Installation Manual: Switzerland (Head Office) New Zealand

INSTALLATION MANUAL
for
DOME LOADED PRESSURE REDUCING VALVE
TYPE C1 / C2-K32
Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Industriestr. 2, CH-8590 Romanshorn P.O.Box 16134, NZ-Christchurch
Tel. + 41 71 466 80 80 Fax + 41 71 466 80 66 Tel. + 64 3 349 7029 Fax + 64 3 349 4337
e-mail: info@ascoco2.com www.ascoco2.com e-mail: info@asco.co.nz
Congratulations on your choice
and thank you for your confidence
in our product!
ASCO CARBON DIOXIDE LTD
Romanshorn / Switzerland
c ASCO 2007
Version 4.0 C1/C2/E

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TABLE OF CONTENTS Page - 1 -
Information: Pages
Short introduction 2-4

General instructions 5/6
Installation and operation 7/8
Spare parts 9/10
Maintenance 11-13
Fault location and rectification 14
Trouble shooting 15
Technical specification 16
Contact 17

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SHORT INTRODUCTION Page - 2 -
1. DOME LOADED PRESSURE REGULATOR
Used for accurate control of outlet pressure.
Medium pressure - heavy duty - economic - dome controlled pressure reducing valve - constant
and non delayed regulation even on pressure fluctuations
2. FEATURES
- Constructed in brass (C1).

- Constructed (C2) cast iron.
- Abrasion and dirt resistant rubber valve seats.
- Stable and noiseless operation.
- Fail-safe at closed position.
- Positive bubble-tight shut-off.
- C1 1" BSP, C2-K32 2" BSP
- High flow contoured passages; ideal for CO2
3. MEDIA
CO2 - Carbon Dioxide
4. PRESSURE RANGE
C1 (1 inch) Inlet : max. 100 Bar (1400 psi)

Outlet : 0 - 69 Bar (0 - 1000 psi)
C2-K32 (2 inch) Inlet : max. 100 Bar (1400 psi)
Outlet : 0 - 65 Bar (0 - 950 psi)
5. CAPACITIES
Type Part No. Connection CO2 Gas output per hour calculated
at inlet pressur at 18 bar
outlet at 5 bar at 8 bar at 10 bar
C1 914000 R 1" 500 kgh/hr 800 kg/hr 1000 kg/hr
C2-K32 914006 R 2" 2500 kg/hr 4000 kg/hr 5000 kg/hr

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ASCO dome loaded pressure regulators operate under the simple basic law governing gas pressure
and volume within closed chambers. Briefly stated, this law provides that " the pressure of an enclosed
gas varies inversely to its volume." A reduction in volume therefore results in an immediate increase
in pressure - an increase in volume conversely produces an immediate decrease in pressure. Both of
these factors are effectively used by I. V. Pressure Dome in its operation. Although a relatively small
change in the large volume within the dome power chamber produces only a slight pressure variation,
the slightest variation in the small volume within the actuating chamber creates an enormous change
in pressure. The restricting orifice connecting those two chambers governs the rate of pressure
equalization by retarding the flow of gas from one chamber to the other. The momentary extreme
pressure differential between the two chambers supplies the dependable automatic reaction within
the dome.
Quick changing forces, such as flow turbulence, off balance and other effects common to single seated
valve construction move the diaphragm by means of the connecting valve stem. This movement tends
to change the small volume within the actuating chamber and results in an enormous momentary
resisting force which eliminates undesirable effects on the control system.
The design with nearly equalized diaphragm pressures permits the use of extraordinarily large
diaphragm areas. This not only exerts a powerful leverage in the control of the diaphragm over the
valve, but also provides instantaneous response to changes in differential between dome pressure
and outlet pressure.
The diaphragm is made of a thin synthetic rubber composition permitting a greater sensitivity than
would normally result with a spring loaded controller in which the reacting forces on the diaphragm
are unequal, so that the dome plate above the diaphragm and the valve body surface below it provide
a positive support; therefore under no conditions the diaphragm is ever subjected to a bursting
pressure as would be the case with a spring loaded type of controller.
FUNCTIONING
The pressure reducing regulator is of the type - deriving its powerful equalizing force from the large
volume power dome or loading chamber, which is charged with a compressible gas or air, at a pressure
equal to the reduced pressure desired. When the chamber is loaded and the loading valve closed,
the dome will retain its charge almost indefinitely. In operation the trapped pressure within the dome
passes into the actuating chamber through the small separation plate orifice and impels the large
flexible diaphragm forcing the reverse acting valve off its seat. The supply of pressure entering the
regulator is then permitted to flow through the open valve into the reduced pressure line. A large
internal control impulse passage transmits this pressure in the down stream line approximates the
loading pressure is the dome and the unbalanced forces are equalized, the valve is closed. With the
slightest drop in delivered pressure, the pressure charge in the dome instantly forces the valve open,
allowing a measured volume of flow to pass, thereby maintaining the delivery at a constant pressure.

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C1
C2-K32

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GENERAL INSTRUCTIONS Page - 5 -
POWER TRANSMISSION
The only moving parts in the pressure reducing regulator consist of the diaphragm, diaphragm plate,
diaphragm spring, the valve and valve spring. Each of these parts is a separate independent unit.
Actuating pressure in the dome exerts its downward force on the diaphragm plate, which transmits
this force to the valve stem, pushing the valve open. The differential pressure and the valve spring
acting on the lower face of the valve create a counteracting force tending to close the valve. The
diaphragm spring, in addition to supporting the diaphragm plate, acts as a frictionless guide. The
valve spring supports the valve, keeping it in constant contact with the diaphragm plate.
SAFETY
In case of a failure of the membrane the valve closes automatically.
RE-ENTRY INTO SERVICE
After replacing VALVE and SEAT, open outlet stop-valve and then open the inlet stop-valve. Check
the reduced-pressure reading on the gauge and adjust as necessary by venting or increasing pressure
in the dome. After replacing DIAPHRAGM, open outlet stop-valve and then open inlet stop-valve.
Check if the dome needle valve is closed and then load the dome in the manner described on page 7.

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GENERAL INSTRUCTIONS Page - 6 -
A. Maximum reactive force to

Valve chamber
1. Dome chamber
2. Pressure balancing chamber
3. Restricted orifice
4. Outlet passage
B. Maximum flexibility
from Valve stability
and reactive force
C. Max. Valve stability

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INSTALLATION AND OPERATION Page - 7 -
INSTALLATION
Before commencement of any instalation work, it is important that any source of pressurised media
must be turned off or isolated from the point at which the C1/C2-K32 will be installed. Damage may
occur to the valve if subjected to any impact. This risk increases at lower temperatures. If the valve is
dropped or subjected to any impact it should be returned to the manufacturer for inspection. At all
times, it is essential that isolating valves must be actuated slowly. The two ports are diametrically
opposite and it is important that the PRV is correctly oriented into the pipe-work. A Flow direction
arrow is cast on the body. Other than for ease of maintencance, the angular orientation of the PRV in
the line is not important.
SETTING TO WORK / INSTALLATION
• Ensure that inlet and outlet connections are leak-tight.

Check with "leak detection" fluid if necessary.
• Ensure that supply and outlet isolation valves are closed.
• Close all needle valves.
• Ensure that correct supply pressure is available, before slowly
opending supply isolation valve.
Outlet isolating valve remains closed.
• Loading from the line: Slowly open line loading needle valve C approximately 1/4 turn anti-
clockwise. Then gently open the other needle valve B and monitor pressure on the outlet gauge.
This should rise as the dome is charged. When correct outlet pressure is reached , close needle
valve B (clock-wise) and then close line loading needle valve C. Very slowly, open outlet- isolation
valve to run system.

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INSTALLATION AND OPERATION Page - 8 -
1. Open closing-screw (A) and dome needle valve (B) and allow any residual pressure there in
to vent to atmosphere, then close closing-screw (A) and needle valve (B) .
2. Open outlet and inlet stop-valve.
3. Insert small loading wrench or key into line needle valve head (C) and open the valve ONE-HALF
turn.
4. Now open dome needle valve (B) very gently and watch outlet pressure gauge. Continue to
charge dome until the gauge needle registers the reduced outlet pressure desired. Next, close
dome needle valve (B) and then close the line needle valve (C) . If outlet pressure is high, open
the outlet closing-screw (A) and then open the dome needle valve (B) very slightly until the pressure
gauge needle settles at the desired point. Then close tightly the closing-screw (A) and dome
needle valve (B) and check if the line needle valve is tightly closed.
5. The reduced pressure setting is now fixed and the controller is ready for operation. Finally, open
full the outlet stop-valve and also check whether the inlet stop-valve is full open.

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SPARE PARTS C1 Page - 9 -
SPARE PARTS C1
Pos. Description part no.

Repair kit consisting of: 914011
1 Membrane (Diaphragm) (Ø76x1.5mm)
6 O-ring (3 Stk. à Ø2.9x1.78mm)
7a Soft insert (Ø17x 8x 3mm)
8 O-ring (Ø15.6x1.78mm)
9 O-ring (Ø12.42x1.78mm)
10 O-ring (Ø25.12x1.78mm)
other spare parts:

2 Diaphragm spring 914077
3 Valve spring 914007
4 Washer with sealing lip 914085
5 Needle valve (2 x)(incl. O-Ring) 914084
7 Valve cone (inkl. Pos. 7a) 914078
11 Valve seat 914079
12 Connecting-Rod 914086
13 Floor nut 914087
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SPARE PARTS C2 - K32 Page - 10 -
6a
SPARE PARTS C2 - K32
Pos. Description part no.

Repair kit consisting of: 914041
1 Membrane (Diaphragm) (Ø125x2.5mm)
6a O-ring (1 Stk. à Ø2.9x1.78mm)
6 O-ring (2 Stk. à Ø4.78x1.78mm)
8 O-ring (Ø36x2.6mm)
9 O-ring (Ø20x2.6mm)
10 O-ring (Ø54.x2.6mm)
other spare parts:

2 Diaphragm spring 914190
3 Valve spring 914181
4 Washer with sealing lip 914182
5 Needle valve (2 x)(incl. O-Ring) 914193
7 Valve cone 914194
11 Valve seat 914195
12 Connecting-Rod 914196
13 Floor nut 914197
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MAINTENANCE Page - 11 -
To ensure reliability and long service, periodic inspection should be made of all parts liable to wear or
deterioration. It is advisable to carry sets of replacement parts so that servicing time is reduced to a
minimum and delays are avoided when parts are not immediately available. The procedure for ordering
spares is detailed under the appropriate heading.
WARNING: Units must never be subjected to any pressure surpassing their operating range.
MAINTENANCE
Having few moving parts, the C1/C2-K32 will require only periodic inspection of those items subject
to wear, or deterioration to, ensure long service and realiability. It is recommended that when servicing
or repair becomes necessary the C1/C2-K32 shall be returned for factory refurbishment. However,
the design of the C1/C2-K32 does enable servicing in the field, with minimal inconvenience, to satisfy
plant operations and minimise down times. It is recommended that all repairs and servicing be carried
out using only quality assured spares supplied by the manufacturer.
PREVENTATIVE MAINTENANCE
In a clean system, the C1/C2-K32 will continue to deliver trouble free service over long periods of
time. During preventative maintenance periods, the following procedure is suggested:
a) Inspect all "O" seals for wear, brittleness or other signs of damage. All those displaying any indication
of damage or deterioration should be replaced. However, it is recommended that all seals , regardless
of any damages should be routinely replaced.
b) Remove the valves and seat and inspect closely for wear or damage. Typical signs of damage will
be nicks or raised burrs around the seating edge of the seat, or indentations, abrasions and hard
particle inclusions in the soft (seating) area of the valve member. Severe wear and/or very apparent
nicks, burrs or particle inclusion would indicate that replacement is necessary. Light wear and the
presence of a clean, continuous seating ring on both parts would indicate that they are suitable for re-
use.
c) Any components showing signs of corrosion should be inspected for indications of permanent
damage (i.e. pitting) and replaced if any are present.

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MAINTANANCE Page - 12 -
STRIPPING
• Remove M10 socket head capscrews and washers.

• Lift off dome complete with needle valves and plug taking care with small "O"-ring between
the two.
• The needle valves, "O"-rings, plug (if fitted), and bonded seal can be removed.
• Working at the other end of the valve, unscrew and withdraw the body plug complete with
valve spring and "O"-rings. Note that some residual pressure may escape during removal
of the body plug.
• At this stage the seat and "O"-ring may come out with the body plug, however if not gently
pull out with a hooked instrument.
RE-ASSEMBLY
• This is a direct reversal of stripping.

• It is important that components are clean
• Replace the dome in the correct orientation i.e. with the boss containing the needle valves
facing the inlet.
Torque figures:
M10 Socket head capscrews 35 Nm

Body plug 40 Nm
Blanking plug 35 Nm

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MAINTENANCE Page - 13 -
REMEDIAL MAINTENANCE
If the C1/C2-K32 is maintained to a planned programme, it is unlikely that the need for remedial
service will arise. However, if the system becomes contaminated or an operating system problem
causes damage to one of the control elements, the C1/C2-K32 malfunction. In general it is
recommended that damaged C1/C2-K32 's be returned to the factory for repair. To facilitate field
repair, and minimise plant downtime, Table 1 lists some possible faults and probable causes/solutions.
We also make the following recomendations:
It is preferable that the PRV (Pressure Reducing Valve) shall be repaired or serviced under workshop
conditions, as the opened equipment must be protected from ingress of dirt and other foreign mate-
rial. Should operational requirements make it necessary to service the PRV in the pipeline, then
precautions should be taken to avoid contamination of the unit or parts.
Safety note: When undertaking any repair or servicing in which the C1/C2-K32 remains in the line, it
is essential that the equipment is isolated from the pressurised media. It is also important that the
dome is fully vented - see "setting to work" for procedure.
STRIPPING AND RE-ASSEMBLY
Having few parts, stripping and re-assembly of the C1/C2-K32 may be regarded as straightforward,
provided certain conditions are observed.
• Cleanliness is of the utmost importance, even the smallest of inclusions may seriously affect the
operation of the PRV.
• Tool list: Torque wrench, 3 mm A/F Hexagon Wrench Key, 8 mm A/F Hexagon Wrench Key,
25 mm A/F Hexagon Socket, Circlip Pliers (small)
• use only sparing amounts of grease during re-assembly. I hat recommended is "Dow Corning
MS4", any alternative should be checked carefully. Use os greases at all, with media other than
inert gases, MUST BE CHEKCED WITH LUBRICANT SUPPLIERS!
• For safety, all thigtening torque values must be adhered to. Refer to assembly drawing.

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FAULT LOCATION AND RECTIFICATION Page - 14 -
FAULT PROBABLE CAUSE REMEDY

1. Escape of CO2 gas through (a) Foreign matter between inlet (a.b.c) Remove inlet valve
controller when control knob valve and seat assembly, examine and
is turned fully anti-clockwise. clean as necessary.
(b) Inlet valve stuck open Replace damaged parts.
(c) Damaged inlet valve
2. Continuous discharge of (a) Relief valve sensitivity (a) Adjust as necessary

CO2 gas through spill adjustment incorrect.
pipeline or vent when
controller is in operation. (b) Relief valve damaged. (b) Renew
(c) Foreign matter between relief (c) Dismantle and clean as

valve and seat. necessary.
(d) Defective seals between piston (d) Remove spring housing

and piston plate and body. and renew seals.
3. Erratic control of pressure or (a) Foreign matter between inlet or Turn control knob fully anti-
failure to maintain set relief O-valve and seat. clockwise; if fluid or gas
pressure. (b) Damaged inlet or relief valve continues to discharge from the
and seat. outlet connection, check inlet
(c) Sticking inlet or relief valve and valve assembly as in item (1).
seat. If no discharge from outlet,
investigate relief valve as in
item (2)
4. Rise in outlet pressure Damaged or dirty valve and/or seat Replace or clean parts
above that set Damaged valve or seat "O" ring Replace part
Valve spring failure Replace part
Valve jamed open and can not be Investigate cause - replace
closed anymore. valve if necessary.
5. Loss of outlet pressure Damaged diaphragm Replace part

Leaking dome Thighten or replace part

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TROUBLE SHOOTING Page - 15 -
The only parts liable to wear or deterioration are the VALVES , VALVE SEATS and
DIAPHRAGMS. Any trouble with the Controller can usually be traced to these parts.
CAUSE EFFECT REMEDY
1.(a) Damaged or pitted VALVE BUILDING UP of reduced pressure (a) Replace VALVE and SEAT.
and SEAT. under no-flow conditions.
(b) Dirty VALVE and / or SEAT. BUILDING UP of reduced pressure (b) Remove VALVE and SEAT and
under no-flow conditions. CLEAN with soft rag.
2. Deteriorated or ruptured DECREASE of reduced pressure or Replace DIAPHRAGM

DIAPHRAGM. complete shut off.
3. DOME NEEDLE VALVES DECREASE of reduced pressure or Check and tighten NEEDLE
not tightened down. complete shut off. VALVE.
IMPORTANT: Before effecting the remedial action indicated, the inlet stop valve must be CLOSED
and the outlet stop valve OPEN.
Removing VALVES and SEATS:
To clean or replace a valve and seat, unscrew the body plug at the base of the Controller and the
VALVE SEAT, VALVE and SPRING can be removed.
NOTE: When re-assembling, clean all seating surfaces thoroughly.

Tighten body plug well and test for leaks around base.
Removing DIAPHRAGM:
To replace or inspect diaphragm proceed as follows:
1. Evacuate all air charge from the dome by opening the dome needle valve.
2. Remove dome clamping bolts.
3. The diaphragm is now uncovered and can be withdrawn easily.
NOTE: When re-assembling, ensure that (a) the diaphragm plate is centred correctly on the spring
and (b) the dome is correctly positioned in relation to the PORTS.

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TECHNICAL SPECIFICATION Page - 16 -
C1 C2-K32
metric metric Imperial 2 in.

Pressure range Imperial 1 in.
25 mm 50 mm
Tested Hydraulic 103 Bar 1500 psi 103 Bar 1500 psi
Maximum Operating (Inlet) 69 Bar 1000 psi 69 Bar 1000 psi
Outlet Range 0 - 69 Bar 0 - 1000 psi 0 - 65 Bar 0 - 950 psi
Performance
1%
Pressure: Repeatability 1%
4%
Accuracy 4%
0-3%
Dependancy 0-3%
1.5%
Std. Valve 1%
-10°C to +100°C
Temperature: Operating -10°C to +100°C
0-3%°C-1
Dependancy 0-3%°C-1
10-4 At. cm.3 Sec.-1
Sealing: 10-4 At. cm.3 Sec.-1
Valve Size and Flow

Standard: Valve Ø 12.7mm 1/2 in. 25.4 mm 1 in.
Orifice Area A1 97 mm2 15 in.2 323 mm2 50 in.2
Port Area A2 387 mm2 60 in.2 1503 mm2 2.33 in.2
Flow Coefficient KV = 2.9 CV = 3.4 KV = 9.7 CV = 11.4
Connections
Line 1 inch BSP 2 inch BSP
Dome Loading Port 1/4 inch BSP 1/4 inch BSP
C1 C2-K32
Dimension in mm:
A B C D weight
C1 170 126 dia. 52 127 approx. 6 kg
C2-K32 263 227 197 dia. 75 approx. 19 kg

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CONTACT Page - 17 -
If you need any further help or in case of emergency, please contact:
ASCO CARBON DIOXIDE LTD

Industriestrasse 2
CH-8590 ROMANSHORN / SWITZERLAND
TEL: + 41 71 466 80 80
FAX: + 41 71 466 80 66
E-MAIL: info@ascoco2.com
HOMEPAGE: www.ascoco2.com
Although the information and advice contained in this manual accurates to be the best of our knowledge,
no liability can be accepted in respect of such information and advice, and all warranties, conditions
and statements expressed or implied statutory or otherwise in respect of such information and
advice or the plant described in the manual are excluded. In particular we must stress that nothing
contained in the manual shall form part of any contract made between a customer and ourselves.
ASCO CO2 Products will be frequently assessed for improvement

and the specifications listed are subject to change without notice.

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ASCO also manufactures and supplies:
Automatic CO2 Production Plants

CO2 Stack Gas Recovery Plants
CO2 and Cryogenic Static and Transportable Tanks
Dry Ice Machines and Pelletizers
CO2 Gas Recovery Systems for Dry Ice Machines
Dry Ice Blasting Systems ASCOJET
CO2 Pumps and Cylinder Filling Systems
CO2 Atmospheric Vaporisers
CO2 Cylinder Manifolds and Reducing Valve Stations
CO2 Detectors
CO2 Flowmeters
CO2 Dew Point Tester
CO2 Gas Purity Tester up to 99,995 %
CO2 Carbonation Tester
Ancillary CO2 Equipment
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INSTALLATION MANUAL

DOME LOADED PRESSURE REDUCING VALVE

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

and thank you for your confidence

ASCO CARBON DIOXIDE LTD

Version 4.0 C1/C2/E

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Short introduction 2-4

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

1. DOME LOADED PRESSURE REGULATOR

Used for accurate control of outlet pressure.

- Constructed in brass (C1).

CO2 - Carbon Dioxide

C1 (1 inch) Inlet : max. 100 Bar (1400 psi)

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

In case of a failure of the membrane the valve closes automatically.

RE-ENTRY INTO SERVICE

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

A. Maximum reactive force to

2. Pressure balancing chamber

C. Max. Valve stability

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

SETTING TO WORK / INSTALLATION

• Ensure that inlet and outlet connections are leak-tight.

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

2. Open outlet and inlet stop-valve.

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Pos. Description part no.

other spare parts:

SPARE PARTS C2 - K32

Pos. Description part no.

other spare parts:

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

• Remove M10 socket head capscrews and washers.

• This is a direct reversal of stripping.

M10 Socket head capscrews 35 Nm

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

We also make the following recomendations:

STRIPPING AND RE-ASSEMBLY

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

FAULT PROBABLE CAUSE REMEDY

(c) Damaged inlet valve

2. Continuous discharge of (a) Relief valve sensitivity (a) Adjust as necessary

(c) Foreign matter between relief (c) Dismantle and clean as

(d) Defective seals between piston (d) Remove spring housing

5. Loss of outlet pressure Damaged diaphragm Replace part

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

CAUSE EFFECT REMEDY

2. Deteriorated or ruptured DECREASE of reduced pressure or Replace DIAPHRAGM

Removing VALVES and SEATS:

NOTE: When re-assembling, clean all seating surfaces thoroughly.

To replace or inspect diaphragm proceed as follows:

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

metric metric Imperial 2 in.

Valve Size and Flow

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

If you need any further help or in case of emergency, please contact:

ASCO CARBON DIOXIDE LTD

ASCO CO2 Products will be frequently assessed for improvement

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand