFlow pressure reducing valve type The manufacturer s specifications regarding the maximum pressure...

Page 34: ...n e Check thoroughly for leaks around the valve 3 4 SETTING PRV DOWNSTREAM PRESSURE 3 4 1 WITH HYDRANT a Attach pressure gauges to valve body to monitor upstream downstream pressure b Open hydrant H a...

Page 35: ...35 g Fully open the outlet isolation valve O h Fine tune pilot setpoint to desired downstream pressure then tighten and secure with the nut...

Page 36: ...E SPEED CONTROL Turning the Speed Control Valve clockwise will increase valve response time Turning the Speed Control Valve anti clockwise will improve valve stability Only if instability is observed...

Page 37: ...ium Use eye protection Provide for safe collection of the medium flowing out by implementing appropriate actions Allow the valve to drain in a vertical position and collect the medium during the proce...

Page 38: ...may be ejected at high pressure Ensure eye protection is worn at all times a Isolate the control space by closing CS this will hold the current actuator position and hold the setpoint provided the fl...

Page 39: ...the valve is live i e still in service but it is recommended that the downstream system is isolated i e downstream gate valve closed a Depressurised control system as per section 4 1 b Ensure BV1 BV2...

Page 40: ...l block peeling body 1 Ensure eye protection is worn at all times Assume a protected position Only open ball valves slowly Securely collect the medium Water may be ejected at high pressure e Replace h...

Page 41: ...l pressure and do not remove until satisfied the line is depressurised and drained Assume a protected position Securely collect the medium a Loosen and remove all flange bolts from around the valve in...

Page 42: ...42...

Page 43: ...the valve always use two spanners on both sides of the fitting to prevent the valve body metal thread inserts becoming loose a The pilot control system can be detached and serviced by removing the sta...

Page 44: ...Remove Strainer with an alley key and flush through with water in accordance with section 4 2 b Remove the restrictor insert with a flat head screwdriver and inspect for any blockages c On reassembly...

Page 45: ...4 5 2 PRV PILOT Refer to Section 1 10 for Bill of Materials a Wind the pilot screw anticlockwise until the loading spring force can no longer be felt b Undo the eight bolts and lift the spring housin...

Page 46: ...onents off the shaft Replace the diaphragm and reassemble e Inspect the base assembly for wear or damage paying particular attention to the O Ring and poppet f On reassembly it is recommended that all...

Page 47: ...ove the Speed Control Assembly Note the Control Space Seal below it b Rest the valve on the rear face c To gain access to the internal O ring seals loosen the casing bolts around the valve d Lift the...

Page 48: ...ator piston Inspect the primary shaft O ring seal for wear or damage f If a metal thread insert becomes loose remove fully and apply Loctite 5331 thread sealant across the whole thread Reinsert until...

Page 49: ...approved lubricant Correct lubrication of the seals and sliding components is required for the correct functioning of the valve Other lubricants may attack materials and seals and are not permissible...

Page 50: ...med with the control system still on the valve a Remove the inlet screws using a Torx Plus screwdriver head Remove the inlet strainer and inlet piece to reveal the shut off seal b Remove the shut off...

Page 51: ...al first place it on the inlet component as shown then place the inlet component back onto the main body casing e Retighten inlet screws Note these are self tapping screws tighten until tightening tor...

Page 52: ...valve is not working as intended follow NeoFlow Diagnostics Flow Chart A If the diagnostics flow charts cannot find the root cause or resolve the issue full valve removal and service is necessary Cont...

Page 53: ...53 NeoFlow Diagnostic Flow Chart A...

Page 54: ...54 NeoFlow Diagnostic Flow Chart B...

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