GE Energy

Rev.: B
Page: 1/11
OPERATION AND MAINTENANCE MANUAL
COMPONENT LITERATURE

EQUIPMENT DEFINITION

GE DEVICE : VPR2-1

DESIGNATION : BEARING HEADER PRESSURE REGULATOR

VALVE

SUPPLIER : MASONEILAN

TYPE : N°525

LITERATURE REFERENCE : EY 5200 E+176420 E (10 PAGES)

All right reserved copyright

OMML_0416_24_VPR2-1_B_EN Revision: B Date: 12/2013
No. 525 Reducing Valve

No. 525 Pump Pressure Regulator

II II

No. 526 Pressure Regulator

Before installing. blow out line thoroughly remove all
foreign matter which might foul the valve. Place the
regulator vertically in a horizontal run of pipe so that the
controlled fluid will flow through the valve in the direction
indicated by the arrow on the valve body or the words IN
and OUT marked on the connections. On steam service,
the valve should be installed with the diaphragm chamber
down so that the diaphragm will be protected by a water
seal. If installed otherwise. an adequate water seal must
be incorporated.
Pipe the controlled pressure from a convenient point in
ADJUSTMENT
When pressure setting is specified, the regulator is set
accordingly at the factory; otherwise it is set at the
mum of the range shown on the serial plate.
Open stop valve on the outlet side of the regulator and
partially open stop valve on the inlet side, allowing
sure in the system to build up slowly. Then open control
MAINTENANCE
Failure to Shut Off: If there is excessive leakage through
the valve when it is shut off, the cause may be --
( Foreign matter holding valve off seat disassemble
and clean.
(2) Normal wear regrind seating surfaces, or if neces-
sary, replace valve plug seat rings.
Proceed as follows to disassemble valve to clean or regrind
seats :
No. 525 and 535 Reducing and Pump Pressure Regulators
Disassembly: Disconnect the control line at the upper
diaphragm case (43). Remove body stud nuts (or cap
screws) and lift actuator, bonnet valve plug (4) and
plug stem (5) from valve body. Clean seating surfaces.
with a clean soft cloth.
Seats: stem locknuts turn them
down plug stem and lock them together. With wrench
applied over locknuts, turn plug out of actuator
stem (26). Remove clamping nut (9) and detach yoke
(17) from bonnet. Replace bonnet with valve plug, on
body and grind seats lightly using bonnet as guide. Grind
only a small amount using a “fine” compound on all
seating surfaces. Excessive grinding will only shoulder
the seat ring. and will not improve seating. If seating
surfaces are damaged to the extent that light lapping
not the condition, surfaces should be remachined
or parts replaced. Clean seats thoroughly and reassemble.
Reassembly: Turn plug stem into actuator stem as far
will go and replace actuator and bonnet on body.
Apply slightly more pressure to diaphragm actuator than
spring is set for. Turn plug stem out of actuator stem
until plug is seated. Relieve diaphragm pressure and
turn plug stem out of actuator stem to turn more.
Lock stems with locknuts.’
No. 526 and 536 Back-Pressure Regulators
Apply sufficient pressure to diaphragm to
move valve plug off seats. Remove bottom flange (7).
Loosen packing box flange nuts (13). Turn plug stem
out of actuator stem as directed for No. 525 valves.
Remove locknuts from and turn stem out of pack-
ing box. Remove valve plug from body and clean seating
surfaces clean soft cloth.
the line 6-10 feet from the regulator (or in the discharge
line 6-10 feet from the pump on pump pressure applica-
tions) to the NPT connection in the diaphragm case.
Install a gauge and a needle valve in the control line.
The valve permits shutting off the control line and also
serves as an adjustable choke to prevent cycling of the
regulator, which may result from the pulsation of a pump
in the system.
A three valve by-pass around the regulators permits re-
moving the regulator from the line without shutting down
the system.
line valve and check setting by means of the gauge. To
increase pressure setting, turn adjusting screw clockwise
to compress the spring. To decrease the setting, turn
adjusting screw counterclockwise to relieve spring
pression. Fully open stop valve on the inlet side of the
regulator.
Grinding Seats: Relieve diaphragm pressure, remove
clamping nut (9) actuator from bonnet. Reinsert
stem and valve plug and grind lightly using bonnet as a
guide. Employ caution in grinding as noted for No. 525
valves. Clean seats thoroughly and reassemble.
Reassembly: Replace drivenut, valve plug with
and bottom flange. Thread locknuts onto plug stem and
turn plug stem into actuator stem until plug is seated.
Tighten packing box flange nuts slightly, but not too
tight. Apply sufficient pressure to diaphragm to
valve plug off seats. Turn plug stem into actuator stem
an additional to turn hnd lock stems with locknuts.
Relieve diaphragm pressure.
All Valves
R e p l a c i n g D i a p h r a g m : Relieve all spring compression.
Remove upper diaphragm case, actuator and
washer, and diaphragm. Install diaphragm, lining
up holes with holes in diaphragm case. Readjust spring
compression.
Packing Box Lubricator Keep lubricator filled with
specified Masoneilan lubricant and turned in firmly but
not tightly. The lubricant is intended as an aid to the
packing, not as a packing itself. Too little lubricant is
better than too much.
A ball (and isolating valve on steel regula-
tors) prevents leakage when lubricator is being filled..
Packing: The packing box gland should be kept firmly
against packing only pressure to prevent
leakage, since tight packing affects control characteristics
adversely. Be sure that ends of the flange exert
equal pressure on the gland. If necessary to renew pack-
ing, disassemble valve as directed previously, remove
locknuts and turn plug stem out through packing box.
Remove packing box flange and gland, push out old
packing, together with lubricant ring, by working from
underside of bonnet. Insert new- ring packing one
half inch depth of packing, then lubricant ring, then more
packing rings to fill packing box. In an emergency, string
packing may be inserted without removing old packing,
after first taking valve out of service.
 No. 525 Double Ported No. 526 Double Ported
(No. 535 is single ported type) (No. 536 is single ported type)

PARTS REFERENCE

No. Part Name No. Part Name Part Name

1 Packing. 44 Diaphragm Case (lower).

Seat Ring. 16 Lubricant Ring. 45 Cap Screw (diaph-case).
Small Seat Ring 17 Yoke. 46 Nut (diaph-case).
Valve Plug. 18 Cap Screw. 47 Body Stud.
Valve Plug Stem. 22 Actuator Spring. 48 Nut (body stud).
Plug-Pin. Actuator Stem. Body Gasket.
Bottom Flange. Stem Locknut. 54 Guide Bushing w/ref. 7 8)
Bonnet. 34 Spring Seat.
36 62 Serial Plate.
9 Clamping Nut. Spring Adjustor.
Diaphragm. 63 Screw (serial plate).
10 Packing Gland.
11 Packing Flange. 40 Diaphragm Plate. 65 Pipe Plug.
12 Packing Flange Stud. 41 Diaphragm Washer. 75 Cap Screw.
13 Packing Flange Nut. 43 Diaphragm Case (upper). 78 Dynaseal Washer.

. Recommended spare part.

: When ordering replacement and in correspondence give contained on serial plate (62) attached to regulator
107, av. Ch.-de-Gaulle 92521 Neuilly-sur-Seine Cedex Tel. (1) 47.45.17.80 Telecopier (1) 46.24.77.68 620046 F
FRANCE

PLANTS, SPARE PARTS and AFTER SALES DEPARTMENTS: 3, rue Saint-Pierre 14110
Tel. 31.69.03.40 Telecopier 170728 F

16, CAEN MAY 1973

Masoneilan
Valve &Co
General
These adjustment and maintenance instructions apply to
the 10900 Series Actuators used with the Masoneilan
500 Series Pressure Regulators. They include a parts
reference list including recommended spare parts (see
pages 3 4).
For installation, operation, adjustment and maintenance
of the 500 Series Regulators body S/A refer to instruc-
tions Nos indicated by the following table.
525; 525-50 EY 5200 E ; EY 4550 E
526; 526-50
I I
535H; 176418E
536H; II
I I
176419E
Spare parts
When performing maintenance always use Masoneilan
replacement parts. Parts are obtainable through your
local Masoneilan Representative or Spare Parts
Department. When ordering parts, always include Model
and Serial Numbers shown on serial plate.
After sales Department
Masoneilan has a highly skilled After Sales Department
available for start-up, maintenance and repair of our
regulators and components parts. Contact the nearest
Masoneilan Sales Office or Representative or, directly
the After Sales Department of Plant.
Training
regularly holds training seminars for
technicians in its factory of In order
to participate in one of these training seminars you
should get in touch with our local Masoneilan
Representative or our Training Department.
I The following instructions should be thoroughly
reviewed and understood prior to installing opera-
ting or performing maintenance on this equipment.
Only qualified personnel to service this equip-
ment.
Non-compliance with safety rules and caution
notes of this instruction may bring about malfunc-
tion of the device or damage it seriously. In addi-
tion, such negligence might expose personnel pre-
sent on the field to grave hazards.

Description-Operation
The 10900 Actuator is a simple powerful mechanical
device. It is Air-to-Extend Stem type. The nominal range
of an actuator is the pressure range in pounds per squa-
re inch (psi) in which the pressure setting can be obtai-
ned by adjustment.
Conformation of the diaphragm (11) to the diaphram
plate (10) serves as a flexible upper guide for the actua-
tor stem (6). Nylon reinforced neoprene diaphragms per-
mit smooth, sensitive operation. The lower guide is an
oil impregnated bronze bushing (3) located in the spring
adjuster (2).
Note: On request, for special services, the nylon rein-
forced neoprene diaphragm may be provided with a
PTFE coating.
The 10900 Series Actuators are designed for use with
the 500 Series Regulators for reducing, back pressure
and differential pressure applications.
The opposite chart indicates the combinations available
to provide the desired function. The 10900 Series
Actuators are designated by the nominal range (psi).
See the following chart.
In Spring Diaphragm Actuators, three actuator cases are
available: a case rated for 60 psi static pressure, a case
rated for 250 psi static pressure and a case rated for
750 psi static pressure.
In Differential Pressure Actuators, two actuator cases
are available: a low-pressure case rated for 250 psi sta-
tic pressure, and a high-pressure case rated at 600,
1000 and 1500 psi static pressure.
11
Spring

525
REDUCING 535H
Spring Diaphragm
5
BACK 526
PRESSURE 60-125
536H 250 I -4 - -

525-50
DIFFERENTIAL
REDUCING Differential

DIFFERENTIAL 526-50
BACK PRESSURE I 100-330 I

Instruction No 176420 E
Rev. B
 15

16

and 80-250 psi ranges

Plug Stem Serial

Nuts Plate

Regulator
Plug
Stem

Design the ; ; 2-10 6-20

and 15-40 psi ranges

Figure 1 Spring-Diaphragm Actuators for 500,

500H and 500V Models Regulators

Design for the 150-750 psi range

PARTS REFERENCE
Part Name Part Name Ref. Part Name
Yoke Diaphragm Chamber stop cup
Spring Adjuster 10 Diaphragm Plate Diaphragm Screw
Bushing Ref. 2) 11 Diaphragm 020 Dynaseal Washer
Lower Spring Seat 13 Diaphragm Case (Upper) Reducing Ring
Actuator Spring Diaphragm Washer 022 Stop Screw
Actuator Stem 15 Cap Screw 023 Stop Spacer
Cap Screw (L. case to yoke) 16 Nut (Diaph.case) 027 Upper Spring Washer
Diaphragm Case (Lower) Stud (Diaph. case) 028 Locknut (Actuator stem)
Recommended spare parts
Only on 30-75; 25 and psi ranges
on ; 6-20 and psi r a n g e s Only on 60-l 25 and 80-250 psi ranges
O n l y o n 1 5 0 - 7 5 0 psi range
Only on ;2-l 0 and psi r a n g e s a c t u a t o r s
mounted on types 526 and 536H regulators

3
 12 13 14 28 25 24 25 13
1 9

9 6
8 6

Plug
Nuts Serial
Plate

Regulator
Plug
Stem

Low Pressure Case Design High Pressure Case Design

Figure 2 Differential Pressure Actuators for and Models Regulators

PARTS REFERENCE
Ref. Part Name Ref. Part Name Ref Part Name
Yoke 9 Diaphragm Chamber Stud (Diaph. case)
Spring Adjuster 10 Diaphragm Plate w. Ref. 24) 24 Plunger Sub-assembly
Bushing Ref. 2) 11 Diaphragm 025 O-Ring
Lower Spring Seat 012 Upper Diaphragm Plate 26 O-Ring Retainer
Actuator Spring 13 Diaphragm Case (Upper) 27 Upper Spring Seat w. Ref. 6)
Actuator Stem Diaphragm Washer 028 Locknut
Cap Screw (L. case to yoke) Cap Screw 029 Connection Adapter
Diaphragm Case (Lower) 16 Nut (Diaph.case)

Recommended spare parts

Qty: 2 on Low Pressure Case Design
Only on Low Pressure Case Design Qty: on High Pressure Case Design
Only on High Pressure Case Design

Instruction No 176420 E
Rev. B
 Installation
On steam service, the regulator should be installed with In the Differential Pressure Actuators, the NPT high
the actuator down so that the diaphragm will be protec- pressure connection is located on the upper diaphragm
ted by a condensate barrier. If installed otherwise, an case (13) and the NPT low pressure connection is
adequate condensate barrier must be incorporated. located on the diaphragm chamber (9) or on the connec-
tion adapter (29).
In the Spring Diaphragm Actuators, the NPT pres-
sure connection is located on the upper diaphragm Refer to Regulators Body Instructions for installation
case (13). according to the regulator function.

Adjustment
When pressure setting has been specified in order, the
regulator is set accordingly at the factory for test. Then,
the spring compression is fully removed to avoid
unnecessary stress to parts (diaphragm, spring)
during the stocking.
It is necessary to proceed with adjustment before
servicing.
The regulator pressure range is engraved on the serial
plate.
Open stop valve on the outlet side of the regulator and
partially open stop valve on the inlet side, allowing
pressure in the system to build up slowly.
Open controlled pressure line valve(s) and check set-
ting by means of the gauge(s). Set by means of the
spring adjuster (2) of the actuator.
(To increase pressure setting (or pressure differen-
tial), turn adjusting screw clockwise to compress the
spring. To decrease the setting, turn adjusting screw
counterclockwise to relieve spring compression).

Proceed as follows : Fully open stop valve on the inlet side of the regulator.

Maintenance
CAUTION: Regulator must be isolated and pres- On differential actuators series
sure vented before disassembly. Regulators), (Figure 2)
a. On low pressure case design:
Remove the high and low pressure lines from the
Replacing diaphragm diaphragm case (13) and the diaphragm cham-
ber (9).
On spring diaphragm actuators (500 Relieve all spring compression by unscrewing
series Regulators), (Figure 1) spring adjuster (2).
Remove nuts (16) and cap screws (15). Remove
z Remove the controlled pressure line from the dia-
upper diaphragm case (13).
phragm case (13) and relieve all spring compression
by unscrewing spring adjuster (2). Remove locknut upper diaphragm plate
upper O-Ring washer (14) and dia-
z Remove upper diaphragm case [nuts (16) and phragm (11).
screws [not screws (15) on 150-750 psi range].
Install new diaphragm and reassemble by
z a) On 6-20 and psi ranges: reversing of the above description order. Replace
upper O-Ring (25) if necessary.
Remove locknut diaphragm washer (14) and
diaphragm (11). z Readjust the spring compression (see above).
b) On 30-75, 60-125 and 80-250 psi ranges:
b. On high pressure case design:
Remove diaphragm screw seal washer
Remove the high and low pressure lines from
stop cup (18) and diaphragm (11).
the diaphragm case (13) and the diaphragm
c) On psi range: chamber (9).
Remove diaphragm (11). Relieve all spring compression by
spring adjuster (2).
Note: means of a wrench applied on the plug stem Remove nuts upper diaphragm case (13) and
nuts, hold the actuator stem during this operation. diaphragm (11).
z Install new diaphragm and reassemble by reversing of Install new diaphragm and reassemble by rever-
the above description order. sing of the above description order.

z the compression (see above). Readjust the spring compression (see above).

5
Replacing O-ring(s) (25) (low and z With a wrench applied over O-Ring retainer
unscrew it out of diaphragm chamber (9).
high pressure case)
z Remove O-Ring being careful not to damage
On differential actuators, (Figure 2) plonger. Install new O-Ring, replace and tighten O-
* Disassemble the actuator head as described on the Ring retainer (26).
paragraph : “Replacing diaphragm”, (see page 5).
z Remove diaphragm chamber (9) with plunger z Reassemble and readjust spring compression,
S/A (24). (see page 5).

Uniformly tighten diaphragm

when reassembling,

Masoneilan
4, p l a c e d e Saverne 92971 P A R I S LA CEDEX- Tel. 0 1 4 9 0 4 9 0 0 0 -Telecopier 0 1 4 9 0 4 9 0 -Telex 620046 F
FRANCE

PLANTS, SPARE PARTS and AFTER SALES DEPARTMENTS: 3, rue Saint-Pierre-14110

Tel. 0 2 3 1 6 9 5 9 0 0 -Telecopier02 3 1 6 9 3 8 44-Telex
MN DESKTOP PUBLISHING. August 1997

instruction No 176420 E
Rev. B and 6