Ebsray RV Series Leitfaden

Publication # 1910-01

EBSRAY PUMPS

INSTALLATION, OPERATION & MAINTENANCE

INSTRUCTIONS

RV Series

Bypass Valve

Model RV26

EBSRAY PUMPS PTY. LTD

628 Pittwater Road

Brookvale NSW 2100 Australia

Ph: (61 2) 9905 0234

Fax: (61 2) 9938 3825

www.ebsraypumps.com.au

SECTION 1- GENERAL

WARNING NON-COMPLIANCE WITH REQUIREMENTS UNDER THIS HEADING COULD CREATE

CIRCUMSTANCES WHICH MAY LEAD TO PERSONAL INJURY AND/OR WHICH MAY CAUSE

DAMAGE TO THE PUMPSET AND OR ANCILLARY EQUIPMENT

CAUTION

ITEMS UNDER THIS HEADING DRAW ATTENTION TO LEGAL AND/OR STATUTORY

REQUIREMENTS WHICH CONTROL THE INSTALLATION AND USE OF THIS TYPE OF

EQUIPMENT. NON-COMPLIANCE WITH THESE REQUIREMENTS MAY CREATE A

DANGEROUS SITUATION AND/OR RESULT IN DAMAGE TO THE PUMPSET AND

ANCILLARY EQUIPMENT.

NOTE

Items under this heading are to draw attention to assembly procedures, techniques and

methods of operation etc. which are important to ensure correct installation and operation

of equipment and which, if not followed, may result in damage, failure or poor performance

of pumpset and ancillary equipment.

Error! Bookmark not defined.

1.1 - CAUTION

INSTALLATION AND SERVICING OF THESE

VALVES SHOULD BE CARRIED OUT BY

QUALIFIED, COMPETENT PERSONNEL IN

ACCORDANCE WITH RELEVANT STATUTORY

REGULATIONS OR CODES, IN CONJUNCTION

WITH THESE INSTRUCTIONS.

1.2 - WARNING

THESE VALVES MUST BE OPERATED WITHIN

THE ORIGINAL SELECTED DESIGN

PARAMETERS OF PRESSURE, TEMPERATURE,

FLOW AND VISCOSITY. SHOULD ANY CHANGE

BE CONTEMPLATED, PLEASE CONFER WITH

EBSRAY IN ORDER TO VERIFY THE SUITABILITY

OF SUCH A CHANGE.

1.3 TRANSPORTATION AND PACKING

Standard domestic packing is suitable for shipment in

covered transports. Ports must be sealed to exclude

ingress of solids. When received on site the valve

should be stored in a dry covered area.

1.4 INSPECTION ON RECEIPT

On receipt of equipment, check all items against the

dispatch documents and inspect for damage. Any

damage or shortage incurred during transit should be

noted on the packing note and on both your own and

the carrier's copy of the consignment note and a

claim should be made immediately on the transport

company. Should a shortage be evident on receipt,

notify EBSRAY immediately giving full details and

packing note number.

1.5 STORAGE

If storage is required for other than a short period

prior to installation, special preservatives and

protective wrappings will be required.

SECTION 2- INSTALLATION

Ensure pipework is clean before installation. Bypass

Valve must only be installed in accurately aligned

pipework to ensure that pipe stresses are not

transferred to valve housing. The port which is

opposite the Adjusting Screw is the inlet port and the

other port is the outlet port.

The preferred installation orientation is with the

adjusting screw up however the valve may be

mounted in any position as required by the

installation and available space. Ensure that the

adjusting screw is accessible

WARNING

NEVER ALLOW WATER OR

ANY CORROSIVE PRODUCT TO

ENTER THE VALVE AS THIS

MAY DAMAGE THE VALVE AND

WILL VOID THE WARRANTY.

SECTION 3 - OPERATION

The EBSRAY Model RV26 BYPASS VALVE is a

spring actuated pump and system protection device

that by design cannot be positively shut-off. With the

VRS option, It also provides for controlled and rapid

'bleed-off' of vapour. This enhances the self priming

capabilities of the pump. The valve is installed in the

pump discharge system and normally returns flow to

the supply vessel.

The RV26 Valve is available in various configurations

including 'O'Ring sealed or Gasket sealed versions,

with or without the 'VRS' (Vapour Removal System)

option.

On commissioning, the bypass valve must be set in

accordance with the required/specified pump

differential pressure, ensuring that total system

pressure does not exceed regulatory codes or

requirements of equipment installed.

SECTION 4 - MAINTENANCE

PRIOR TO ANY DISASSEMBLY OR SERVICE, VERIFY THAT ALL REQUIREMENTS OF STATUTORY

REGULATIONS OR CODES ARE MET AND THAT SPECIFIC SITE REQUIREMENTS ETC ARE SATISFIED.

Apart from Housing replacement, other maintenance

tasks and inspections can be carried out with the

valve 'in line', so long as complete isolation,

depressurising and purging have been completed.

4.1 SPARE PARTS

1. When ordering spare parts, to ensure correct

replacement to original specification, always

quote valve Serial Number, which is located on

the nameplate of the valve. Please advise if

valve has been upgraded with VRS option

original supply from EBSRAY.

2. Advise the name, item number and quantity

required. Refer to Drg CMP112.

3. Advise complete delivery instructions,

transportation, etc.

4.2 PREPARATION FOR DISASSEMBLY

1. Obtain the appropriate Work Permit if required.

2. Isolate valve from liquids/vapour in suction and

discharge lines, depressurise and purge out any

toxic, flammable, corrosive or air hardening

liquid/vapour.

3. Ensure the associated pump motor power supply

has been isolated, before proceeding with the

valve disassembly.

4.3 DISASSEMBLY

1. Remove Adjusting Screw Cap (18) (Gasket

sealed version only)

2. Unlock Adjusting Screw Locknut (10).

3. Release all spring pressure by rotating Adjusting

Screw (8) anti-clockwise.

4. Remove Valve Cover (2) from Housing (1).

5. Remove components from Valve cover (2) and

Housing (1).

6. OPTIONAL VRS ONLY: If disassembly is

necessary, the Ball (12) and Spring (13) will

have to be replaced as heat is required to break

the bond between the Spring Retainer (16) and

the Valve (3).

To disassemble:

a, Screw a bolt or setscrew (M12) into Spring

Retainer (16) and lock in position with a

locknut (10).

b, Apply heat to the Valve (3) until the Spring

Retainer (16) can be unscrewed from the

Valve (3).

c, Remove the Spring Retainer (16), Spring

(13) and Ball (12) from the Valve (3).

4.4 INSPECTION

1. Inspect Housing and Valve seat for damage or

wear. If required, remove Housing and replace.

2. Check all components for for damage or

deposits, clean thoroughly, replace if broken or

damaged.

3. It is advised that 'O'rings and Gaskets be

replaced at every overhaul.

4. OPTIONAL VRS ONLY:

Check condition of Ball (12), Spring (13) and

Spring Retainer (16). Replace as required.

4.5 REASSEMBLY

(Refer drawing No CMP112).

NOTE: Lightly smear all 'O' rings with a

compatible good quality lubricant before

assembly.

1. OPTIONAL VRS ONLY:

NOTE: To facilitate assembly, screw a bolt or

setscrew (M12) into Spring Retainer and lock in

position with a locknut.

a. Insert Ball (12) into Valve (3).

b, Position Spring (13) on Ball (12).

c, Apply loctite 620 (High temperature

retaining compound) or equivalent to Spring

Retainer thread.

d, Carefully screw in Spring Retainer (16)

ensuring that Spring (13) enters the bore of

the Spring Retainer (16).

e, Loosen locknut (10) and unscrew bolt or

setscrew from Valve assembly.

2. Fit Locknut (10) to Adjusting Screw (8) and

partially screw Adjusting Screw (8) into Valve

Cover (2). For Gasket sealed versions, screw

Adjusting Screw (8) in to Valve Cover(2) far

enough to allow engagement with Spring Cap 4)

during assembly.

3. Fit Valve (3) into Housing (1), ensuring freedom

of movement.

4. Fit Spring (5) on to top of Valve (3).

5. Fit 'O'Ring (7) or Gasket (17) to Valve Cover (2).

6. 'O'RING SEALED VERSIONS ONLY: Fit

'O'Ring (6) to Spring Cap (4) and fit Spring Cap

(4) onto Valve Cover (2).

7. GASKET SEALED VERSIONS ONLY:

Place Spring Cap (4) on Spring(5).

8. With a new 'O'ring or gasket in place, fit Valve

Cover (2).

4.6 SETTING

NOTE: Final pressure setting is carried out after

the valve is installed or reassembled 'in line'.

Refer to Section 6 for notes on Bypass Valve

setting and operation.

1. For increased bypass pressure, rotate Adjusting

Screw (8) in clockwise direction (i.e. screw in).

DO NOT exceed system design pressure.

2. For decreased bypass pressure, rotate Adjusting

Screw (8) anti-clockwise (i.e. screw out).

3. Lock Adjusting Screw Locknut (10) against

Housing immediately after any adjustment is

made.

4. For Gasket sealed versions, replace Adjusting

Screw Cap with a new Gasket after setting is

completed.

SECTION 5 - PARTS DESIGNATION

Cat # Description Qty Cat # Description Qty

1 Housing 1 9 Setscrew 8

2 Valve Cover 1 10 Locknut 1

3 Valve 1 12* Ball 1

4 Spring Cap 1 13* Spring - Vent 1

5 Spring 1 16* Spring Retainer 1

6* 'O'Ring 1 17* Gasket 1

7* 'O'Ring 1 18 Adjusting Screw Cap 1

8 Adjusting Screw 1 19* Gasket 1

* Items marked with asterisk are not common to all builds of RV26 valves.

Please ensure that parts are identified correctly before ordering.

SECTION 6 - NOTES ON SETTING AND OPERATION

WARNING SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT MAY OCCUR IF

SYSTEM OR COMPONENT DESIGN PRESSURE IS EXCEEDED. SHOULD THERE BE ANY

DOUBT AS TO THE PRESSURES LIKELY TO BE GENERATED IN THE SYSTEM WITH AN

INOPERATIVE OR INCORRECTLY SET BYPASS VALVE, PLEASE CONTACT EBSRAY FOR

MORE INFORMATION.

NOTE In order to set the bypass valve, a throttling valve must be located in the discharge line

downstream of the bypass valve. A pressure gauge must be installed in the discharge line

between the pump and the throttling valve.

6.1 ADJUSTMENT PROCEDURE

1. First open the throttling valve and any other

valves in the discharge line in order to minimise

the discharge pressure as much as possible.

Failure to do this could cause excessive and /or

dangerous pressures to be generated.

2. Before starting the pump, loosen the locknut on

the bypass valve adjusting screw and screw the

adjusting screw fully in (clockwise). This

increases the tension on the spring and is the

maximum pressure setting for the particular

spring as fitted. [A number of springs are

available to give different pressure ranges]

3. Start the pump and slowly close the throttling

valve (ensuring pump/system maximum

operating pressure is not exceeded) until the

pressure gauge shows expected bypass valve

cracking pressure. (Also called 'set pressure')

Now turn the adjusting screw out (anticlockwise)

until the gauge registers a slight drop in

pressure. At this point the bypass valve has

begun to open ie. cracking. Screw in the

adjusting screw one turn (clockwise) and then

tighten the locknut. The Bypass Valve is now set

6.2 VERIFICATION OF ADJUSTMENT

Re-open the throttling valve. Stop pump then

restart pump. Observe the pressure gauge whilst

again slowly and cautiously closing the throttling

valve. The gauge should register a levelling off

(or reduction) in the characteristic pressure rise

once the bypass valve cracking pressure has

been reached.

6.3 IMPORTANT NOTES

1. The Bypass Valve is only one item controlling

pressure-rise in the bypass system. Other

valves, fittings and pipework downstream of the

bypass valve also cause system resistance, this

may affect maximum system pressure.

2. Bypass valves only control differential pressure -

not total system pressure.

Typical Bypass Valve Characteristics

1 Cracking pressure (set pressure) (Where valve

starts to bypass)

2 Maximum pressure (At the rated operating

parameters)

3 Full flow pressure (bypass) (At the rated

operating parameters)

NOTE: Any pressure rise (or fall) after the cracking

point may depend upon:

a. Flow rate through the bypass valve.

(Excessive pressure rise may signify

restrictions in pipework, fittings etc.)

b. Viscosity of product at pumping temperature.

c. Specific bypass valve design and size.

The graph represents three typical bypass valve

characteristics. Actual performance during operation

will depend on bypass valve design, system design

and may also be affected by the parameters (a. b. &

c.) as listed above.

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