Instruction No 18-V8165A Crosby Valve Inc. Effective: February 1993, — CROSBY Installation, Operating and Maintenance Instructions for Crosby® Style HPV-ST Pressurmatic® Vent Valve 2-1/2" Styles HPV-ST-6( ), 7( ), 8(), 9(), 10() and 11() With Controller Style APS 2Table of Contents: Page | _ Description Page Introduction 3. | Figures 1 through 8 12-18 Section! - General Arrangement Ordering Spare Parts 19 Of Installation 4 | Crosby Field Service and Ri sectont = WinngDiagam ——-g_ | CSPYFielsSeviceandepae Section Ill - Description of Operation 5 9 Section IV - Testing and Adjustments 5 | Crosby Products 20 Section V_- Valve Maintenance 8 | Warranty and Warning 20 Figures 1 through 8 (Pagesi2 through 18) 1 Schematic Diagram of Typical Pressurmatic” || 4B Installation Data (Wiring Connections) for Vent Valve Installation Pressurmatic® Vent Valve Style HPV-ST || (0C Power Source) 2. Pressurmatic” Vent Valve, Style HPV-ST and List of Materials 3A Installation Data for Pressurmatic® Vent Valve 5 Main Valve Nozzle Removal Style HPV-ST (AC Power Source) 6 Main Valve Seal Ring and Seating Surfaces 38 Installation Data for Pressurmatic” Vent Valve Style HPV-ST (DC Power Source) 7 Pilot Valve Seal Ring and Seating Surfaces 4A Installation Data (Wiring Connections) for Se pee Pressurmatic” Vent Valve Style HPV-ST {AC Power Source) Vent Vaive Testing Without System Pressure The safety of lives and property often depends on the proper operation of the | safety valves. Consequently, the valves should be kept clean and should be periodically tested and reconditioned to make sure they function properly. WARNING: Suitability of the material and product for the use contemplated by the buyer is the sole responsibility of the buyer. Also.storage, installation and propor use and application are the sole responsibility of the purchaser. CROSBY disclaims any and all ability arising out of sa Any installation, maintenance, adjustment, repair and testing performed on safety relief valves should be done in accordance with the requirements of all applicable Codes and Standards under which those ing such work should maintain proper authorization through appropriate governingauthorities, No assembly and test work done by other than CROSBY shall be covered by the warranty extended by CROSBY to its customers. You assume full responsibility for your work. In maintaining and repairing ‘CROSBY products you should use only parts manufacturedby the Crosby Valve & Gage Company. Call your nearest CROSBY sales office or our factory in Wrentham, Massachusetts for a CROSBY service engineer should you wish assistance with your fieldneeds. cRosey,INTRODUCTION Crosby Style HPV-ST PressurmaticVent Valves have been selected for installation because of their performance features, reliability and ease of maintenance. Adherence to the installation and maintenance procedures specified herein will provide the utmost in safety, a minimum of maintenance, and a long service life. Details of the HPV-ST valve design, materials of construction, pressure/temperature ratings and dimensions are provided in Crosby Catalog No. 403. ‘Storageand Handling The HPV-ST Valve, APS 2 Controller, and PS Panel Switchesand elated equipmentare often on hand at the job site months before they are installed. Unless properly stored andprotected, valve performance may be adversely affected. Rough handling and dirt may damage the valve parts or cause the electrical components to malfunction. Itis recommended that the units be left in their original shipping containers and that they be stored in a warehouse or butler type building until they are used. Installation Warning: To have trouble-free perfor- mance, be sure to clean the inlets and outlets of valves thoroughly before install- ing. All dirt, sediment and scale in the pressure vessel and piping and the pres- sure sensing line must be completely re-| moved before installation. Foreign mate- rialenteringthe valve may cause valveseat leakage, plugthe pressure sensing line or cause valve malfunction. igging Pressure relieving valves must be handled carefully and never subjected to sharp im- pactloads. Whileinthe shipmentcase orwhen tuncrated they should notbe struck, bumped or dropped. Rough handling may alter the pres- sure setting of the APS 2 Controller, deform valve parts and adversely atfect seat tightness and valve performance. When itis necessary to use a hoist, the chain or sling should be placed around the valve body in a manner that will ensure that the valve is in a vertical position to facilitate installation. The valve should never be lifted orhandled using the pilot valve of solenoid bracket. Inlet protectors should remain in place until the valve is ready to be installed on the system. Inspection Pressure relieving valves should be visually in- spected before they are installed to ensure that, no damage has occurred during shipment or while in storage. All protective material, sealing plugs and any extraneous material inside the valve body or nozzle must be removed. The valve nameplate and other identifying tags should be checked to ensure that the particular valve is being installed at the location for which it was intended. Pressurmatic Vent Valves are intended to open andclose within anarrow pressure range; there- fore, the installation requires careful and accu- rate piping design including the location of the pressure tap and controllerandPS Panel Switch placement. The higher the operating pressure and the greater the valve capacity, the more critical becomes the need for proper design of the installation. Inlet Piping Pressurmatic Vent Valves should always be mounted in a vertical position directly on isolat- ing valves and nozzles with the same or larger inside diameteras the valve inlet. The inletpiping length should be kept to a minimum to avoid an excessive pressure drop. The Pressurmatic Vent Valve installation andinletpiping shouldbe designed to withstand all pressure, reaction forces and moments due to valve discharge. Outlet Reaction Forces The discharge of a Pressurmatic Vent Valve will impose a reactive load on the inlet of the valve, Rosey snosey,‘ isolating valve, and the mounting nozzle and adjacent supporting vessel shellasaresultofthe reaction force of the flowing stream. The precise nature of the loading and the resulting stresses will depend on the configuration of the valve and the discharge piping. This must be taken into consideration by those responsible for the in- stallation of the valve and associated vessel or piping. Determination of the outlet reaction forces is the responsibilty of the designer of the vessel andior piping. Discharge Piping The discharge piping from Pressurmatic Vent Valves should be equal in sizetto, or larger than, the normal valve outlet and shouldbe simple and direct as possible. Connections with generous clearances are preferred. The discharge pipe above the drip pan should be sized adequately to avoid "blowback" of steam from around the drip pan into the boiler room when the valve is discharging. The discharge pipe should be firmly braced. Fittings or pipe having a smaller inside diameter than the valve outlet connections must not be used. The flow from the valve outletand the pilot valve exhaust vent must discharge to a safe disposal area. ‘Where piping extends to a considerable length, it may be necessary to increase the pipe size at the upper part of the stack. Where flexible hose connections are used in place of or in conjunc- tion with drip pans, they must be of sufficient length and flexibility so as to absorb expansion and impose no strains on the valve outlet when. the pressure vessels at normal operating pres- sure. ‘Adequate drainage is required to prevent corro- sive media from collecting in the drip pan assem- bly. Low point drains shall be provided. Particu- lar care must be observed to ensure that the drains are ditected or piped to a safe disposal area, emeeey, SECTION | - General Arrangement of Installation (Figure 1 on page 12) Figure 1 shows.a schematic diagram of a typical Pressurmatic® Vent Valve installation. A com- plete installation consists of the following units: (One Pressurmatic Vent Valve, Style HPV-ST One Panel Switch, Style PS ‘One Controller, Style APS 2 Customer approved drawings supplied for each Pressurmatic Vent Valve, Panel Switch and Controller should be used for the spe- cific installation. The Pressurmatic Vent Valve, Style HPV-ST (Figure 2 on page 13) is normally mounted on the supetheater header with an isolating gate valve between it and the header. It is recom- mended that the isolating valve be equipped with a by-pass valve The Panel Switch, Style PS (Figures 3A & 3B on pages 14 & 15) is normally mounted in the control room convenient to the operator. Both manualand automatic operation of the valve can beselected. Turning the three position Selector Switch (4B) to"HANDcauses the valve to open until the Selector Switch is returned to "OFF" which then closes the valve. Under "AUTO" operation, the Controller, Style APS2, automati- cally opens (at the highest pressure) and closes (at the low blowdown pressure) the valve ac- cording to the sensing line pressure. RED and GREEN indicating lightsindicate valve open and closed positions respectively. The Controller, Style APS 2 (Figures 3A &3B on pages 14 & 15) must be securely mounted ina controlled environment that will riaintain a 45F 10 100F (7C to 38C) ambient temperature. The pressure transducer (1F) must be connected to the pressure sensing line within 10 to 500 feetof the controller, depending on the pressure trans ducer selected (see specific customer approved installation drawings). Within the controller en- closure (1) isa subpanel (18) mounted on four standoffs containing the APS 2electronies, which includes terminal blocks for the pressure trans-ducer, panel switch, valve solenoid and indicat- ing switch connections. Also on the subpanel are blowdown adjustment and set point adjust ‘ment controls. The subpanel can be removed for punching and driling of the enclosure during initial installation. A siphon should be installed in the pressure sensing line before the pressure transducer to protect the transducer from system steam temperatures. The transducer and wiring should be protected from extremes in ambient temperature and humidity. SECTION II - Wiring Diagram (Figures 4A & 4B on page 16) Atypical schematic wiring diagram for the APS 2 Controller is shown in Figure 4A for AC operation and Figure 4B for DC operation. Ap- proveddrawings supplied with each valve should be used for specific installation and/or wiring information. SECTION III- Description of Operation (Figure 2 on page 13) Under normal operating conditions, the Inlet Port A (see Figure 2), the Cavities B and C, and the Pilot Valve connecting Cavity D are at the same fluid pressure. The disc (main valve) (3) seats against the nozzle (5) since the pressure in Cavity C is greater than the pressure in Dis- charge Port E (which is atmospheric) ‘The disc (pilot valve) (9) seats against the guide (pilot valve) (10) seat since the pressure in the, connecting Cavity Dis greaterthanthe pressure in pilot valve Discharge Port F (which is atmo- spheric) Operation of the system in the automatic mode is as follows: When the pressure in the sensing line increases to the opening (set) pressure, the solid state relay ofthe APS 2 Controller energizes the valve solenoid (21). Asthe solenoid energizes, the solenoids plunger lifts the operating lever (27) up which causes the adjusting bolt (32) to push down on the disc (pilot valve) (9). This unseats the disc (pilot valve) (9) and allows steam in Cavity D to pass through the vent holes in the guide (pilot valve) (10) tothe pilot valve Discharge PortF andoutto, atmosphere. While the steam in Cavity D vents to atmo- sphere, the pressure in Cavity C is rapidly de- creasing thereby allowing the greater pressure in Cavity B to push the disc (main valve) (3) down, This unseats the disc (main valve) (3)and allowssteamin Cavities Band A todischarge out through the nozzle Discharge Port E to the exhaust pipe. As the valve discharges, the system pressure and the sensing line pressure decrease. When the pressure in the sensing line decreasestothe closing (blowdown) pressure, the solid state relay in the APS 2 Controller de-energizes the valve solenoid. The solenoic's plunger falls to its original ree position andallows the pilot valve to close thereby causing pressure in Cavities D and C to build up. This increasing pressure moves the disc (main valve) (3) onto the nozzle (5) seat and closes off the valve discharge. Operation of the system in the manual mode isas follows: When the three position selector switch (48) (Figures 3A & 3B) is moved to the "HAND" position, the solenoid (2) (Figure 2) is energized causing the pilot valve to open, followed by the opening of the main vaive. The valve discharges until the three position selector switch (4B) (Fig ures 3A & 3B) is returned to the "OFF" position. At the "OFF" position, the solenoid is de-ener- gized. This action closes the pilot valve whichin turn closes the main valve. SECTION IV- Testing and Adjustments (Figure 1) Schematic Diagram ofinstallation (Figure2) Assembly of Pressurmatic Valve (Figure3) Schematic Diagram of Controller andPanelSwitch The Crosby Pressurmatic Vent Valve has been shop tested and the Controller Style APS 2 has6 been adjusted before shipment. However, a system operational test should be performed before the boiler is started up. CAUTION: When performing hydrostatic tests onthe boiler, the isolating gate valve (Figure’ 1) in‘the-pressure sensing line should be closed before imposing any hydrostatic testing on the boiler drum and/ or-superheater sections to prevent dam- age to the pressure transducer of the con- troller. - = The controller can be tested by two methods. The first method is done with an auxiliary pres- sure source appliedto the pressure sensing line. This method shouldbe usedto verify the control- ler installation. The second method is with the system pressure applied Testing Without System Pressure NOTE: When testing in this manner, close the isolating gate valve and by-pass valve, Isolating the Pressurmatic Vent Valve from the system, itis suggested that an auxiliary pressure source (dead weight tester, etc.) and a test gage of suitable acouracy be used in testing and adjust- ing the controller as shown in Figure 8 on page 18. Before proceeding, be sure that the following conditions exist (refer to Figures 1 & 8): - Isolating gate valve and by-pass valve be- neath the Pressurmatic Valve is closed. - Shut off vaive in the pressure sensing line to pressure transducer is closed. - Electrical circuitis properly fused andener- gized. ~ Panel switch is in the "OFF" position, + Test gage for checking pressure in the pressure sensing line is in operation. cRosey, enosey, - Auxiliary pressure source is connected to the pressure sensing line drain but not pressurized. NOTE:..Do not apply pressure-with the auxiliary pressure source at this time. After checking that all elements of the test sys- temare in condition to operate, check the opera- tion of the valve by turning the three position selector switch (48) (Figures 3A & 3B) to" HAND" Position. This will energize the solenoid. When the solenoidis energized, the pilotvalveis opened by the solenoid lever (27). The indicating switch will be activated by the solenoid lever and light the RED lightatthe panel switch. Afterchecking the operation by "HAND" control, the selector switch should be turned to "AUTO" position. NOTE: No pressure should be applied with the auxiliary pressure source at this time. With the selector switch (48) tumed to the "AUTO" position, the automatic circuit is acti- vated and the GREEN light at the panel switch willbe lit. This shows that the valve is closed and the system is ready for "AUTO" operation. Now, using the auxiliary pressure source, slowly raise the pressure sensing line pressure, Ob- serve the pressure on the test gage. Raise the pressure until the solenoid on the Pressurmatic Valveis energized. Recordthis pressure. Allow the pressure to decay until the solenoid closes. Record this pressure. The pressures recorded atthe solenoid opening and closing are the Pressurmatic Vent Valve ‘opening and closing points. |f the opening (set) and closing (blowdown) pressures need adjust- ment, refertothe section, “APS 2 Controller Set Pressure and Blowdown Adjustment Instruc- tions." Testing With System Pressure To test the Pressurmatic Vent Valve using sys- tem pressure, before raising pressure on the system be sure the following conditions exist (refer to Figures 1 & 8):= Isolating gate valve beneath the Pressurmatic Valve is fully open. Shut off valve in the pressure sensing line to pressure transducer is open. Drain stop valve in the pressure sensing fine to pressure transducer is closed. Electrical circuits properly fused and ener- gized. Panel switch is in the "OFF * position - Test gage for checking pressure in the pressure sensing line is in operation, Pilot valve ventline is open to atmosphere. After checking that all elements of the valve system are in condition to operate, check the operation of the valve by turning the three posi- tion selector switch (4B) (Figures 3A & 3B) to *HAND" position. This willenergize the solenoid and open the Pressurmatic Valve. When the solenoid energizes, the RED light willbe litatthe panel switch (4) (Figures 3A & 3B). ‘Afterchecking the operation by *HAND' control, the selector switch (48) (Figures 3A & 3B) should be turnedto "AUTO" position. This activates the automaticcircuit lightingthe GREEN lightatthe Panel Switch (4) (Figures 3A & 38) which shows, that the valve is closed and the system is ready for ‘AUTO" operation. Raise pressure in the system until the Pressurmatic Valve opens. Allow the pressure to decay until the valve closes. ‘The pressure in the pressure sensing line at the opening and closing points should be read from the test gage. If the opening (set) and closing (blowdown) pressures need adjustment, then use the pressure adjustment instructions following. It pressure adjustmentis necessary, itis recom- mended thatthe system be setupin accordance with the section for testing without system pres- sure, using an auxiliary pressure source applied to the pressure sensing line. APS2Controller Set Pressure and Blowdown Adjustment Instructions (Figures 3A & 3B) Apply the desired opening (set) pressure to the pressure transducer, using either the auxiliary pressure source or system pressure (Figure 1 or Figure 8). If the output (RED) LED on the controller (1B) has not indicated "ON," unlock and slowly tum, the set point adjustment knob until the output (RED) LED onthe controllerjustiights. Lockthe set pressure adjustment knob at this point. Ifthe controller (1B) indicates output "ON" prior to reaching the desired opening (set) pressure, reduce the pressure to the pressure transducer. Unlock the set point adjustment knob, tur it to a higher value, and lock it. Repeat the above sequence until the opening (set) pressure has been satisfactorily set. Check the opening (set) pressure one more time by releasing all sensing line pressure and then slowly increasingit. Afterthe controller (18) indicates output "ON," slowly decrease sensing line pressure to the desired valve closing (blowdown) pressure. CAUTION: itis not recommended that the blowdown be setforless than 2% of the set pressure. : lithe controller (1B) output "OFF" (GREEN) LED has not lit, unlock and slowly turn the blowdown adjustment knob until the output LED does light. Lock the blowdown adjustment knob at this point. Ifthe controller (1B) output "OFF" (GREEN) LED lights prior to reaching the desired closing {blowdown) pressure, unlock the blowdown adjustment knob, tum it to a higher value, and lock it. Increase the sensing line pressure until the controller (RED) LED again indicates output "ON." Slowly decrease sensing line pressure to the desired valve closing (blowdown) pressure and repeat the above. ‘Gnosey yenosey) 78 NOTE: Iftests are performed without system pressure on the valve, itis recommended that solenoid actuation be confirmed by observ- ing movernent of the lever connected to the solenoid. Should any problems occur, place the three position selector switch (4B) in the "OFF" posi- tion and recheck all wiring connections. If all connections are correct, contact Crosby Valve & Gage Company for assistance. Adjustment for Proper Pilot Valve Actuation (Figure 2 on page 13) To ensure proper actuation of the disc (pilot valve) (9), the adjustment of the adjusting bolt (pilot vaive) (32) should be checked as follows: CAUTION: This adjustment should be made with the panel switch in the "OFF" position and ZERO pressure in the Pressurematic Valve (isolating valve closed). Manually raise the solenoid's plunger until the adjusting bolt (32) makes contact with the disc 9), ‘These surfaces should make contact when the face ofthe operating lever (27) andthe adjusting bolt (32) ishorizontal and/or when the solenoid’s plunger is at half stroke. At about the same instant, the indicating switch (micro) (34) should make contact with the operating lever (27). To adjust the adjusting bolt (pilot valve) (32), proceed as follows: Remove the cotter pin (adjusting bolt) (35) and loosen pilot valve adjusting bolt nut (33) by turning tothe left (counterclockwise). Raise the solenoid! plunger to place the operating lever (27) in a horizontal position and turn the adjust- ing bolt (32) until it contacts with disc (9). Posi- tion the adjusting bolt (32) so that the hole is in line with the slot on the operating lever (27), install the cotter pin (adjusting bolt) (35), and tighten the pilot valve adjusting bolt nut (33) to lock adjusting bolt (32) in place. Grosey, SECTION V - Valve Maintenance When, atter long service or due to damage from foreign particles, it is necessary to repair the valve seats, the following procedures should be followed: Actuate the solenoid by turning the three posi- tion selector panel switch (4B) (Figures 3A & 3B) to "HAND" to make certain that all pressure is removed from Cavities B, C and D (Figure 2). Now, place the panel switch in the "OFF* posi- tion. Disconnect all electric power going to the panel switch, Disassembly of Main Valve (Figure 2 on page 13) Remove bolts (drip pan assembly) (16) and remove drip pan assembly (17) from the valve. Loosen the nozzle (5) from the valve body (1) by placing a wrench on the flats provided and turning in a counterclockwise direction (see cau- tion note below). CAUTION: During disassembly, the disc (8) should be separated from the nozzle (5) sothat the disc (3) seat and nozzle (5) seat are not in contact. This may be accom- plished by applying pressure to the top face of the disc (3) with a wooden dowel through cavity E, compressing spring (disc main valve) (4) (‘see Figure 5 on page 17). With the nozzle (5) loose and away from the disc (3), continue to remove the nozzle (5) from the body (1) by tuning counterclockwise untilitcan bellifted from the valve body (1). Care should be exercised fo ensure no damage occurs to the seal ring (nozzle) (6) surfaces. Remove the seal ing nozzle) (6). Inspect -ring surfaces and refinish as outlined in "Recondi- tioning of Seats and Seal Ring Surfaces." Re- move disc (3) and spring (4) from valve body (1). Disassembly of Pilot Valve (Figure 2 on page 13) The pilot valve may be disassembled withoutremoving the solenoid and bracket assembly by following the steps outlined below. Should it be desired to remove the solenoid and bracket assembly, the following steps should be fok lowed. De-energize the electrical circuit. Re- move the solenoid cover (25). Disconnect the electrical supply wires (S1 and S2)(Figures 4A. & 4B on page 16) on the solenoid (21) and the (NC) and (common) wires from the indicating switch (micro) (34), CAUTION: Reassembly of bracket should be performed by reversing the steps above. However, the adjusting bolt (pilot valve) (32) ‘should be checked per Section IV, "Adjust- ment for Proper Pilot Valve Actuation.’ Remove pin (31) after removing cotter pin (37). Holding the solenoia's plunger and end of oper- ating lever (27), disengage link (29) from the solenoia's plunger, then lower and remove from solenoid. Hold operatinglever (27), remove pin (operating lever) (28) after removing cotter pin (36), and remove operating lever (27). Remove bolts (pilot valve guide)(12) and lock washers (13). Remove guide (10) and disc (9) as a unit from body (1). After removal, the parts may be separated as follows: remove retaining ring (7), dust cover (8) and spring (14). The disc (9) may now be removed from the guide (10). Remove seal ring (pilot valve guide) (11). In- spect metal V-ring seating surfaces and refinish per "Reconditioning of Seats and Seal Ring Seating Surfaces. Reconditioning of Seats and Seal Ring Seating Surfaces Disc Seat (Main Valve) (3) Disc (3) seat may be lapped if slight or minor impertectionsexist. Otherwise, it maybe chucked ina lathe with guide diameters and seat face runningtrue, and machined, removing sufficient metaltoclean up the seat and to re-establish the dimension shown in Figure 6 on page 17. After machining, the disc (3) should be lapped in accordance with the lapping procedures out- lined on pages 10nd 11 using the laps shown in Figure 6. Nozzle Seats Nozzle (5) seat may be lapped if slight or minor imperfections exist. Otherwise, it maybe chucked inalathewith the quiding surfaces and seatface runningtrue, andmachined, removing sufficient metalto clean up the seat andto re-establish the dimensions shown in Figure6. After machining, the nozzle (8) should be lapped in accordance with the lapping procedures outlined on pages 10nd 11 using the laps specified in Figure 6 on page 17. Pilot Vaive Disc and Pilot Valve Guide Seats The pilot valve disc (9) seat and guide (10) seat may be lapped or remachined to restore the seating surfaces. Thelappingtools and machin- ing dimensions are specified in Figure 7 on page 18. Tomachine the disc (9) seat, itshouldbe chucked in a lathe (seat end in center) with the guiding diameters of the two lands and seat face running true, andsufficient material removedtoclean up the seating surface. To machine the guide (10) seat, it should be chucked in a lathe with pilot valve stem guide diameterandthe seatrunning true andsutficient material removed to clean up the seating sur- face. The lapping of the pilot valve disc (9) and guide (10) should be done in accordance with the lapping procedure outlined on pages 10 and 11 using the laps specified in Figure 7 on page 18. Seal Ring Surfaces, Pilot Valve and Main Valve ‘The seal ring (6 and 11)sealing surfaces of the nozzle (5) and body (1) and the guide (pilot valve) (10) and body (1) must, after each disas- sembly, be inspected for surface damage. If surface damageis apparent, reconditioning may be accomplished through lapping, cRosey, SResey,[CAUTION: When lapping the pilot guide (10) sealing surface, Dimension G (Figure '7) of the guide must exceed Dimension G* lof the body by .003 inch. The finished sealing surface shouldbe an 8 rms finish and dimensions which agree with those specifiedin Figures 6 and. Thislapping can be accomplished through the use of the laps speci- fied in Figures 6 and 7 on pages 17 and 18. Lapping procedures are as follows: Lapping Procedures Laps The laps specified for lapping all seating and sealing surfaces are made of a special grade of annealed cast iron and are lapped optically fat. Itis essential that the lap remain flat to produce aluly flatseating or sealing surface. Inchecking the lap for restoring flatness after use, a lapping block resurfacing plate should be used. Lapping Block Resurfacing Plate Thisis also made of a special grade of annealed castiiron (Meehanite). Itis machined "all over", one side being machinedinto small squares with 364" grooves forbetter cutting action. This side is the surface on which the laps are recondi- tioned. Lapping Compounds Experience has proven that medium coarse, medium, fine, and polish lapping compounds will properly condition any damaged pressure relieving valve seat except where the damage requires remachining. The lapping compounds or their commercial equivalents are suggested below. Different individuals have different methods of lapping valve seats, but certain essential steps must be taken to get satisfactory results. The following procedure is suggested for lapping of valveseats: Never lap the disc against the nozzle. Lap each part separately against a cast iron lapping block of the proper size. These blocks hold the lapping compound in their surface pores but must be recharged and reconditioned frequently. Check the lapping block often on a good lapping block resurfacing plate to make certain it is perfectly fat. considerable lappingis required, spreada thin coat of medium coarse lapping compound on the block LappingCompounds\ “ €5% i ‘ele : : Manufacturer Trade. =, Grit: | Micron}. “fg ug Name.or-- é Abrasive Size | Size_| “Description | ~ Equivalent Silicon Carbide [320 | 31 | Medium Coarse _| U.S. Products No. 2 Crystolon Silicon Carbide | 400 [22 | Medium U.S. Products No. 3F Crystolon Silicon Carbide | 600 | 16 | Fine U.S. Products No. A-600Crystolon Hard Alumina oF Aluminum Oxide | 900 | 9 _| Polish U.S. Products No. 38-900-A 10 Gaasay, pCLLELIAAfter lapping with this compound, lap again with ‘medium grade compound. Unless much lap- ping is called for, the first step can be omitted. Next, lap again using a fine grade compound. Lap the block against the seat. Never rotate the block continuously; use an oscillating move- ment. ‘When all nicks and marks have disappeared, remove all the compound from the block and seat. Apply polish compound to another block and lap the seat with this. As the lapping nears completion, only the compound left in the pores ofthe block should be present. This should give avery smooth finish. If scratches appear, the cause is probably dirty lapping compound. These scratches should be removed by using compound free from foreign material Extreme care should be taken throughout to make certain that the seats are kept perfectly flat Reconditioning Parts Allother valve parts should requirea minimum of maintenance to be put in working order. ‘These parts shouldbe thoroughly cleaned. Fine emery cloth or crocus cloth may be used to polish guiding surfaces and surfaces in intimate rubbing contact, Care must be used to ensure critical dimensions are not affected. Final clean the parts with acetone or any other acceptable cleaner prior to assembly. Reassembly Lubrication The following areas should be lubricated before and during assembly with a suitable sealant or lubricant - Main valve nozzle threads - Silver Goop or equivalent - Adjusting boltthreads- "Never-Seez" or equivalent - All studs and nuts - “Never-Seez" or ‘equivalent ~ Lever and link pins - "Never-Seez" or ‘equivalent = Solenoid’s plunger - spray with silicon spray or equivalent ~ Sealring contact surface on body, guide (pilot valve) and nozzle - petroleum jelly (Vaseline) Main Valve (Figure 2 on page 13) Prior to assembly, inspect surfaces on valve body (1), nozzle (5) and guide (pilot vaive) (10) where the seal rings (6 and 11) make contact to conformwith dimensions per Figures 6 and7 on pages 17 and 18. Ensure that the sealing sur- faces arenotdamaged andhavea surface finish of 8 ims, Dimensions must agree or seal ring leakage may result, To ensure that the nozzle is making metal-to- metal contact with the body, the following proce- dure should be followed: Lubricate the nozzle (5) threads andthe body (1) where the nozzle flange makes contact (Surface B, Figure 6). Do not place disc (main valve) (8), disc spring (main valve) (4) or seat ring (6) in body. Screw nozzle (5) into body (1) until metal-to-metal con- tact occurs. Using a wrench on flats provided, tighten nozzle until contact of the nozzle flange to body is made. Scribe a line on the side of the nozzle flange and the top of the body. Remove nozzle from body. Place disc spring (main valve) (4) and disc (main valve) (3) in position. Clean surfaces in valve body (1) and nozzle (6) where the seal ring makes contactand lubricate with petroleum jelly (Vaseline). Install seal ring (6)inthecounterbore provided ‘cnasey 11CAUTION: Place the nozzle (5) in the body (1) and turn clockwise. Care should be cercised so that the seal ring is not dam- aged. During assembly of the nozzle (5) to the body (1), the disc (main valve) (3) seat and nozzle (5) seat should not be in con- tact. This can be accomplished by appl ing pressure to the top face of disc (main valve) (3) with a wooden dowel through Discharge PortE, compressing disc spring (main valve) (4). This will allow the nozzle (6)tobe rotated freely and the seats will not be in contact (see Figure 5 on page 17). The nozzle (5) is tightened in the body (1) using wrench on the flats provided until the scribed marks are inline. After the nozzle (5) has been tightened, the disc (3) may be released so that the spring (4) will allow the nozzle and disc (3) seats tomake contact. Position drip panassem- bly (17) on top of valve body (1) and bolt flange to valve body (1) using bolts (16). Pilot Valve Clean seal ring seating sur- faces in body (1) and guide (10), Assemble disc (9) to guide Holding guide (10) in place, assemble lock washer (pilotvalve) (13)andbolt 12) andttighten. CAUTION: During assembly of guide (10), care should be exercised to prevent rota- tion of guide (10) on seal ring (11). Place operating lever (27) in solenoid bracket (18)and assemble pin (operating lever) (28) and cotter pin (36), Raise the solenoid's plunger into solenoid (21) and while holding plunger, slide the solenoids plunger pin (31) through the solenoid's plunger andlink (solenoid) (29) andinstall cotterpin (37) Lubricate the solenoid's plunger pins and lever pins (28, 30 and 31) with lubricant and actuate the solenoid's plunger by hand to ensure free movement. Refer to Section IV for "Adjustment for Proper Pilot Valve Actuation’ on page 8. communes mS (10) and install spring (14), dust cover (8) and retaining ring (7). CAUTION: Donotrotate ldisc (9) seat on guide (10) seatasdamagemay result. Apply a small amount of petroleumjelly (Vaseline) to a new seal ring (11) and install it into the groove of Guide (10) so that it will ad- here to the groove. Install the complete assembly into body (1) takingeare that the seal ring remains in the groove (see Caution), 12 nosey, {~ reese er ye Erie mmnco Ongnereremse Figure 1 ‘Schematic Diagram of Typical Pressurmatic® Vent Valve Installationa Ty See Figure 2 © | es ai va) ayes ay. — Prossurmatic* Vent Valve, Style HPV-ST ‘Song Ose WV] — ~~] emt ‘and List of Materials ‘gener FoR PILOT VALVE OXHAUST MAIN VALVE ‘SOLENOID COVER ‘@ Pre fopeag sie ‘rafeseraa) me ‘M4 NPT-FOR CONDUIT ee CUSTOMER'S | Seok ob ee oor oe oe — I "Reng sor Pv noronnn seams oot YY Bk] ©@O ©0O© O@® wero pr PER CusTOMER's ‘SPECIFICATIONS Trosey, 13 ronossy,Figure 3A Installation Data for Pressurmatic* Vent Valve Style HPV-ST (AC Power Source) [APS 2 Contr ‘Terminal 6 “Terminal Block Pressure Transducer Solenoid (AC) ind. Switon Selenigh Panel Swich (PS) Terminal Bicck (PS) — Three Poston Selector Switch (PS) aie (FS) ® | [ao [Panet swich Box PS) “Furnished as eub-aseembiy only [2] wszcoPeousr [2] BS PANEL SWITCH @ 14 Gnosay, enosey,Figure 38 Installation Data for Pressurmatic® Vent Valve Style HPV-ST (DC Power Source) ind, Switch (Sclerci) Panel Swich (PS) “Terminal Block (PS) — ‘Three Postion Selacior © Sich (PS) reszoovtroues [Oo] [La gate ES) —§ 20 | Panel Swich Box (5 “Fumie a sub-assembly ey aes PSPANE swrcH © 15 cRosey,Figure 48 Installation Data for Pressurmatic’ Vent Valve Style HPV-ST (AC Power Source) NOTE: Wiring connections shown are for AC Power Source Figure 48 Installation Data for Pressurmatic® Vent Valve Style HPV-ST (DC Power Source) NOTE: Wiring connections shown are for DC Power Source 16 ‘GaaseyFigure 5 Main Valve Nozzle Removal ® Figure 6 Main Valve Seal Ring and Seating Surfaces HPVST6(),70.8(),9() | HPV-ST10(), 1) a MI Mi Max Bato] 4.585 387 | p10" 200 [oes { 4 Bors 2250 fe sam as ao” saunrccne.« Original | . Surtace | — Use Lap No. 28036" | Use Lap Na. 65000 200% 7.80. save het aaa Psircos | — Usa ase” —| setae 7a827 — See ticwoe No.283 a ron ‘Sufeoo | Use Lap ats : Noses ena z ‘Siac Teataprie B60 No5&6. NOZZLE NOZZLE 4 DISC SEAT ovoMn quips oa. Grassy, 17 ronasey,Figure 7 Pilot Valve Seal Ring and ‘Seating Surfaces ee! Figure 8 cOMMEINEEISEcge ‘Schematic Diagram of Typical = Pressurmatic® Vent Valve Testing Without System Pressure Hin, 18 Gaosey eaossy,SPARE PARTS Crosby recommends spare parts as shown on the outline drawing Figure 2 on page 13. When ordering spare parts, the valve size, style and assembly number and/or serial number should be given together with set pressure, part name, reference number from Figure 2, and quantity. The valve assembly number is shown on the valve nameplate as "Shop No."(See nameplate below.) Crosby recommends that sufficient inventory of spare parts be maintained to support process requirements. Always be sure to use genuine Crosby parts to ensure continued product, performance and warranty. Crosby provides special “fast response" delivery service of spare parts to satisfy unplanned parts requirements. Fast response delivery service can be initiated by contacting your local Crosby representative. Emergency delivery @) CROSBY VALVE & GAGE CO. (© WRENTHAM, MASS. SIZE SET, service is available direct from the factory ses ne 24 hours a day, 7 days a week by calling [CAPACITY @| (608)384-3121, or FAX (508)384-8675. CROSBY FIELD SERVICE AND REPAIR PROGRAMS Field Servic Crosby Field Service provides on-site, in line testing and repair capability for all types of pressure relief devices. It is strongly recommended that on new installations, a Crosby Service Engineer be present for assembly and testing of safety valves. Parts: Crosby will help you establish the right mix of on- site spares with Crosby's own distribution and manufacturing support Training: Crosby offers intensive factory or on-site training seminars toimprove maintenance and application skils Testing: Crosby has the capability to evaluate safety valve operability either in the field or at various Crosby facilities. Special qualifications programs may also be conducted in our laboratories. Contract Management: Crosby will combine a group of services to satisfy your special maintenance needs. CROSBY FULL-SPECTRUM SERVICE ‘Gnosay, 19 enesey,rosby Products Presse Rolo! Ves tc A, Steam, Vepor and Liquid Sonic - Spring Loaded and Pt Operates Silty Vaves for Foes and ular Power Pants Cuickres™ crossover valves for continuous fow operons. Preseure/Vacuum Riel Vatves for Sanitary, Beverage, Feed and Pharmaceutical ndstes Valves or Chonine, Bromine, Fue and ahar corosive svicos Vive Test Genenes and Sioncers Sot pressure Voticaton Davie (SPVD) and Vaio Psion Indication (Va) Systems Comprehensive Test Fcitos fr A, Stoam and Water Valo Sone, Repair and econdtoning. and raining Cr [Ask for Crosby's Condensed Catalog Replacement Spare Parts Ordering Information FME-Crosby recommends that asuffcient inventory of spare parts be maintained fo suppor process requirements. Aways be sure to Use Genuine FAC-Crosby parts Yo ensure connvee praduet perormarce and waranty. Parts ‘To order parts, the following information should always be included “Quanity 2 Part name, is. (isc insert) 43.Size, style, type and valve ruber 4. Shop andior serial number '5.Onginal purchase order number (the nameplate has been cestroyed), Note:The size, svi, shop cumber, set pressure and serial number can always be fourd on the valve nameplate Springs with Washers ‘To order springs with washers, the required valve set prossure must also be spectod in adlion tothe other pars information Shouls back pressure (xed or varable) or elovated temperature exist during operation also spect these conaltions. WARRANTY Crosby Vave tne, Crety Vane and Enginooing Compe. Uimteg, Crosby Serves Intemational uct Creo) Wave Pe Lid, Crosby Vai Uc. or Grsby Vale Sales and Service erporaton{calectvey ‘Crosby hereby wararstatnegooce elvered wer contac le be Fo rom Stet natal ard ‘wormanstip fora peed ef 18 monte om shipment of 12 ‘mont to stalin whichever eae, Win Dis pried, any of our prosuat daimed derive maybe eure out {actor ater weit otiaten to and eutarastis ys, sna fourdtobeddlocive ste examination us te prods wil be ‘pated or repicod foe of charge, FOS ofr. Such Gates shal be excinve of thesia of coosion, crac, onal wear or reope: hain or slorage Cree makes no representation waranty orquarante express or epiog, wih regard to a proce expt ae spacey ‘Sale. Wihenindoaxestotnepepesppleatonolanypartoar ‘rode, yousrelnutedtoconat yournesest CROSBY ofa ar feprsstiaive. We carrot thane be response fr the Selcion of unstable equerent. Satay othe mater and reer the use covtamplt bythe baer shal be these Fesponsy fhe buyer: xcept at speccaly ast orn above andor waranty of ti (CROSBY MAKES NO WARRANTY, EXPRESS OF WIPLED, OFANY KIND NCLLIOING VATHOUT LINTATION WARRAN. TieS OF MERCHANTABILITY OR FITNESS FOR APARTICU. Lan PURPOSE Inno even wil CROSBY bela for incerta consequent canages wannins ‘Tho Product sat ted component tended for ue in crcl appeatins. The egroper apples, isaliton ‘mabtonare oth Prosutor eure cpa canons ot ‘mandacuredby Gosbymayrectin afalureotheProdit The Sevce ata altedengooar sno be su pray ne ‘ny instaaten, maktorance, adjustment, teal oF tet pet formas on the Precuct must be done in acsoraance ft te requremons of a appleable Code and Stencards ‘Tabvormatonspecifeatonsanstactncs tthe ‘Specie ‘one ovtained mts coeur are ube to change win rite,” Crosy doos ret wera ha tho Spaotostone are Current and assumes no respon fr tho uso of misuse Ihorct. ‘The Pucresar shou vest tat hae have boen no changes the Spestietene porto use, Crosby Valve Inc. CROSBY "MFG Corporation Sabtsary USA Operations UK Operations Asia Pacific Operations Executive and Seles Headquarter, Sales Otce, Hesaquartere ena Headquarters and ana Wanatacturing Plant Ssioe Ofoe Manufacturing Plant Crosby Valve ine MC Corporation (UK) Lt. Crosby Valve Pe, Lt. SSkenaner Sveet Crosby Valve and Engineering tes Gucrse PO Gox 00 Biveion Singapore 620605 Viren, Massachusetts rosy oad Tat (65) 882-2177 (2085 3588 Harel Harborough Fx (65)862-1776 UeceLe te SEE, Engine Tot (4a) 1888) ae72e% (08) 304-3121 (50a) a64-rage Fax (606) 364-8675, Fea (4) (1858) 408720 The (a5) Seas: cACSBYG Joint Ventures - rena Manufacturing files Paros Japan ‘Sales Representatives, Pressure Management Genter, Assemblers Designated Repalr Centers - Worse "Ask for Crosby Woiawrde Di worame.comfEteg rectory igang