Pressure reducer and flow control valve type E2114-02

Pressure reducer and flow control valve type E2114-02

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Dimensions and mass basic valve

Flanges in conformity with ISO 7005-2.

PN10-16

DNABKDE
mmmmmmmmmmmm
5023014824616585
6029014824618595
6529014824618595
80310148246200100
100350206272220110
125400267330250125
150480267330285145
200600356402340170
250730445569400200
300850597649455230
350980597649520255
4001100750786565285
5001250842840670335
6001450905956780390
700165011101080910460

PN25

DNABKDE
mmmmmmmmmmmm
5023014824616585
6029014824618595
6529014824618595
80310148246200100
100350206272220110
125400267330250125
150480267330285145
200600356402340170
250730445569400200
300850597649455230
350980597649520255
4001100750786565285
5001250842840670335
6001450905956780390
700165011101080910460

Material and coating

Item

Quantity

Description

Material

01

01

Body

FGS 400-15 (coating BFE epoxy 250μm mini)

02

01

Cover

FGS 400-15 (coating BFE epoxy 250μm mini)

03

01

Cover bearing

Bronze

04

01

Seat

AISI 316

05

01

Quad-ring retainer plate

AISI 316

06

01

Quad-ring retainer size 50-200

Quad-ring retainer size 250-700

AISI 316

FGS 500-15 + Epoxy

07

01

Stem

AISI 303

08

02

Stem nuts

AISI 303

09

01

Spacer

AISI 303

10

02

Diaphragm washers epoxy coated

Steel

11

01

Spring

AISI 302

12

*

Stud

AISI 303

13

*

Nut

AISI 303

14

*

Washer

AISI 303

15

01

Quad-ring

NBR (KTW-WRC)

16

01

Seat O-ring

Viton

17

01

Diaphragm

NBR nylon reinforced (KTW-WRC)

18

01

O-ring

NBR

19

02

Centring taper pin

AISI 303

20

01

Base position indicator

Brass Ni-plated

21

01

Position indicator housing

Brass Ni-plated

22

01

Position indicator stem

AISI 303

23

01

Position indicator

Glass

24

02

O-ring

NBR

25

01

Brass Ni-plated

Brass Ni-plated

26

01

O-ring

NBR

27

01

Reduction

AISI 304

Central Control Unit TUP 93

Item

Quantity

Description

Material (type)

01

01

Body

AISI 303

02

03

Cock

AISI 303

03

03

Plug

AISI 303

04

03

O-ring

NBR

05

02

Non return valve (WRC)

06

01

Screen

AISI 316

07

01

Rivet

Brass

08

01

Bottom label

Polycarbonate makrolon

09

01

Top label

Polycarbonate makrolon

Mounting scheme (I)

Item

Quantity

Description

01

2

Attachment flange

02

2

Flanged taper

03

3

Isolating valve

04

1

Strainer with drain cock

05

1

Automatic control valve E2001

06

1

Dismantling joint

07

1

Air release / vacuum breaker valve

Hydraulic scheme

item

Description

Material

1

Rate of flow control pilot

IS14

3a-3b-3c

Ball valve

Brass Ni-plated

3d

Ball valve

Brass Ni-plated

3e-3f

Ball valve(differential manometer)

Brass Ni-plated

4

Main valve

E2001

5

Position indicator with manual venting cock

E50

7

Centralized control unit

TUP 93

8

Clamping ring

Bronze

9

Calibrated orifice plate

Inox AISI 304

10

Tube

Inox AISI 304

11

Pressure reducer pilot

SS 263 RS

Pilot IS 14

Item

Description

Material

1

Cap

PVC

2

Top cover

Brass Ni-plated

3

Top spring guide

Brass Ni-plated

4

Spring

Inox AISI 302

5

Bottom spring guide

Brass Ni-plated

6

Bottom cover

Bronze + Ni-plated

7

Obturator bushing

Delrin

8

Main body

Bronze + Ni-plated

9

Obturator

Inox AISI-303

10

Adaptor

Brass Ni-plated

11

Bottom diaphragm washer

Inox AISI-304

12

Diaphragm

NBR nylon reinforced

13

Top diaphragm washer

Inox AISI-304
14Pilot extensionBronze + Ni-plated
15Setting screw with counter nutInox AISI-304

Flow rate/depression - diagram (measured on the office ref.9)

Pilot 263 SS

ItemNumberDescriptionMaterial

01

01

Protection cap (lockable)

PVC

02

01

Plastic label (identity card)

03

01

Nut-adj-screw

AISI 302

04

01

Setting screw

AISI 302

05

01

Cap adaptor

Brass

06

04

Cover screw

AISI 302

07

01

Pilot cover

AISI 303

08

01

Top spring guide

AISI 303

09

01

Spring

AISI 302

10

01

Diaphragm washer

AISI 304

11

01

Diaphragm

NBR nylon reinforced

12

01

Diaphragm button

AISI 303

13

01

Bottom obturator plug

AISI 303

14

01

O'ring

NBR

15

01

Obturator - spring - button

AISI 302

16

01

Obturator (Y-poppet)

AISI 303

17

01

Body

AISI 303

Functioning (see hydraulic scheme)

The automatic control valve E2114-02 is controlled by a two ways pilot (1) operated by a diaphragm, submitted on a side by a spring and on the other side by a differential of pressure ([HP] - [LP]) obtained by a measured calibrated diaphragm (9). When the hydraulic power created by the differential of pressure balances mechanic force given to the spring regulated in function of required flow rate, the pilot starts regulating giving flow rate value.

The differential of pressure represents the difference between inlet [HP] and outlet [LP] of calibrated diaphragm. This is the quadratic function of flow rate passing through measure diaphragm (9). The pressure [HP] works directly under the membrane of flow rate control pilot (1) while reduced pressure comes into the pilot upper chamber through a sensing line and it operates on the diaphragm upper surface. In this way the pilot membrane it is submitted to differential of pressure given by calibrated diaphragm (9), contrasted by spring action working on the membrane. Pilot setting range permits to regulate the flow rate passing through the main valve (4) in the ratio of 1:2,5 if the system consents to have higher flow rates than this value.

When flow rate increases over the value regulated on the pilot (1), the membrane sets against the spring action closing partially the pilot, reducing flow rate and straining the circuit into main valve control chamber (4) that shuts controlling flow rate. Main valve closing speed (4) can be changed by control unit TUP - 93 (7) from value 1 (minimum speed) up to value 6 (maximum speed).

When flow rate decreases below regulated value on pilot (1), the membrane helps spring action that makes pilot open, increasing passing flow rate and discharging circuit pressure from main valve control chamber (4), increasing flow rate. Main valve closing speed (4) can be changed by control unit TUP - 93 from value 1 (minimum speed) up to value 6 (maximum speed).

Acting on the adjusting screw of pressure reducing pilot (11) is possible to control the downstream pressure. The pressure reducing pilot (11) controls downstream pressure and avoids that downstream pressure value exceeds the one regulated by the adjusting screw.

When downstream pressure increases, due to the lower flow, the pilot (11) makes main valve (4) toward closed position. In the opposite case the pilot (11) makes main valve (4) opening. In this way it is insured the regulated pressure value.

Recommended flow rate range

Differential pressure to be done or available headloss
≤ 2 bars≥ 2 bars

> 1 bar

Fluid velocity in the inlet section valve
2,3 m/s3,4 m/s4,3 m/s
Flow Q miniFlow Q maxi
DNAdvisableMax. cont.
mmm³ / hm³ / hm³ / hm³ / hm³ / h
501,253,85152529
651,253,85284050
801,253,85436179
1001,905,856597122
1253,009,20101151191
1503,009,20148216274
2005,8518,00259385486
2509,2028,25407601760
30013,5041,505838641094
35013,5041,5079611771487
40019,0058,50104015371944
50026,5081,50162424013038
60036,00110,50234034604374
70060,00190,00318647105957

Operational limits

Cavitation diagram: it's the admissible differential pressure normally used in the regulating valve

P1 = Maximum inlet pressure of the valve

P2 = Minimum outlet pressure before danger of cavitation occurs

Green area: no danger of cavitation (and therefore no significant wear on the valve)

Red area: notable danger of cavitation (with accelerate wear and damage of the valve)

Installation

Packing and storage

The valves are packed in special cardboard boxes. Outside the carton are clearly pointed out:

  • The arrow indicating the position of the valve
  • The name of the customer
  • The code of the valve
  • The number of order confirmation

The valve is protected by two hardening foam cushions, carefully coated by a thermal plate.

This kind of packing if properly stored avoids all the damages originated from transport, unloading, and handling before installation. Avoid storing it under the rain for more than 24 hours!

Open the upper side of the carton and remove the upper cushion. Do not lift the valve by utilizing the pilot, the pilot circuit, or the position indicator.

For any kind of handling we recommend to utilize proper eyebolts.

Installation

The mounting scheme of an automatic control valve must follow the indications. The choice of the proper "by-pass" alternative must be taken considering the following points:

  • a- Could alimentation line be put out of service for several hours (corresponding to the time requested for valve maintenance) without creating pipeline utilization problems? In particular must be considered that putting back in service an empty pipeline needs several days before air total and perfect evacuation.
  • b- Could the downstream plant part be exposed to overpressures in case of sudden reductions of consumption at lower values than the one limited by the valve ?

With the purpose to obtain a perfect working of control valve, the prescribed flow rate must be contained within the setting range of pilot IS14 (1). Setting range it is usually included between a minimum value corresponding to a flow speed of 1 m/s and a maximum value of 2.5 m/s (flow speed measured on flow rate control valve inlet section). If flow rate it is out of this range, measure diaphragm (9) must be replaced!!

Should installation require the main valve stem to be horizontal (cover pointed sideways), manufacturer should be consulted concerning valves of DN200 mm and larger.

Note: All sizes on request are available with an additional venting cover device ( venting cock installed at the top of the cover ) to permit a simple escaping of air during the first commissioning.

  • Before control valve assembly, make sure that pipeline it is free from foreign matters or any other obstacle. (note: pipeline must be cleaned, possibly, before assembly. For an ideal pipeline cleaning we suggest a 1.5 m/sec speed during several hours!).
  • In presence of foreign matters into the fluid it is indispensable to adopt a strainer on valve upstream side.
  • Keep free around the valve space enough for operations as maintenance and calibration.
  • Set up the valve according to main valve cast arrow indicating flow sense.
  • Install the valve so that the FLOW ARROW marked on the valve body matches flow through the line: UPSTREAM → DOWNSTREAM
  • Regulate control unit TUP - 93 (Q5 14 02 06, ref. 3) as follows: a- Valve reaction speed [RS] is normally realized in factory during assembling and testing. Reaction speed adjusting screw must be positioned on value 2,5; b- Opening speed adjusting [OS]: 2; c) Closing speed adjusting [CS]: 4. c- b) and c) values must be verified and eventually modified on plant with the purpose to optimize valve working.
  • Close main valve (4) upstream and downstream side isolating valves.
  • Open isolating ball valve (3) of valve control circuit excepted the ones, (3E) and (3F), utilized as pressure drive; non cocks opening can create troubles to the valve.

For a correct start-up of the valve it is indispensable to have on plant a flow rate meter adjusting needed flow rate. If not available it is possible to replace it by a differential manometer linked as follows:

  • Manometer upstream side [HP] on pilot (1) cock (3F);
  • Manometer downstream side [LP] on cock (3E) of the flange containing measure diaphragm (9).

THE START-UP OF AN AUTOMATIC VALVE REQUIRES THAT PROPER PROCEDURES BE FOLLOWED. TIME MUST ALLOW AFTER EACH SETTING, FOR THE VALVE TO REACT TO ADJUSTEMENT AND THE SYSTEM STABILIZE. THE PURPOSE IS TO BRING THE VALVE INTO SERVICE IN A CONTROLLED MANNER.

Initial set up

Open isolating cocks 3 A-B-D and maintain closed the 3C, of control circuit

Rate of flow pilot (1): remove pilot valve protection unscrewing it, turn counter clockwise (OUT) adjusting screw up to be completely screwed out (on feeling mechanic resistance do not force movement in a view to avoid screw lock pin damages). This operation is the simulation of minimum value setting. It must rescind from this value to reach the needed one. Pressure reducer pilot (11): On pressure reducing pilot (11), loose lock nut and turn the setting screw counter clockwise (OUT), until the screw is practically unloaded. This is the simulation of the lowest setting value of the range, from which the commissioner has to gradually increase the pressure, up to the prescribed one. Check TUP - 93 (7) as above described. Open slowly (one or two turns) upstream isolating valve allowing controlled filling of the main valve (4) that starts closing. Venting air inside the valve by venting valve placed above the position indicator (5). Open completely upstream isolating valve. Check downstream pressure gauge. If the main chamber with air wasn't able to close very fast, the downstream pressure could be the same that inlet. Take out the downstream pressure (through the manometer gauge holder ball valve until to reach the 0 value. Turn the reducing control adjusting screw (11) CLOCKWISE (IN) to increase the pressure at the prescribed value. Slowly 180° degree for time and wait the pressure stabilized on the new value step by step. Open completely the upstream isolating valve and open downstream isolating valve (one or two turns) in a view to permit valve downstream side part filling and consequent pilot valve (1) air release. At the beginning of this operation main valve (4) is closed; it will appear a small flow rate through pilot circuit. Screw clockwise pilot (1) adjusting screw up to when main valve (4) starts opening and puts in pressure pipeline downstream part. To reach needed flow rate keep on turning adjusting screw of pilot (1) clockwise half turn each time with pauses of 30 seconds after each adjusting up to reach the needed flow rate. After each variation check reached value by flow rate meter or by differential manometer. If the downstream pipeline results empty, we recommend to execute adjusting slowly and gradually so to avoid overpressures caused by air presence into the pipeline. Air must be ejected by drain devices positioned either on control valve downstream side or along the main pipeline. After adjusting, wait system stabilization and then open completely isolating valve on downstream side. Adjusting of control unit TUP - 93: Adjusting of opening speed determines a reduction of flow rate in exit from main valve control chamber (4). If flow rate restoring it is too slow (regulator pre-adjusting value = 3), when there is a raising demand on downstream side, let increase adjusting value up to 4 and so on up to reaching sufficient value. In case of restoring too speed let decrease adjusting value of 1 as maximum. Adjusting of closing speed determines a reduction of incoming flow rate on main valve control chamber (4). If closing speed it is so high to cause overpressures on upstream side, pre-adjusting value = 3 it must be weakened so to attenuate this fact.

(*) During flow rate adjusting of a base valve calibrated diaphragm (9) drop pressure with minimum flow rate (1 m/s) corresponds to 1,6mHW. So to minimum and maximum flow rate correspond respectively a minimum speed (v1) and a maximum one (v2). The drop pressure measured on the differential manometer permit to calculate the flow rate as follow:

Q = ∆p 1,6 D².π 4 3600

with Q= flow rate [m3/h], ∆p = drop pressure [mWh], D = nominal diameter valve [m]

Maintenance

Recommended spare parts:

  • Full set of gaskets for E2001
  • Full set of gaskets for IS14
  • Full set of gaskets for 263AP in nickel plated brass or 263 SS in stainless steel (specify which model is concerned).

The quality of the material used in the manufacture of our valves should produce no wear of the internal components.

However we are recommending:

After 6 months of service :

  • Control and clean eventually the TUP - 93 screen Note: an obstructed screen due progressively the valve out of order.

After 12/18 months of service :

  • Control and clean the TUP - 93screen.
  • Take the main valve apart, by removing first the complete pilot circuit.
  • Unscrew the stud nuts and remove the cover and internal diaphragm assembly.
  • Check for any eventual damage of the QUAD-RING and the diaphragm.
  • Clean thoroughly the internal part of the valve, grease slightly the stem at both guided locations (water grease, non-toxic!!).
  • Assemble the main valve and the pilot circuit.
  • Put the valve back into service.

This control should then allow to determine the cycle of the requested maintenance, since it is taking into consideration the true service conditions of the valve.

For any further information contact our Customer Service, indicating all data as per plastic label on main valve body. Give full detailed information's about working conditions, the type of problem, and report the adjusting values (OS-CS-RS).