You are on page 1of 11

SERVICE INSTRUCTION

HALE HAMILTON (VALVES) LIMITED

SERVICE INSTRUCTIONS

FOR

AUTO DRAIN VALVE

TYPE DV4

6 AN18895 TF 22/08/11
5 AN18845 TF 01/08/11
4 AN17833 TF 15/03/10
differences between mark numbers clarified, non-
3 TF 17/07/03
electrical compliance with ATEX included
2 formatted for word 97, made generic TF 10/09/02
1 FIRST ISSUE 10/06/99
ISSUE NO REVISION SIGNED DATE

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 1
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

CONTENTS
1 SAFETY INSTRUCTIONS............................................................................................ 2
2 DESCRIPTION............................................................................................................. 3
3 CERTIFICATION.......................................................................................................... 3
4 INSTALLATION............................................................................................................ 3
5 SETTING TO WORK.................................................................................................... 4
6 OPERATION ................................................................................................................ 4
7 PERIODIC MAINTENANCE ......................................................................................... 4
8 SERVICING PROCEDURE.......................................................................................... 5
9 FIGURES ..................................................................................................................... 7

1 SAFETY INSTRUCTIONS
THIS EQUIPMENT CONTAINS HIGH PRESSURE AIR. IMPROPER USE CAN ENDANGER
HUMAN LIFE.
THE EQUIPMENT MUST BE ISOLATED FROM HIGH PRESSURE SUPPLIES AND ALL
PRESSURE MUST BE VENTED BEFORE ANY SERVICING WORK IS UNDERTAKEN.
EVERY REASONABLE PRECAUTION HAS BEEN OBSERVED IN THE DESIGN OF THIS
EQUIPMENT TO ENSURE THAT COMPETENT PERSONS CAN USE AND SERVICE IT
SAFELY.
SOME VARIANTS OF THIS EQUIPMENT ARE FOR USE IN POTENTIALLY EXPLOSIVE
ATMOSPHERES. ONLY PERSONS COMPETENT TO CARRY OUT WORK ON SUCH
EQUIPMENT ARE PERMITTED TO SERVICE THIS EQUIPMENT. IN PARTICULAR, THE
ELECTRICAL CONNECTIONS MUST BE MADE BY COMPETENT PERSONS.
UNAUTHORISED PERSONNEL SHOULD BE PROHIBITED FROM TAMPERING WITH THIS
EQUIPMENT.

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 2
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

2 DESCRIPTION
2.1. DV4 is a 1" (24mm) nominal bore, actuated stop valve. The actuator is pneumatic
and is integrated into the valve body.
2.2. The valves are used in gas turbine installations to drain unburnt fuel in case of a
failed turbine start or to drain water after washing operations.
2.3. The valves are suitable for use with combinations of particulate fuel combustion
products, diesel/paraffin type fuel, de-mineralised water and detergent.
2.4. The valve and actuator working pressures are shown on the GA.
2.5. The base model DV4 (Mk 0) is rated for 250 C. It has no electrical position
indication.
2.6. DV4 Mk 1 is rated for 150 C. It has a single microswitch to give electrical indication
that the valve is closed.
2.7. DV4 Mk 2, Mk 3, Mk 4 and Mk 5 are rated for 200 C.
2.8. DV4 Mk 2, Mk 3, Mk 4 and Mk 5 have a mechanical visual/tactile indicator.
2.9. DV4 Mk 2, Mk 3 and Mk4 may be supplied with micro switches to indicate fully
open only; fully closed only; fully open and fully closed or with no switches. The
options are detailed on the GA drawing.
2.10. DV4 Mk3 has a hard (metal) seat.
2.11. DV4 Mk4 is designed to hold open at a higher pilot pressure.
2.12. DV4 Mk5 has a hard (metal) seat and two switches which both indicate fully closed.

3 CERTIFICATION
3.1. All marks except Mk1 are ATEX category 3, Zone 2, Group II gas atmospheres.
3.2. DV4 Mk 1 is NOT suitable for use in potentially explosive atmospheres.
3.3. DV4 is NOT suitable for use in dusty atmospheres.
3.4. DV4 Mk 2, Mk 3, Mk 4 and Mk 5 are suitable for use in Class I, Division 2 Groups A
B C & D hazardous (classified) locations.

4 INSTALLATION
4.1. Unpacking
4.1.1 Units are supplied in sealed bags. If a unit is damaged or contaminated, it
should not be used.
4.1.2 The packaging should only be removed just prior to installation and
cleanliness, and lubrication specifications should be followed. When removing
the packaging, make sure that nothing contaminates the equipment.
4.1.3 Protective plugs and caps should be removed just prior to installation. If
possible, the plugs and caps should be kept so that they can be reused if the
equipment is returned for servicing.
4.1.4 On removal of the protective plugs, ensure no dirt or moulding flash from the
plugs contaminates the equipment.

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 3
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

4.2. Cleaning
4.2.1 Units supplied by HH(V) are cleaned to the Cleanliness Specification stated on
the GA drawing before despatch.
4.2.2 The equipment to which the unit is to be connected should be cleaned to a
similar specification and the operating medium should also be clean.
4.3. Lubrication
4.3.1 Units supplied by HH(V) are assembled using the lubricants specified in the
Lubrication Specification stated on the GA drawing. The same lubricants
should be used for installation.
4.4. Connections
4.4.1 The inlet and outlet ports are threaded 1" NPT female.
4.4.2 The actuator port is 1/4" NPT.
4.4.3 The vent port must be kept clear.
4.4.4 The 1/8" NPT vent port, where fitted, should be connected to a safe drain. This
vent is to prevent the process fluids from reaching the switch compartment if
the seal fails. It can also be used to test the seals (see Figure 5).
4.4.5 Where electrical position indication is fitted, the switch electrical rating and
wiring connection information is shown on the GA.
4.4.6 The cable exit port, where fitted, is 1/2" NPT female.
4.5. Mounting
4.5.1 The valve may be supported by its 1" NPT connections.
4.5.2 The valve must be protected against impact.

5 SETTING TO WORK
5.1. The valve does not require setting to work.

6 OPERATION
6.1. The valve is held open by a spring and closed when the actuator port is
pressurised.
6.2. The valve is designed to be operated with the pilot supplied from the inlet (see
Figure 1). If the pilot pressure is supplied independently, the operating pressures
cannot be guaranteed.

7 PERIODIC MAINTENANCE
7.1. Every 5 years or 10,000 cycles or as part of the regular re-fit, whichever comes
first: the valve should be stripped and all recommended spare parts changed.
Recommended spare parts are identified on the Parts Lists.

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 4
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

8 SERVICING PROCEDURE
8.1. In the following instructions DV4 (Mk 0) is similar to DV4 Mk1 except that switches
are not fitted. DV4 Mk2, Mk3, Mk4 and Mk5 are similar except for differences noted
for Mk4.
8.2. The valve should be disconnected from piping and stripped in a clean area.

SAFETY WARNING
If possible, put the valve in the open position.
8.2.1 Isolate the valve and vent pressure from both the outlet and inlet sides.
8.2.2 Vent and disconnect the actuator line.
8.2.3 Disconnect the position indicator cable, if fitted.
8.3. To remove the diaphragm:
8.3.1 Refer to Figure 2, Figure 3 or Figure 4.
8.3.2 Clamp the valve body in a soft jawed vice.
8.3.3 Unscrew the six cap screws from the end plate. The end plate is under spring
tension.
8.3.4 Remove the end plate.
8.3.5 Remove and discard the diaphragm. Renew on re-assembly.
8.3.6 On DV4 Mk4, press in the diaphragm support piston and unscrew and remove
the screws holding the diaphragm support ring.
8.3.7 Remove the diaphragm support ring where fitted (see Figure 3). Take care not
to damage or dislodge the visual indicator rod, where fitted (see Figure 6).
8.4. To disassemble the valve:
8.4.1 Unscrew the six cap screws from the inlet flange.
8.4.2 Remove the inlet flange.
8.4.3 Remove and discard the valve seat. Renew on re-assembly.
8.4.4 Using an Allen key, loosen the set screw in the diaphragm support piston.
8.4.5 Using an Allen key, unscrew the valve spindle from the diaphragm support
piston.
8.4.6 Remove the diaphragm support piston.
8.4.7 Take care when removing diaphragm support piston as the indicator rod,
where fitted, is under spring tension. Remove indicator rod, rod guide and
indicator rod spring (see Figure 6).
8.4.8 Remove and discard valve spring. Renew on re-assembly.
8.4.9 Remove valve spindle.
8.4.10 Unscrew seal retainer.
8.4.11 Remove and discard O ring from valve body. Renew on re-assembly.
8.4.12 Remove and discard O ring and sealing washer from seal retainer, where
fitted. Renew on re-assembly.

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 5
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

8.5. To replace switch on DV4 Mk 1:


8.5.1 It is not necessary to remove the switch for routine maintenance.
8.5.2 Refer to Figure 2.
8.5.3 The switch can be removed without dismantling the valve.
8.5.4 Remove the screws from the switch cover.
8.5.5 Remove the screws from the switch bracket and remove the switch assembly.
8.5.6 On re-assembly, ensure that the switch actuator arm is under the edge of the
diaphragm support piston.
8.6. To replace switches on DV4 Mk 2, Mk 3, Mk 4 and Mk 5:

SAFETY WARNING
Substitution of the following components may impair suitability for Division 2 and for ATEX:
Part number Description Type of protection
BO12281 Microswitch (Top) Hermetically sealed contacts
BO12282 Microswitch (Bottom) Hermetically sealed contacts

8.6.1 It is not necessary to remove the switches for routine maintenance.


8.6.2 Disassemble the valve according to sections 8.3 and 8.4.
8.6.3 Refer to Figure 3 and Figure 7.
8.6.4 Remove the screw from the end of the switch mounting block and remove the
switch assembly.
8.6.5 On re-assembly, ensure that each switch actuator arm deflects smoothly over
the cam profile on the skirt of the diaphragm support piston.
8.6.6 Lubricate the cam profile (see 4.3).
8.7. The valve is now completely stripped down. Inspect the components for wear.
Clean all components (see 4.2) and check small drilled passages for blockage.
8.8. Re-assembly.
8.8.1 Re-assembly is the reverse of disassembly. Use the specified lubricants (see
4.3).
8.8.2 Apply threadlocking adhesive, as stated on the GA, to the set screw in the
diaphragm support piston.
8.8.3 On DV4 Mk4, press in the diaphragm support piston and retain the diaphragm
support ring using the two screws.
8.8.4 Ensure that the diaphragm clamping surfaces are clean and undamaged.
8.8.5 Ensure that the clamping screw access hole in the skirt of the diaphragm
support piston is approximately opposite the switch location as shown on the
GA.
8.8.6 On DV4 Mk4, ensure that the diaphragm is fitted the correct way round as
shown in Figure 4.
8.8.7 Ensure that the diaphragm is central. Tighten the end plate screws
progressively, in a 1-4-2-5-3-6 sequence, to the torque settings shown on the
GA.

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 6
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

8.8.8 To align valve seat:


8.8.8.1 Assemble the inlet flange mounting screws finger tight only.
8.8.8.2 Apply approximately 0.35 bar (5 psi) to the pilot port and tighten the
screws progressively, in a 1-4-2-5-3-6 sequence, to the torque settings
shown on the GA.
8.8.8.3 Increase pilot pressure to 20 bar (290 psi) for 5 minutes to indent seat.
8.9. Test the valve to the specification stated on the GA.
8.10. The valve is now ready for installation (see 4.5).

9 FIGURES
Figure 1 Typical installation

Inlet Pilot Port

Outlet

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 7
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

Figure 2 DV4 Mk 1 Cross Section (valve shown closed)

Switch Cover
Switch Bracket

Body Switch Switch Actuating Arm

Inlet End Plate


Flange

Diaphragm

Inlet Pilot Port

Set Screw

Diaphragm
Outlet Support Piston
Seat

Valve
Spindle
Seal Vent Valve Spring
Retainer

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 8
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

Figure 3 DV4 Mk 2 Cross Section (valve shown open)


Switch & Mounting Block assembly

Body Switch Actuating Arm

Inlet View in Figure 7


Flange
End Plate
Diaphragm

Pilot Port
Inlet

Set Screw

Diaphragm
Outlet Support Piston
Seat
Diaphragm
Valve Support Ring
Spindle Section in Valve Spring
Figure 5
Seal Retainer

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 9
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

Figure 4 DV4 Mk 4 Cross Section (valve shown open)

Body Switch & Mounting Block assembly

Switch Actuating Arm

Inlet
End Plate
Flange

Diaphragm

Inlet Pilot Port

Diaphragm
Support Piston
Outlet
Seat Set Screw

Valve Diaphragm
Spindle Support Ring
Valve Spring
Seal Retainer

Figure 5 Part Section of DV4 Mk 2 Showing Vent Port

Vent
Outlet

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 10
SERVICE INSTRUCTION SI 946 OF 11
SERVICE INSTRUCTION

Figure 6 Part Section of DV4 Mk 2 showing Indicator

Diaphragm
Support Piston

Indicator Rod

Indicator Rod Rod Guide


Spring

Figure 7 Part View of DV4 Mk 2 showing both switches (End Plate and Diaphragm Support
Ring removed)
Top Switch Bottom Switch
Section in Figure 6

Indicator Rod

HALE HAMILTON (VALVES) LTD., UXBRIDGE


SHEET 11
SERVICE INSTRUCTION SI 946 OF 11