INSTALLATION, OPERATION AND

MAINTENANCE MANUAL
FOR
DIAPHRAGM OPERATED
PRESSURE / FLOW CONTROL VALVE
INTRODUCTION – BASIC VALVE

These are hydraulically operated, diaphragm actuated globe

valve with elastomeric seal on metal. The primary benefit of
using a hydraulically actuated valve is the use of line pressure as
motive power to operate. Whether used to control pressure,
flow or level,
evel, these valves operate without the need for
external pressures and/or electricity.

However, these control valves are closed

closed-loop systems. The
main valve is controlled by a pilot that compares its spring
setting (set-point)
point) to the process variable (i
(i.e., pressure, flow,
and/or level).

As the process variable changes, the pilot senses the change and compensates to keep the process
variable as close to the desired set
set-point
point as possible. As such, these valves are single set-point
set
control valves, and a set-point
point change will require operators to change the spring setting of the
pilot.

THEORY BEHIND

The control fluid exerts pressure on the top of diaphragm. Line

pressure presses the seal upwards. Since the diaphragm area is
larger than the sealing area, the differential pressure keeps the
valve closed.

The control chamber is drained off off/depressurised resulting in

line pressure opening the seal allowing water to flow across the
valve.

The control chamber is pressurised or de

de-pressurised as a direct
result of the control device.

PRESSURE REDUCING VALVE

These maintain a constant set pressure downstream of the valve irrespective of changes in the
upstream pressure or flow through the valve; maximum pressure reduction achievable
downstream being 1/7th of the inlet pressure.

SHIPMENT, STORAGE & HANDLING

IVC Pressure Reducing Valves are delivered packed in boxes, to protect the valve from potential
damage during shipment / transportation.
Storage should be in clean and dry environment and wherever possible, should be indoors. Valves
should be in fully closed
osed position, kept packed in original boxes and covered with protective sheet
to mitigate damages from weather conditions, debris and dirt. Water should not be allowed to
enter the valves while in storage.
Appropriate lifting equipment (e (e.g. fork lift) may be used for moving. Local safety regulations
should be followed during handling. While handling valves out of boxes, lifting and handling
should be carried out by using appropriate means and by respecting carrying limits. When lifting
large diameter valves,
alves, the sling and hooking of the load must be carried out by using the
appropriate tools to prevent the valve from falling.
PRECAUTIONS
For safety reasons, it is important to take the following precautions before undertaking installation
activities:

1. The line must be depressurized without water before installing the valve.

2. Only personnel trained in all aspects of manual and mechanical handling techniques
should be assigned to handle the valve.

3. While lifting the valve, use steel cable with hook to go through the body lifting hole or eye
bolts.

INSTALLATION

IVC PRdV is furnished fully factory assembled and ready for installation at the appropriate point in
the system. In order to ensure safe, accurate and efficient operation of the valve, the following
list of checkpoints and procedures should be followed when installing the valve.

1. Carry out a careful visual inspection of the valve to ensure that there has been no damage
to the external piping, fittings or controls. Check that all fittings are tight.

2. Thoroughly flush all interconnecting piping (on which the valve is to be fitted)of chips, scale
and foreign matter prior to mounting the valve.

3. Install the valve in the line according to the flow arrow on the inlet f l a n g e . The arrow
should point downstream. Ensure that the valve is vertical and not inclined.

4. Allow sufficient room around the valve for ease of adjustment and maintenance service.

In addition, it is also recommended that:

a. Isolation valves are installed on the

inlet and discharge sides of the
valve to facilitate isolating the
valve for maintenance.

b. All valves larger than 6" dia. be

installed horizontally, i.e. with the
bonnet pointed up, for ease of
adjustment and maintenance
servicing.
c. Ensure there are no bends or
appurtenances within 6 x Valve dia.
On either side of the valve.
OPERATION

Adjustment of the outlet pressure can be made by the screw on

the relay (pilot) valve. Operation is achieved by the interaction of
three pressures:

P1 : Inlet (upstream) pressure

P2 : Outlet (downstream) pressure
P3: Intermediate
ntermediate pressure, which is produced by the relay system
and acts on the upper side of mai
main valve piston

A fixed orifice (A),

), protected by the strainer, is fitted on the
strainer block. The relay valve, basically an adjustable orifice ((B),
is actuated by its diaphragm, which is connected to the outlet
pressure on its underside and is subject to a constant spring load
from the above.

If the outlet pressure P2 becomes too high to balance the spring load, the relay valve tends to
close (i.e.
e. B tends to Zero), allowing pressure P3 to increase, causing the main valve tending to
close, thus reducing P2 to the set value. Why the main valve tendtends to close? The control pressure
is applied by the control device to the control chamber (top of the diaphragm). The pipeline
pressure pushes the seal to open, and the control chamber pressure forces the diaphragm to
close. Since the diaphragm area is large
largerr than the seal area, it has greater hydraulic force so the
valve tends to close.

Similarly, if P2 becomes too low to balance the spring load, the relay valve tends to open (i.e. B ≥
A),
), P3 decreases, the main valve opens further and P2 rises again to thee set value. Why the main
valve tends to open? The control device relieves the pressure from the control chamber. The
pipeline pressure forces the seal upwards as the outlet pressure is applied to the lower side of the
diaphragm. Thus the valve continuousl
continuouslyy maintains the desired constant downstream pressure P2,
which is determined only by the spring load (thus A to B ratio) and is entirely independent of the
upstream pressure.
There is another restrictor assembled in this circuit – a needle valve. The relay
rela system acts as a
dashpot, giving slow steady movement to the main valve and preventing its motion setting up
surges in the water main. The dashpot action can be regulated by manipulation of the needle
regulating valve.

Start the system flowing

Pressuree reducing control adjustment: Turn the adjusting screw
clockwise to increase the setting.
Turn the adjusting screw counter clockwise until it is loose enough to
be turned by hand. Turn the adjusting screw of the needle valve fully
clockwise, and then back it off three full turns. Slowly turn the
adjusting screw of the control pilot clockwise until downstream
pressure increases to the desired set point.

Operating speed adjustment: Turn the adjusting screw on the Needle Valve clockwise to make
the main valve open or close slowly
slowly, counter clockwise will make it faster

The isolation ball valves are used to isolate the pilot system from main line pressure. These
isolation ball valves must be open during normal operation.
TROUBLE SHOOTING

MAIN VALVE
SYMPTOM PROBABLE CAUSE SOLUTION
Fails to Close Closed isolation valves in control system or Open isolation valves
in main line
Lack of pressure in intermediate chamber Check upstream pressure, pilot
system, strainer, tubing,
needle valves for obstruction
Diaphragm damaged Replace
Diaphragm assembly inoperative Clean and polish stem. Inspect
and replace any damaged or
badly eroded part.
Mechanical obstruction. Clean
Worn disc Replace
Fails to Open Closed upstream and/ or downstream Open
isolation valves in main line
In sufficient line pressure Check
Diaphragm assembly inoperative Clean. Replace damaged or
badly worn out parts
Diaphragm damaged Replace

PILOT
SYMPTOM PROBABLE CAUSE SOLUTION
Fails to close when Spring over compression Loosen adjustment screw
downstream pressure Mechanical obstruction Reassemble
increases Worn out disc Replace
Fails to open when No spring compression Tighten adjustment screw
downstream pressure Damaged Spring Replace
decreases Spring guide is not in place Reassemble
Leakage from cover Damaged diaphragm Replace
Loose diaphragm nut Remove cover and tighten

MAINTENANCE

PREVENTIVE MAINTENANCE
The valve requires no lubrication or packing and a minimal maintenance. However, a periodic
inspection schedule should be established to determine how the operating conditions of the
system are affecting the valve. The effect of these actions must be determined by inspection.

DISASSEMBLY
Inspection or maintenance can be accomplished without removing the valve from the line. Repair
kits with new diaphragm and disc are recommended to be on hand before work begins.
Close upstream and downstream isolation valves to shut off all pressure to the valve. Loosen tube
fittings in the pilot system to remove pressure from valve body and cover chamber. After
pressure has been released from the valve remove the controls and tubing gently. Remove cover
nuts and remove cover. Pull cover straight up to keep from damaging the integral seat bearing
and stem. Remove the diaphragm and disc assembly from the valve body. Following this
diaphragm assembly breaks down into its component parts. Take care of the smaller parts like
washers etc.
After the valve has been disassembled, each part should be examined carefully for signs of wear,
corrosion, or any other abnormal condition. Usually, it is a sound practice to replace the rubber
parts (diaphragm and disc) unless they are free of signs of wear. These are available in a repair kit.
Any other parts which appear dubious should be replaced.

Once done, follow the reverse order and re-assemble.

It is recommended to keep in stock the Relay (Pilot) valve assembly, strainer that can be replaced
without touching the main valve.
The main valve remaining same, variation of hydraulic circuit and in some cases pilot type,
following functions are derived:

Rate of Flow Control Valve

Pressure Relief/ Sustaining Valve

Altitude Control Valve (Float controlled)

Altitude Control Valve (Solenoid controlled

controlled)

Pump Control Valve

The installation, operation and maintenance of these variants are almost same as that of the
Pressure Reducing Valve as explained earlier.

*****