Fuel Gas Control Valve

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 Revision History

Revision Content of Change Document Pages

total :
A Fig. 1 modified
18
B Fig. 2 and legend modified (limit switch added)
C Servomotor section removed, separate manual for servomotor, valve
dismantling and reassembly procedure improved
D Leakage test

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Contents

1 DESCRIPTION ..............................................................................................................5
1.1 Control Valve Assembly .......................................................................................5
1.2 Control Valve .........................................................................................................6
1.2.1 Design ..............................................................................................................8
1.2.2 Mode of Operation............................................................................................8

2 VALVE INSTALLATION................................................................................................9

3 MAINTENANCE ..........................................................................................................10
3.1 General Information ............................................................................................10
3.1.1 Spare Parts.....................................................................................................10
3.1.2 Marking of Components .................................................................................10
3.2 Disassembly ........................................................................................................10
3.2.1 Servomotor Removal ......................................................................................10
3.2.2 Valve Disassembly .........................................................................................11
3.3 Reassembly .........................................................................................................13
3.3.1 Torques of Screws and Nuts ..........................................................................13
3.3.2 Checks and Preparations ...............................................................................13
3.3.3 Valve Assembly ..............................................................................................14
3.3.4 Assembly of Servomotor to the Valve.............................................................15
3.4 Tests after Reassembly......................................................................................16
3.4.1 Stroke adjustment...........................................................................................16
3.4.2 Leakage test ...................................................................................................16

Figures

Fig. 1 Gas Control Valve Assembly.................................................................................5

Fig. 2 Control Valve, Sectional View ...............................................................................6

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1 DESCRIPTION
1.1 Control Valve Assembly
The control valve is operated by the servomotor and regulates the fuel gas
supply to the burners.

) For operation and maintenance of the servomotor refer to

the instructions given in the manufacturer’s manual.

1 Gas Control Valve 3 Control Valve Position (not show)

2 Servomotor (not show) 4 Proximity Switch

Fig. 1 Gas Control Valve Assembly

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 1.2 Control Valve

Fig. 2 Control Valve, Sectional View

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 Key to Fig. 2

Pos Qty Designation Pos Qty Designation

102 1 Body 608 8 Locking washer
104 8 Stud M16 610 1 Spring
106 8 Hexagon nut M16 612 1 Spacer ring
108 8 Locking washer 614 1 Stuffing box nut
202 2 O - ring 616 1 Locking screw
204 2 O - ring 702 1 Seal ring
302 1 Upper cone 704 1 Packing set
304 1 Lower cone 706 1 O - ring
306 4 Cylinder screw M6 708 1 Rod guide ring
308 8 Locking washer 710 1 Dirt wiper
310 1 Stem 804 1 Stuffing box insert
312 1 Locking plate M16 806 3 Column
314 1 Hexagon nut M16 808 1 Ring
316 1 Balance cylinder 810 3 Hexagon nut M16
318 1 Rotation protection 812 3 Locking washer
320 4 Cylinder screw M6 814 4 Cylinder screw M16
322 1 Feather key 816 4 Locking washer
324 2 Cylinder screw M4 (peened over) 818 2 Roundheaded notched pin
326 1 Valve seat 820 1 Stroke scale
402 1 O - ring 902 1 Coupling
404 1 O - ring 904 4 Cylinder screw M8
406 1 O - ring 906 4 Locking washer
408 2 Piston guide ring 908 1 Tension ring
410 1 Seal ring 910 1 Threaded pin
412 2 O - ring 912 1 Pin
414 1 Quad-ring 914 1 Hexagon screw M6
416 1 O - ring 916 1 Hexagon nut M6
418 1 O - ring 1002 1 Metal bellows (comprises 5 parts)
502 1 Yoke 1102 1 Console
504 1 Intermediate ring 1104 2 Cylinder screw M6
506 4 Cylinder screw M6 1106 2 Locking washer
508 4 Locking washer 1108 2 Disk
604 8 Stud M10 1114 1 Proximity switch
606 8 Hexagon nut M10

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 1.2.1 Design
The valve is a weld-in armature. A soft seal ensures inner leak-proofness.
The valve cone is designed to relieve the piston. A bellows element (1002)
and a safety stuffing box (PFTE bushing) seal the valve stem (310) towards
the outside. There is an intermediate balance between the bellows element
and the safety stuffing box. For the rest, O-rings seal the valve off towards
the outside.
The valve cone (302, 304) has a pressure-relief bore so only relatively weak
forces are necessary to activate the valve. The servomotor is attached to the
ring (808) with cylinder screws (814, 816). The coupling (902) links the piston
of the servomotor to the valve stem (310).

1.2.2 Mode of Operation

The medium must flow through the valve in the direction indicated by the
arrow. A piston seal assembly, consisting of two O-rings (412), one Quad-
ring (414) and seal ring (410) seals the valve cone (302, 304) off towards the
balance cylinder (316) in which it is centered. The two piston guide rings
(408) make sure the valve cone (302, 304) is centered exactly in the balance
cylinder (316). Bores in the base of the valve cone balance the pressure
between the space within the valve cone and the space underneath the valve
cone.
The actuating force (without friction values) necessary to open the valve
results from the differential surface between seal diameter of the seal ring
(402) and diameter of the balance cylinder (316) and metal bellows (1002)
multiplied by the available differential pressure (p1 minus p2).

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2 VALVE INSTALLATION

The valve is to be welded without any tension into a

horizontal pipe with the servomotor facing upwards.

Enough space has to be provided for installation and removal of the

servomotor.
The flow direction has to be taken into consideration.
The pipe has to be supported in the vicinity of the valve. The support must,
however, not be fixed on the valve or servomotor.

Prior to installation of the valve into the pipe, the pipe has
to be cleaned thoroughly. Foreign substances which might
be contained within the flow medium - e.g. globules,
packing particles, etc. - may cause damage to the interior
parts of the valve thus resulting in a deterioration of the
faultless operation of the valve.
For welding the valve into the pipe, the valve should - if possible - be brought
into the "open" position.
After welding the valve, and prior to blowing through the pipe, bring the valve
into the "open” position. Before blowing through the pipe we recommend you
remove the interior parts of the valve and close the open valve body with a
blind flange.

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 3 MAINTENANCE
3.1 General Information
Solid professional knowledge is required to carry out the maintenance work
involved.
The valve supplier is not liable for any damage caused by unprofessional
maintenance work or insufficient maintenance respectively.

3.1.1 Spare Parts

Only spare parts which are delivered by the valve manufacturer have to be
used. Liability will be declined in case of malfunction resp. damages at the
valve, resulting from application of improper spare parts.

Check availability of spare parts before starting work and

make sure all spare parts are available.

3.1.2 Marking of Components

For assembly and disassembly work described herein it is advised to clearly
mark components which have to be disassembled to make sure that during
assembly work they may easily be put together into their original position.

3.2 Disassembly

Prior to disassembly check and ensure that pipe, valve and

servomotor are pressureless!

3.2.1 Servomotor Removal

Disconnect the pipes and the electrical connections from the Servomotor.

) With the servomotor disconnected from the oil feed pipe

and electrically isolated, the control valve is in the closed
position (fail save position).

See also separate instruction manual of the servomotor.

1. Remove the threaded pin (910) from the tension ring (908) and the
coupling (902).
2. Pull the tension ring (908) downwards off the coupling (902).

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 3. Loosen the 4 cylinder screws (904, 906) in the coupling (902).
4. Remove the pin (912) from the coupling (902) and the valve stem (310).
5. Dismantle the two coupling halves (902). Carefully and evenly loosen the
4 cylinder screws (814, 816).
With this the servomotor is separated from the valve and can be removed
upwards.

Do not change the setting of the hexagon screw (914, 916)!

3.2.2 Valve Disassembly

1. After having disassembled the control servomotor from the valve, remove
the tension ring (908) from the valve stem (310).
2. Unscrew the hexagon nuts (810, 812) from the columns (806).
3. Lift the assembly, consisting of three columns (806), ring (808) and
console (1102) with proximity switch (1114), upwards out of the stuffing
box insert (804).

While lifting out the assembly make sure you do not

damage the proximity switch (1114).

4. Use a suitable tool to turn (4 turns at most) and loosen the stuffing box
nut (614).
5. Unscrew the hexagon nuts (606, 608) from the studs (604). The stuffing
box insert (804) is now separated from the valve body (102) and the yoke
(502).
6. Pull the stuffing box, together with all the installed components, upwards
off the valve stem (310).
7. Unscrew the stuffing box nut (614) from the stuffing box insert (804) in
order to replace the packing set (704).
8. Unscrew the hexagon nuts (106, 108) from the studs (104).
9. Loosen the cylinder screws (506, 508) and remove the intermediate ring
(504) upwards over the valve stem (310).
10. Pull the yoke (502) off over the valve stem (310).

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 11. Unscrew the cylinder screws (320, 308) and carefully pull the rotation
protection (318) upwards over the valve stem (310).

When removing the rotation protection (318) make sure you

do not damage the metal bellows (1002).

12. Remove the balance cylinder (316) from the valve body (102) upwards
over the valve stem.
13. Remove the O-rings (202), the piston seal assembly (410, 412, 414) and
the piston guide rings (408) from the balance cylinder (316).
14. Lift the stem (310) with the metal bellows (1002) and the valve cone (302,
304) upwards out of the valve body (102).
15. After unscrewing the hexagon nuts (314, 312), pull the stem (310)
upwards out of the valve cone (302, 304) and from the metal bellows
(1002).
16. Separate the upper valve cone (302) from the lower valve cone (304 -
valve cage) by unscrewing the cylinder screws (306, 308).
17. Remove the O-rings (402, 416) from the lower valve cone (306).

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3.3 Reassembly
3.3.1 Torques of Screws and Nuts
Screws and nuts of the control valve have to be tightened with the torques as
shown in the table below.
Item No. Thread Starting Torque (Nm)
(Fig. 2)
106 M 16 50
306 M6 7
314 M 16 150
320 M6 7
326 (valve seat) 200
506 M6 7
606 M 10 25
810 M 16 150
814 M 16 220
904 M8 24
3.3.2 Checks and Preparations

) It is strongly recommended that only genuine valve

supplier spares from PRUSS are used. The material from
the seals is FKM. The Pruss-guarantee is not valid if other
materials are used.
The parts to be assembled have to be:
- clean, free of impurities and solvents
- fully functional
- free from damaged
- free from inadmissible abrasions.
The density surfaces have to be clean and free of damage to the surface.
All threads, fittings, contact surfaces and seals have to be coated, prior to
assembly, with a high-temperature resisting lubricant.
In principle, assemble components in the same position only as they were
assembled and marked before their disassembly.
Seals, locking rings etc. have to be replaced by new parts if necessary.

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 3.3.3 Valve Assembly

The piston seal assembly consists of 4 individual pieces.

The two O-rings (412), the seal ring (410) and the quad-ring
(414) have to be assembled non-twisting. This non-twisting
assembly is also applicable for all other O-rings.

The piston guide rings are not endless, but are provided
with an angle cut. At inserted piston guide ring the
dimension between the ends has to be 2 - 5 mm.

) For assembly, follow the dissassambly procedure in

reversed order.

1. Place new O-rings (402, 416) in the lower valve cone (304).
2. Screw the upper valve cone (302) to the lower valve cone (304) with
cylinder screws (306, 308).

Observe the position of the keyway machined in the upper

cone (302) in relation to the position of the feather key
(322).
3. Carefully insert the valve stem (310) into the metal bellows (1002).
4. After positioning the O-ring (404) use hexagon nuts (314, 312) to screw
the valve stem (310) with the metal bellows (1002) to the valve cone (302,
304).
5. Insert this assembly from the top into the valve body (102).
6. Insert the piston guide rings (408), the piston seal assembly (410, 412,
414) and the O-rings (202) into the balance cylinder (316).
7. Insert the balance cylinder into the valve body (102) from above over the
valve stem (310) and push it over the upper valve cone (304).
8. Insert the rotation protection (318) into the balance cylinder (316) and the
upper valve cone (302).

When inserting the rotation protection (318), make sure you

do not damage the metal bellows (1002).

9. Secure the rotation protection (318) with the cylinder screws (320, 308) of
the balance cylinder (316).

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 10. Mount the yoke (502) over the valve stem (310) and the studs (104) onto
the assembled valve body (102).
11. Screw the yoke (502) tight with hexagon nuts (106, 108).
12. Position O-ring (406) in the top attachment of the metal bellows.
13. Position O-ring (204) in the intermediate ring (504).
14. Mount the intermediate ring (504) from above over the stem (310) onto
the yoke (top yoke flange) and secure it to the attachment element of the
metal bellows (1002) with cylinder screws (506, 508).
15. Mount the completely assembled stuffing box insert (804), with the
stuffing box nut (614) not yet tightened, over the valve stem (310) and the
studs of the yoke (604) onto the yoke (502), and secure it to the yoke with
hexagon nuts (606, 608).
16. Tighten the stuffing box nut (614).
17. Insert the tension ring (908) over the valve stem.
18. Mount the assembly consisting of 3 columns (806), ring (808) and console
(1102) with the proximity switch (1114) from above onto the stuffing box
insert (804) and secure it in place with hexagon nuts (810, 812).

3.3.4 Assembly of Servomotor to the Valve

1. Position the servomotor on the ring (808).
2. Secure the servomotor to the ring (808) with 4 cylinder screws (814, 816).

The valve and the servomotor were already set correctly by

the manufacturer. The hexagon screw and nut (914, 916)
screwed into the front end of the piston rod of the
servomotor and secured there with Loctite make sure the
set distance between the valve stem (310) and piston rod of
the servomotor is correct.
Resetting this distance is only necessary when the
servomotor is replaced.
When the servomotor is to 0% stroke position, the piston rod of the
servomotor presses onto the calibration screw (914) and the valve stem (310)
which in turn push the valve cone (302, 304) into the valve seat (326) in the
valve body (102).
3. Mount the first half of coupling (902), ensure the correct position of the
coupling with regards to the valve stem (310) by inserting the pin (912).

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 4. Mount the second half of the coupling (902) and secure the two coupling
halves to each other with 4 cylinder screws (904, 906).
5. Push the tension ring (908) onto the coupling (902) from underneath and
screw in the threaded pin (910) to secure it in the intended, correct
position with regards to the coupling.
6. Reconnect pipes and electrical connections to the servomotor. For details
refer to the separate instruction manual of the servomotor.

3.4 Tests after Reassembly

3.4.1 Stroke adjustment
1. Move servomotor in the upper end position by setting the control signal
higher than 20 mA. Overstroke at position "open" has to be 2 - 3 mm.
2. Now set control signal to 4 mA. Valve moves in position "close".
3. Stop has to be within the valve (seat/control cone). Set control signal 20
mA and check stroke according to stroke scale (820), if necessary
readjust.
4. After stroke adjustment check internal leak-tightness (seat/control cone)
and for body leakage. Stroke = nominal 50 ±1mm.

3.4.2 Leakage test

Check the leak-tightness of the built-in valve after reassembly as follows:
Body leakage test
1. Drive valve to ”opend” position.
2. Apply test-pressure to the system in which the valve is mounted.
3. Check for leakage with soap solution (or equivalent) over complete valve
body.

) The valve design ensures leak-tightness of the body if

serviceable gaskets are used and if valve is assembled and
tested correctly.
Seat leakage test
1. Drive valve to ”closed” position.
2. Apply test-pressure to the system upstream of the valve.

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 3. Measure pressure drop. Note that other components and interference
factors (for example temperature) can disturb the leakage-test.

) The valve design ensures leak-tightness of the seat if

serviceable gaskets are used and if valve and actuator are
mounted and adjusted correctly.
Metal bellows leakage test
1. Drive valve to ”closed”position.
2. Apply test-pressure to the system upstream of the valve.
3. Remove locking screw (616) and check for leakage from the hole with
adequate measuring and test equipment.
4. Screw in locking screw (616) with seal ring (702) after the leakage test.

Body, seat and metal bellows leakage tests have to be

carried out following each dismantling and reassembly.

If valve has been exposed to a temperature higher than

180oC, an inspection and, if necessary, replacement of the
gaskets is required.

) Recommendation: For normal operating conditions, valve

should be serviced every C-Inspection.

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