Hoffman Specialty Installation & Maintenance Instructions HS-601(F) Pilot Operated Pressure and/or Temperature Steam Regulators Series 2000 CAUT WARN ING ION ! WARNING • Before using product, read and understand instructions. • Save these instructions for future reference. • All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of steam systems in accordance with all applicable codes and ordinances.
PLANNING THE INSTALLATION Planning for the Main Valve Installation 1. The regulator main valve must be located in an accessible straight run of horizontal piping. NOTE: Main valve must be installed with diaphragm located on bottom, as shown in Main Valve Installation illustration, page 3. 2. Allow clearance on top of the main valve to remove the cover plate to inspect and service the valve. 3. Allow clearance under the main valve diaphragm cover to replace diaphragms and drop out the stem for service. 4.
INSTALLATION DETAIL Main Valve Installation T B Z A Y D M K N S O V X W C H P J F R 10 Pipe Diameters U L E G 1. Connect a steam line (A) from the steam supply to the area where regulator valve is to be located. Install tee fittings (B) for a bypass line, and (C) for the regulator line. Note: Drip traps prevent condensate from collecting in the piping during light loads or when the regulator is closed.
19. Install the bypass piping and globe valve (T). • Use the same size pipe for the bypass piping and globe valve in the bypass line as the main valve (N) to allow manual regulation during service of regulator. • Support piping to remove any stress from the regulator valve body before connecting to the system. • Make sure pipes and flanges are properly aligned to prevent stress on the regulator valve body. 20.
1. L-Tube 9. J-Tube Cut L- tube to appropriate A & B dimensions listed on Tubing Length chart. No cutting is required if dimension is marked with an * . A No cutting of J-tubes is required B 2. S-Tube C D Cut S- tube to appropriate C & D dimensions listed on Tubing Length chart. No cutting is required if dimension is marked with an * .
Bleed Orifice The function of the bleed orifice is to bleed steam off the main valve diaphragm when the pilot(s) close(s). A 1/16" (1.6mm) diameter orifice is standard, and is installed in the outlet side of the main valve when shipped. This diameter orifice is used in most applications. • Typical applications for 3/32 in (2.4mm) diameter bleed orifice may include: – Pressure differential across the reducing valve is 50 psig (3.5 bar) or greater. – High pressure PRV on a 2-stage pressure reducing station.
Spring/Air Pilots ;; y;y;y; y;y;y;y;y; Feedback Line Balance Tube ;yy;y;y; ;y;y;y;y;y;yy;y;y;y;y;y;y;y;y;y; y;y;y;y;;y;y;y;y;y;y;yy;y;y;y;y; y; y; y;y;y;y;y; Spring Pilot Main Valve Inlet Bleed Orifice 1. The 1/4" feedback tapping must be connected to the downstream piping for either a spring or air pressure pilot: • Use 1/4 black steel pipe for the feedback line (B).
Temperature and Spring Pilot Combination Pneumatic Temperature and Air Pilot Combination ;; ; ;;;;; Self-Contained Temperature Pilot y; y; y;y;y;y; ;yy;y;;y;y;y;y;y;y;y;y;y;yy;y;y; ;y;y;y ;y;y;y;y;y ;y;y;yy;y;y; ;y y; y; y; Spring Pilot Balance Tube Outlet Pilot Inlet Main Valve Inlet Balance Tube AP Air Pilot Temperature Sensor Feedback Line Signal Pilot Inlet Outlet Main Valve Inlet Bleed Orifice Bleed Orifice 1. Install the temperature pilot next to the main valve. 2.
The following chart shows the maximum outlet steam pressure that can be obtained from the main valve. The outlet steam pressure is based on the air pressure from PNT Air Signal Outlet Pressure psig Bar 9 (0.62) 10 (0.69) 11 (0.76) 12 (0.83) 13 (0.90) 14 (0.97) 15 (1.04) 18 (1.24) 20 (1.38) 25 (1.73) 30 (2.07) the pneumatic temperature pilot to an AP-1A or AP-4A Pneumatic Pressure Pilot. Intermediate pressures can be interpolated from the chart.
SYSTEM START-UP 1. Make sure all strainer blow down valves are closed and capped to prevent accidental burns. 2. Open 1/4 NPT feedback control line shut-off valve. 3. Close inlet valve to main valve. Open outlet gate valve and all equipment drain valves. Allow system to drain completely. ! CAUTION Never open a reducing valve without positive indication that the high pressure side is clear of condensate. Be sure no one is in area of any open end of pipes when steam is turned on.
ADJUSTING PILOTS Spring/Air Pilots Adjust spring/air pilot to control the system at desired pressure. The system pressure can be set for full steam or partial steam flow. Full Steam Flow – If the spring pilot is adjusted to the required reduced pressure while the system is running at full steam flow, then the reduced pressure will rise approximately 10% when the system is running at low steam flow.
TROUBLESHOOTING Replace the regulator or pilot(s) when parts no longer operate properly. A new regulator is more economical than replacing individual parts, and will provide greater reliability. General Series 2000 Regulator System Troubleshooting Guidelines Dead End Service The seat leakage rate for metal single seated valves is .01% of rated flow, which is the industry standard. In applications where .01% flow will cause pressure or temperature override, seat lapping may be required.
MAIN VALVE TESTING All tests can be performed on main valve while it remains installed in the steam system, if there are gate valves located upstream and downstream of the main valve. 1. Isolate the main valve from steam pressure by closing the gate valves that are located upstream and downstream of the main valve. 2. If the main valve has a spring pilot or air pilot installed on it, close the shut off valve in the feedback line to the spring or air pilot. 3. Disconnect the pilot valves from the main valve.
MAIN VALVE REPAIR Main Valve Repair Main valves can be repaired without removing them from the piping. Note: If a specific problem has been located during testing, only complete the steps required to complete repair of the damaged parts. 1. Isolate the main valve from the steam line. Make sure the internal pressure is 0 psig and allow the valve to cool to prevent injury. 2. Remove the main valve top cover plate (and stem top guide bushing on larger units). 3.
6. Inspect the valve seat and plug for deep scratches or deposits. Clean or replace if necessary. 7. Place a light film of valve lapping compound on the plug seating surface. Using 400 grit or finer lapping compound is recommended. (Generally available from automotive supply stores.) 8. Slide the plug on the valve stem. Do not install the lock washer or nut for lapping. 9. Slowly reduce the air loading on the main valve diaphragm until the plug touches on the valve seat.
PILOT VALVE TESTING AND REPAIR ! CAUTION Close all steam lines that could pressurize any of the valve chambers before disassembling the system. Use caution when opening any section or valve chamber as there may be hot condensate trapped inside. Failure to do so may result in burns. SPRING PRESSURE PILOT Spring Pilot Quick Test 1. Isolate the main valve from the steam line. Make sure the internal pressure is 0 psig and allow the valve to cool to prevent injury. 2.
SPRING PILOT REPAIR Spring Pilot Inspection 1. Examine the seat and disc sealing surfaces for nicks or other signs of damage by pipeline debris. Slight imperfections may be removed by lapping the surfaces together. Otherwise the seat and disc must be replaced. 2. Examine the stem for build-up of pipeline contaminants or erosion. Remove any build-up with a wire brush and polish with very fine crocus cloth. Work carefully to avoid bending the stem.
AIR PRESSURE PILOT Air Pilot Quick Test 1. Isolate the main valve from the steam line. Make sure the internal pressure is 0 psig and allow the valve to cool to prevent injury. 2. Disconnect the copper tubing line from the main valve diaphragm. Point tubing in a direction to prevent damage or burns. Stem Projection "B" to be Removed as per Instructions Gage C Prick Punch y;y;y; ;yy;y;y; y;y;y;y; y; y; y; y;y;y;y;;y;y;y;y;y;y;y y; A 8 9 ! 11 13 Quick test is done using live steam.
Air Pilot Bench Tests 1. Isolate the main valve from the steam line. Make sure the internal pressure is 0 psig and allow the valve to cool to prevent injury. 2. Disconnect the copper tubing lines and feedback line. Disconnect the pipe union and remove the pilots. If more than one pilot is used, unscrewing the 1/4 " NPT pipe nipples should separate them. 3. Mount individual air pilot in a vice to test. 4. Plug the 1/4" NPT FEEDBACK tapping. 5.
Air Pilot Disassembly (cont’d) 9. Inspect and clean all parts and gasket sealing areas. Replace any worn or damaged parts. • Reassemble using non-hardening sealant on the plug threads. • Note: The hollowed out end of the stem goes against the ball. 10. To service the upper end of the pilot: • Mount it in a vice with the top up. • Unscrew and remove the upper housing. 11. Remove upper diaphragm button, diaphragm(s) and lower diaphragm button.
Temperature Pilot Repair 1. Put pilot in vise with top up. Remove the bottom plug (4). The strainer (8), spring (5) and button (6) should drop out when the bottom plug is removed. 2. Remove the seat (2) using a 9/16" thinwall socket. The valve plug (9) will drop out also. 3. Clean and inspect all parts, lap plug (9) and seat (2) with 400 grit lapping compound. Replace if necessary. 4. Apply non-hardening sealant to bottom plug (4) threads. Reassemble pilot. 5. Retest pilot.
Temperature Actuator Assembly Testing 1. Loosen calibration set screw on indicator ring. Drop away from dial. 2. Loosen Allenlock set screw on knob assembly. Unscrew adjustment knob assembly from actuator. 3. Insert flat ended smooth wooden dowel into the bellows. Note: Bellows should be firm. If it is spongy, the actuator has lost its liquid fill. For more precise testing, use a depth micrometer. The bellows should move 0.00057 inch (0.0144mm) per degree change of the sensing bulb. 4.
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