FINAL TECHNICAL DOCUMENT

PRESSURE CONTROL VALVE

PB/Series Regulator
Operation & manual
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OPERATION & MAINTENANCE

MANUALS
FINAL TECHNICAL DOCUMENT
PRESSURE CONTROL VALVE

PB/Series Regulator
Operation & manual
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Scope of Manual Scope of Manual
This manual deals with detailed information of product:-
• Product Description
• Technical specification
• Standard construction of material
• Installation & Startup procedures
• Maintenance & Trouble Shooting

IntroductionIntroduction
The PB/Series regulator can be used in both gas & liquid
application; Elastomer provides class-VI shutoff. The
special trim & perfluro elastomeric polymer used in
corrosive applications & other polymers are available
upon request. Different pilot main valve combinations
are available to cover wide range of pressure and flow
requirements. Valve body & trims are available in
various material of construction for process fluid
compatibility.
Fig: - 0
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Operation & manual
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Fig: - 01, PB / Series Regulator

Technical Specification: -
Valve Size: - 1”, 2”, 3, 4”, 6”, & 8” Higher sizes on request basis.
Ratings: - 150#, 300# higher ratings are on request basis.
Maximum Design Pressure: - 49 Barg.
Maximum Operating Relief Pressure including build up: - 28 Barg.
Minimum Differential Pressure: - 0.5 Barg.
Temperature Capabilities: - -18°C to 149°C.
Main Valve Flow characteristic: - Linear
Maximum Casing Pressure: - As per Table No: - 01
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Operation & manual
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WARNING
Failure to follow this instruction or improper installation and maintenance of this
equipment could result in explosion, fire or chemical explosion causing property
damage and or personal injury or even death. If a leak develops or if the outlet
continuously vents gas, service to the unit may be required. Only a qualified person
must install or service the unit. Installation, operation, and maintenance procedures
performed by unqualified person may result in improper adjustment and unsafe
operation. Either condition may result in equipment damage or personal injury. Use
only qualified personal when installing PB – Series Back pressure regulating valve.
Maximum casing Pressure

MAIN REGULATOR TYPE & MAXIMUM PRESSURE

CM TYPE Configuration Code 8C 1C` 4C` 9C
CASING PRESSURE (Kg/cm2g) 10.5 6.5 3.5 3.5
PM TYPE Configuration Code 8P 1P 4P 9P
CASING PRESSURE (Kg/cm2g) 28 28 28 28

Note: - For all the valves EN type can be provided with EN type casing pressure = 19 Kg/cm2g
for 150# & 50 Kg/cm2g for 300#

Standard Material of Construction

Body: A216Gr.WCB, A351Gr.CF8, A351Gr.CF8M, A351Gr.CF3, A315Gr.CF3M others on
request.
Diaphragm: Nitrile/Neoprene/EPDM/Viton.
Valve Disc: Nitrile/Neoprene/EPDM/Viton.
Internal Trims: SS316/ SS304/ SS316L/ SS304L others on request basis.

Fig: - 02, PB – Series working Principle

Principle of Operation
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PB/Series Regulator
Operation & manual
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The Inlet pressure remains below Set Pr, the Pilot control spring keeps pilot valve plug
in closed position. Bottom spring of main valve keeps main valve in close position. Any
accumulation in the gas results in increase in the controlled force. This result in increase
in compensating force which balances the controlling spring force. Thus pilot valve
opens and passes the gas to diaphragm chamber of main valve. The diaphragm chamber
of main valve is also provided with a bleed known as Response Adjusting Device. When
the flow through the valve is greater than that through RAD bleed the chamber is
pressurized. This result in opening the port of the main valve. This releases the build up
pressure in the upstream side of valve. It is clear that the pressure indicated by the
pressure gauge installed to indicate the controlled upstream pressure will not be same
during No flow and Flow passing through valve. Hence raise in the controlled pressure
during the operation of valve (flow through valve) is to be accepted in principle and one
should not try to reset valve pressure because of the draw of fluid. The controlled
pressure is expected to rise to allow for discharge to the downstream side of valve
because of major flow taking place through the port of the main valve. The inlet
pressure will drop, when the controlled inlet pressure is below set value of pilot valve, it
tends to be in closed position. The trapped pressure in the diaphragm chamber will be
relieved through RAD to downstream of valve. The diaphragm chamber is completely
depressurized and the port of main valve closed due to bottom spring force.

WARNING

Personal injury, equipment damage, or leakage due to escaping gas (or liquid) or
bursting of pressure containing parts may result if the relief valve is installed where
that capabilities can be exceeded or can exceed any ratings of adjacent piping or piping
connection. Physical damage of valve could cause personal injury. To avoid this install &
handle unit in safe location.

Installation and Startup Procedure

1. Use qualified person for installation, operating and maintaining PB/ Series Pilot
operated valve.
2. Before installing, inspect the main valve, pilot and tubing for any transportation
damage or foreign particles accumulated during transportation & storage
preservation.
3. If any foreign material accumulated in body clean the same & ensure that valves
& pipelines are free from Dust particles.
4. Apply pipe compound only to external pipe threads likes tubing & fitting etc…
5. Use suitable line gaskets and good bolting practices with a flanged body.
6. For considering maintenance & calibration purpose install isolation valve & vent
line to drain gas.
7. Ensure that pilot breathing hole should be in atmospheric pressure.
8. Using good grade of Pipe & Flanges to connect the main valve body. Install tubing
(or) Piping into appropriate pilot connection.
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9. Set Pressure is defined as the pressure at which the pilot starts to discharge. The
Set pressure of a unit is adjusted by changing the control spring compression of
pilot, by using the adjusting set screw.
10. Each pilot is set at factory for controlled set pressure specified on Purchase
order.
11. The valve should be installed such that the flow is in the direction of the arrow
on the valve body.
12. Flush the line before installation of the valves.
13. Pilot operated valve should be mounted in horizontal line and vertical position.
14. Install strainer at the inlet of the valve.

Fig: -03 Installation Diagram of PB – Series Valve

Selection of Pipe
Sensing Line: -
The sensing line of pilot should be 1/2" or 3/8” tubing only, it is directly connected to
the pipe without isolation valve & Ensure that sensing line length should be maintained
as per installation diagram. The bend in sensing line may be restricted the flow so avoid
maximum bend in line. Sensing line should be free from turbulence effect.

Startup, Adjustment and Shutdown

Note: - During shutdown the isolation valve of Upstream should closed first afterwards
downstream valve must be closed. Pressure between PB/ Series valve and upstream
isolation valve should be released before doing any servicing of valve.

Startup
With proper installation and adjustment completed, slowly open the upstream ball
valve while gauge to monitor pressure. On back pressure by pass application use
isolation by pass valve, also open downstream ball valve and close by pass ball valve.
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PB/Series Regulator
Operation & manual
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Adjustment
1. The set pressure of the regulator is pre – defined setting from factory as per
process parameter given by client.
2. If set pressure required to be adjusted, it should be adjusted from pilot set screw.
3. The setting adjustment of system can be done by: -
A. Remove cap from top spring casing of pilot
B. Adjusting the pilot set screw in the clockwise direction set pressure increases
& anti –clockwise direction set pressure decreases.
C. Loosen the locknut and rotate setscrew to clockwise (or) anti – clockwise
direction.
D. The set pressure adjustment should be possible between spring maximum
and minimum allowable range.
E. Once set pressure adjustment done observe changes in upstream pressure.
F. Once the set pressure adjustment is done, tightened the set screw locknut &
fit the cap on its original position.

Maintenance
Regulator internal parts are subjected to normal wear; it should be inspected and
replaced if necessary. The frequency of inspection and servicing of regulator depends
upon system criticality at which regulator is installed. The replacement of soft parts
depends upon the damage level of soft parts & service condition and location of the
system. The soft parts are installed at their respective portion with smooth & pressure
rather than by force. Use good grade of lubricant at which “O” – rings and gaskets are
installed. Use only replacement parts manufactured (or) furnished by NIRMAL. Be
certain that the name plates are updated to accurately indicate any field changes in
equipment of material, service conditioning or pressure setting.

Disassembly and Assembly

During assembly and disassembly of regulator, ensure that the valve is isolated from
upstream and downstream isolation valve. Pressure inside the regulator & pipe lines
should be released. If any instrumentation items installed in pipe line, it must be
deactivated before disassembling the regulator.
M/s NIRMAL recommends that replace soft parts of regulator whenever it is
disassembled and reassembled.
WARNING
To avoid personal injury and equipment damage, isolate the valve from all pressure
sources. Cautiously release pressure from the valve before attempting disassembly.
Main Regulator Maintenance (Casing Type): -
Disassembly of Actuator (Diaphragm Assembly)

1. Slack down tube & fittings & Remove pilot from main valve.
2. Loosen the fasteners (25, 26, 27) fixing the actuator (07) with bottom casing
(05).
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Operation & manual
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3. Separate actuator (07) from bottom casing (05)
4. Loosen Nylon locknut (24) clamping diaphragm washer (10), diaphragm (15),
and diaphragm plate (11) with push rod (09).
5. Remove diaphragm washer (10) from push rod (09).
6. Remove diaphragm (15), diaphragm plate (11) from push rod (09).
7. Clean all the disassembled metal parts followed by flushing with dry compressed
air.
8. Replace the polymer via; diaphragm (15) & “O” – ring (21) from the spare parts.

The “O” – ring and sliding mechanism must be lubricated with a fine layer of silicone
grease before
reassembly, the polymer parts require grease to hold them in their respective positions
(or) slots and also make them softer.

Reassembly of Actuator (Diaphragm Assembly)

1. Replace “O” – ring (21) of diaphragm which is placed in Diaphragm plate (11)
and Diaphragm washer (10).
2. Place the new “O” – ring (21) in diaphragm washer (10) and diaphragm plate
(11).
3. Reassemble the diaphragm (15) between diaphragm washer (10) and
diaphragm plate (11).
4. Tightened nylon locknut (24) for clamping diaphragm washer (10), diaphragm
(15), and diaphragm plate (11) by properly placing on push rod (09).
5. Place diaphragm (15) assembly along with push rod (09) in their respective
portion as shown in fig: - 04.
6. Reassemble the actuator (07) with bottom casing (05) by tightening the fixing
fasteners (25, 26, and 27) after ensuring the proper positioning of diaphragm
between the casings.

Disassembly of Regulator unit (Plug & Soft seat assembly)

1. Loosen fasteners (28, 29, 30) fixing bottom (06) with main regulator body (01)
& ensure bottom spring (16) tension get released.
2. Remove bottom (06) with complete plug assembly and “O”-ring (18) from body
(01).
3. Remove the plug assembly & bottom spring (16) from plug guide (04) & bottom
spring (16).
4. Loosen the plug screw (14), connected with plug (03) and remove disc washer
(13) followed by soft seating disc (12).
5. Clean all disassembled parts followed by flushing dry compressed air.
6. Replace soft seating disc (12) from spares.
7. Replace plug guide “O” – rings (18 & 20) from spare kit.
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Operation & manual
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Reassembly of Regulator unit (Plug & Soft Seating assembly)

1. Insert new soft seating disc (12) properly into plug (03).
2. Place disc washer (13) and adequately tightened the plug screw (14) with plug
(03).
3. Position the plug (03), bottom spring (16) inside the plug guide (04) correctly.
4. Ensure that free movement of plug assembly within plug guide (04).
5. Place the plug guide (04) on bottom (06) by positioning the “O” – ring (18).
6. Reassemble the bottom (06) with plug assembly to body (01); tighten the
fasteners (28, 29, and 30).

Pilot Maintenance

Disassembly of Pilot Valve: -

1. Remove Cap (38) & Unscrew Locknut (40) and Set screw (38) to release spring
(49) tension, Ensure that spring (49) tension is released completely by
unscrewing the set screw.
2. Loosen Fasteners (57, 58, 59) fixing spring casing (37) to bottom casing (42).
3. Remove top spring casing (37) carefully.
4. Remove Top spring washer (47), main spring (49) placed on diaphragm
assembly.
5. Loosen Nylon locknut (56) & remove bottom spring washer (46), diaphragm
plate (44), diaphragm (50) and diaphragm washer (45) along with “O”-rings
(52).
6. Loosen fasteners (60, 61) fixing bottom casing (42) with body (33).
7. Once bottom casing (42) removed whole plug assembly taken from seat (41)
with guide piece (43).
8. Unscrew Plug screw (48) & remove soft seating disc (51) from Plug (34).

Reassembly of Pilot Valve: -

1. Replace soft seating disc (51) new one from spares & placed in plug (34) at their
position properly as gentle.
2. Plug (34) with soft seating disc (51) to be connected with plug rod (35) by
tightening plug screw (48).
3. Place plug assembly along with plug rod (35) on seat (41).
4. Guide piece (43) to be placed on its respective portion in body (33) & fix bottom
casing (42) on body (33) by tightening fasteners (60, 61).
5. According to diaphragm assembly place diaphragm washer (45), “O”-rings (52),
diaphragm (50), diaphragm plate (44), & bottom spring washer (46) on plug rod
(35) in orderly as shown in fig: - 04.
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Operation & manual
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6. Tightened whole diaphragm assembly with plug rod (35) by nylon locknut (56).
7. Place main spring (49) on diaphragm plate (44) & fix top spring washer (47)
over main spring (49).
8. Place spring casing (37) on bottom casing (42) & tightening fixing fasteners (57,
58, and 59).
9. Place set screw (39) in top spring casing (37) & tightened the set screw (39)
according to required set pressure by following setting guide line.
10. Once set pressure is achieved, tightened locknut (40) at which set pressure
achieved.

Fig: -04 PB / Series Assembly – Casing Type

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Operation & manual
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Main Regulator Maintenance (Plate Type): -

Disassembly of Actuator (Diaphragm Assembly & Refer Figure: - 06)

1. Slacken tube and fittings & remove pilot valve from main valve.
2. Loosen the fasteners (25, 26, 27) fixing the actuator (07) with bottom casing
(05).
3. Separate actuator (07) from bottom casing (05).
4. Loosen Nylon locknut (24) clamping diaphragm washer (10), diaphragm (15),
and diaphragm plate (11) with push rod (09).
5. Remove diaphragm washer (10) from push rod (09).
6. Remove diaphragm (15), diaphragm plate (11) from push rod (09).
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PB/Series Regulator
Operation & manual
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7. Clean all the disassembled metal parts followed by flushing with dry compressed
air.
8. Replace the polymer via; diaphragm (15) & “O” – ring (21) from the spare parts.
The “O” – ring and sliding mechanism must be lubricated with a fine layer of silicone
grease before reassembly, the polymer parts require grease to hold them in their
respective positions (or) slots.

Reassembly of Actuator (Diaphragm Assembly)

1. Replace “O” – ring (21) of diaphragm which placed in Diaphragm plate (11) and
Diaphragm washer (10).
2. Place the new “O” – ring (21) in diaphragm washer (10) and diaphragm plate
(11).
3. Reassemble the diaphragm (15) between diaphragm washer (10) and
diaphragm plate (11).
4. Tightened nylon locknut (24) for clamping diaphragm washer (10), diaphragm
(15), and diaphragm plate (11) by properly placing on push rod (09).
5. Place diaphragm (15) assembly along with push rod (09) in their respective
portion as shown in fig: - 06.
6. Reassemble the actuator (07) with bottom casing (05) by tightening the fixing
fasteners (25, 26, and 27) after ensuring the proper positioning of diaphragm
between the casings.

Disassembly of Regulator unit (Plug & Soft seat assembly)

1. Loosen fasteners (28, 29, 30) fixing bottom (06) with main regulator body (01)
& ensure bottom spring (16) tension get released.
2. Remove bottom (06) with complete plug assembly and “O”-ring (18) from body
(01).
3. Remove the plug assembly from plug guide (04) & bottom spring (16).
4. Loosen the plug screw (14), connected with plug (03) and remove disc washer
(13) followed by soft seating disc (12).
5. Clean all disassembled parts followed by flushing dry compressed air.
6. Replace soft seating disc (12) from spares.
7. Replace Plug guide “O” – rings (18 & 20) from spare kit.

Reassembly of Regulator unit (Plug & Soft Seating assembly)

1. Insert new soft seating disc (12) properly into plug (03).
2. Place disc washer (13) and adequately tightened the plug screw (14) with plug
(03).
3. Place new “O”-rings (18 & 20) in Plug guide (04)
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Operation & manual
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4. Position the plug assembly; bottom spring (14) inside the plug guide (04)
correctly.
5. Ensure that free movement of plug assembly within plug guide (04).
6. Place the plug guide (04) on bottom (06) by positioning the “O” – ring (18).
7. Reassemble the bottom (06) with plug assembly to body (01), tighten the
fasteners (28, 29, 30).

Pilot Maintenance (Plate Type)

Disassembly of Pilot Valve (Plate Type & Refer Figure: - 06): -

1. Remove Cap (38) & Unscrew Locknut (40) and Set screw (39) to release spring
(49) tension, Ensure that spring (49) tension is released completely by
unscrewing the set screw.
2. Loosen Fasteners (57, 58, 59) fixing top spring casing (37) to bottom casing
(42).
3. Remove top spring casing (37) carefully.
4. Remove Top spring washer (47), main spring (49) placed on diaphragm.
5. Loosen Nylon locknut (56) & remove diaphragm plate (44), backup plate (45),
diaphragm (50) and diaphragm washer (46) along with “O”-rings (52).
6. Loosen fasteners (60, 61) fixing bottom casing (42) with body (33).
7. Bottom casing (42) removed from body then plug assembly taken from seat (41)
with guide piece (43).
8. Unscrew Plug screw (48) & remove soft seating disc (51) from Plug (34).

Reassembly of Pilot Valve: -

1. Replace soft seating disc (51) new one from spares & placed in plug (34) at their
position properly as gentle.
2. Plug (34) with soft seating disc (51) to be connected with plug rod (35) by
tightening plug screw (48).
3. Place plug assembly along with plug rod (35) on seat (41).
4. Guide piece (43) to be placed on its respective portion in body (33) & fix bottom
casing (42) on body (33) by tightening fasteners (60, 61).
5. For diaphragm assembly place diaphragm washer (46), “O”-rings (52),
diaphragm (50), Backup plate (45), & Diaphragm plate (44) on plug rod (35) in
orderly as shown in fig: - 06.
6. Tightened whole diaphragm assembly with plug rod (35) by nylon locknut (56).
7. Place main spring (49) on diaphragm plate (44) & fix top spring washer (47)
over main spring (49).
8. Place spring casing (37) on bottom casing (42) & tightened fixing fasteners (57,
58, and 59).
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Operation & manual
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9. Place set screw (39) in top spring casing (37) & tightened the set screw (39)
according to required line pressure.
10. Once set pressure is achieved, tightened locknut (40) at which set pressure
achieved.

Fig: - 06, PB / Series Assembly – Plate Type

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Operation & manual
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Fig: - 07, PB/ Series Parts List - Plate Type

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Operation & manual
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Medium Pressure Pilot Maintenance (Operating Pressure Range: - 1.0 barg to 10.0 barg)

Disassembly of Pilot Valve: -

1. Remove Cap (06) & Unscrew Locknut (08) and Set screw (07) to release spring
(17) tension, Ensure that spring (17) tension is released completely by
unscrewing the set screw.
2. Loosen Fasteners (25, 26, 27) fixing spring casing (05) to bottom casing (10).
3. Remove top spring casing (05) carefully.
4. Remove Top spring washer (15), main spring (17) placed on diaphragm
assembly.
5. Loosen Nylon locknut (24) & remove bottom spring washer (14), diaphragm
plate (12), diaphragm (18) and diaphragm washer (13) along with “O”-rings
(20).
6. Loosen fasteners (28, 29) fixing bottom casing (10) with body (01).
7. Once bottom casing (10) is removed whole plug assembly is taken out from seat
(09) with guide piece (11).
8. Unscrew Plug screw (16) & remove soft seating disc (19) from Plug (02).
Rea
Reassembly of Pilot Valve: -ssembly of Pilot Valve: -

1. Replace soft seating disc (19) new one from spares & placed in plug (02) at their
position properly as gentle.
2. Plug (02) with soft seating disc (19) to be connected with plug rod (03) by
tightening plug screw (16).
3. Place plug assembly along with plug rod (03) on seat (09).
4. Guide piece (11) to be placed on its respective portion in body (01) & fix bottom
casing (10) on body (01) by tightening fasteners (28, 29).
5. According to diaphragm assembly place diaphragm washer (13), “O”-rings (20),
diaphragm (18), diaphragm plate (12), & bottom spring washer (14) on plug rod
(03) in orderly as shown in fig: - 08.
6. Tightened whole diaphragm assembly with plug rod (03) by nylon locknut (24).
7. Place main spring (17) on diaphragm plate (12) & place top spring washer (15)
over main spring (17).
8. Place spring casing (05) on bottom casing (10) & tightened fixing fasteners (25,
26, and 28).
9. Place set screw (07) in top spring casing (05) & tightened the set screw (07)
according to required set pressure by following setting guide line.
10. Once set pressure is achieved, tightened locknut (08) at which set pressure
achieved.
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Operation & manual
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Fig: - 08, PB / Series Medium Pressure Pilot Assembly –

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Operation & manual
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Fig: - 08, PB / Series Medium Pressure Pilot Parts List

Note : Disposal of Products / Parts
“The products or parts thereof are to be disposed–off in accordance with existing
Government / Federal / State & local environment control regulations at authorized
recycler regulations prevailing at location of use / disposal.”