Cashco 1049 User Manual

INSTALLATION, OPERATION AND MAINTENANCE MANUAL (IOM)

Model 1049

Secure-Gard Pilot Operated Vent Valve

IOM - 1049

07-05

SECTION I

WARNING

I. DESCRIPTION AND SCOPE

The Model 1049 Secure-Gard is a pilot operated vent
valve intended for installation on atmospheric and low
pressure storage tanks, vapor recovery systems, and
process systems.

The Model 1049 is a low pressure pilot operated valve.
In as such, does not supply vacuum relief. If vacuum
relief is required, it should be provided by a separate
device.

CAUTION

Follow your company’s safety procedures to avoid in­jury to personnel or damage to equipment.

SECTION II

II. PRIOR TO INSTALLATION

Remove all packing material inside and outside of the valve prior to installation.

SAFETY WARNING: In addition to your company’s safety procedures, this section includes guidelines that should

be followed during the installation, operation, and maintenance of Valve Concepts, Inc’s Pilot Operated Vent Valve.

It is necessary to completely read and understand these guidelines.

Tank or system over pressure protection is the primary function of pilot operated vent valves. It must be selected to
meet the total pressure ow requirements within the Maximum Allowable Working Pressure of the system on which
it is installed. Consult API Standard 2000 for tank protection sizing procedures. Improperly specied vent valves

may result in structural damage to the tank or system, and may cause severe personal injury or death.

Valves are pre-set at the factory per customer purchase specications. DO NOT change the set pressure without
consulting the factory or your local VCI representative. Improper adjustment may cause teh valve to malfunction.

DO NOT attempt to remove the valve from the tank or process vessel without rst bleeding all pressure from the
system. ALTERNATIVE MEANS OF PRESSURE VENTING MUST BE PROVIDED WHEN THE VALVE IS OUT
OF SERVICE.

The valve has been exposed to process while in service. Observe all plant procedures and Material Safety Data

Sheets (MSDS) for the products in the system while inspecting, adjusting, or servicing the valve. Take approriate
safety precautions regarding eye protection, respiration and skin contact.

SECTION III

III. INSTALLATION

The inlet and outlet anges are normally standard ANSI 150 lbs. class anges unless otherwise indicated and
should be connected following accepted piping practices.

The inlet is vertical and the outlet is horizontal. The

valve should be installed in the normal upright position

with the cap at the top of the valve and the valve inlet at

the bottom. The outlet is to the side.
For valves using the remote sensing port connection,
sense lines should be a 1/2” O.D. tube or larger and the
length should not exceed fteen feet. Longer lengths
may be used with larger diameter sense lines. The

sense line should slope downward from the sense port

to the tank to allow condensate, if any, to drain back
into the tank and not block the sensing capability.

rotameter. (Standard rotameter supplied by Valve Con-

cepts is rated to 250 psig.) Once the gas source is con-

nected, the purge ow can be adjusted by turning the
knob at the top of the rotameter and observing the ow

indicator. The purge mechanism is designed not to af­fect the set pressure of the vent valve.

When the tank pressure is below set pressure, the main
valve seat will be closed. If the rotameter is mounted
to purge both the pilot sense and discharge lines, there
will be a very small ow to the valve outlet from the

purge mechanism.

VALVES WITH PURGE ROTAMETER

VALVE WITH AIR OR N2 ASSIST:
For valves with a rotameter mounted for purging either
the pilot sense line only or both pilot sense and dis-

charge lines, connect the purge gas source, usually dry

nitrogen, to the 1/4” FNPT connection at the bottom of

the rotameter. The pressure of the purge gas source

must be higher than the set pressure of the vent valve,
but not to exceed the maximum pressure rating of the

For valves with air or nitrogen assist pilot, connect the

gas source to the 1/4” FNPT connection at the inlet of

the lter regulator. The pressure must be a minimum of

5 psig, but not to exceed the maximum pressure rating

of the lter regulator. (The standard lter regulator sup-

plied by Valve Concepts is rated at 300 psig.)

INSTALLATION DIAGRAMS FOR STANDARD ACCESSORIES & CONFIGURATIONS

Standard Conguration

Internal Sensing, SS Pilot Filter Element and

Pilot Exhaust to Atmosphere

Option 1

With Pilot Exhaust Tubed to Main Valve Outlet

With Manual Blowdown Valve

Option 2

With Remote Sensing

Option 3

2 IOM-1049

INSTALLATION DIAGRAMS FOR STANDARD ACCESSORIES & CONFIGURATIONS

Option 4

With Back Flow Preventer to Prevent Back Flow

through Main Valve and Pilot

Option 5

With Field Test Connection

(Back Flow Preventer Included)

Option 7

With Rotameter to Purge Pilot Sense

and Discharge Lines

Option 8

With Field Test Connection, Back Flow Preventer and

Rotameter to Purge Pilot Sense and Discharge Lines

Option 6

With Rotameter to Purge Pilot Sense

Option A

Internal Sensing, SS Pilot Filter Element, Pilot Exhaust

to Main Valve Outlet with Manual Blowdown Valve

3IOM-1049

IV. START-UP

SECTION IV

Operation of the Model 1049 is automatic once the set

pressure has been set. (The set pressure is bench-set
per the customer’s specied setting at the factory prior

to shipment.) NOTE: The set pressure is dened as
the pressure at which the valve should start to open on
increasing tank pressure.

To adjust the set pressure, remove the hex cap at the

top of the valve and loosen the jam nut around the
adjusting screw. Clockwise rotation of the adjusting
screw will increase the set pressure. Counter clockwise
rotation will decrease the set pressure. Do not adjust

the set pressure beyond the nameplate range. Tighten

the jam nut after adjustments are made and replace

SECTION V

V. MAINTENANCE

It is strongly recommended that if the valve needs to

be serviced, that it be sent to the factory or a factory

authorized repair facility. Trained mechanics with

specialized test equipment will ensure that the valve is

accurately set.

The Model 1049 should be periodically checked to
ensure proper operation. The frequency required

depends on the severity of the service conditions. At
least once a year is recommended.

To disassemble the valve, refer to the appropriate

drawings.

To replace soft goods of the pilot valve:

The pilot valve body maybe removed by unscrewing
the item 131 nipple from the item 201 upper case

weldment.

To disassemble the diaphragm case, relax the
compressed spring by rst unscrewing the item 105 cap,
then loosen the item 114 jam nut and back off the item
113 adjusting screw. The ring of item 109 nuts, item
110 lockwashers, item 121 washer, and item 120 bolts
around the periphery can now be removed. Remove
item 120 bolts and item 110 lockwashers, holding
items 104 spring bonnet and 102 upper diaphragm

case together. Replace item 122 round gasket and

reassemble items 102, 104, 110 and 120.

Remove item 115 set pressure spring, 112 spring button,
and 134 ring gasket and set to the side. Hold the item

the hex cap.

For the valve to be in the closed position, tank pressure

must reach the actuator though the pilot.

Upon initial start-up, the vave may be opened for a

few seconds, but will close when the pressure in the

actuator chamber reaches tank pressure.

For valves with air or nitogen assist pilot, the gas source

must be connected to the lter regulator before the

valve will be in the closed position. (The lter regulator

is pre-set at the factory to 5 psig, and the CA-1 back

pressure regulator is pre-set at the factory to 10 psig.)

128 wrenching washers with a wrench, and loosen and

remove item 109 nut. Remove items 110 lockwasher,

111 lower spring guide washers, 128 wrenching

washers, 106 support plates, 107 diaphragm, 126 bolt

gaskets, and 127 spacer and set to the side. Remove

item 110 lock washer and item 120 bolt from item 101

pilot body and 103 lower diaphragm case. Remove

items 124 seal diaphragm, item 125 body gasket and

108 spindle assembly. Take items 133 o-ring seat and

item 126 bolt gasket off item 108 spindle assembly and

replace with new parts.

Reinstall item 108 spindle assembly with items 133

o-ring and 126 bolt gasket. Set new item 124 seal

diaphragm over the stem of the spindle assembly and

item 125 body gasket on top of the item 124. Then,

reinstall the item 103 lower diaphragm case to the

item 101 pilot body with item 110 lock washer and item

120 bolt. Slide item 127 spacer over the stem of the

spindle assembly and place another new item 126

bold gasket on top of the spacer. Place the rst item

106 support plate on the stem, then the new item 107

diaphragm, then item 126 bolt gasket , then the nal

item 106 support plate. Place the items 128 wrenching

washers, 111 lower spring guide washers, and 110

lockwasher on the stem. While holding the item 128

wrenching washers with a wrench, (and making sure

the bolt holes of the diaphragm and diaphragm case

align) thread the item 109 nut and tighten. Place items

115 set pressure spring and item 112 spring button on

item 108 spindle assembly. Place new item 134 ring

gasket on top of the item 107 diaphragm. Place the

item 102 upper diaphragm case on top of item 103

4 IOM-1049

lower diaphragm case. Instal items 121 washers, 120

To replace soft goods of the main valve:

bolts, 110 lockwashers, and 109 nuts and tighten.

Remove the item 311 bolts and 310 lockwashers
Remove item 131 nipple from item 101 pilot body.
Loosen item 114 jam nut. With needle nose pliers
remove item 119 c-ring and unthread item 117 blowdown
needle. Remove item 118 TFE o-ring. Place new
item 118 TFE o-ring on item 117 blowdown needle.

Reinstall in reverse order.

holding the item 202 cover/lower case weldment to

the main body. Carefully remove the item 202 lower

case weldment and item 307 cover gasket. Remove

item 303 seat plate assembly and item 305 o-ring seat.

Remove items 308 bolts and 309 lockwashers holding

item 304 nozzle to item 301 body. Remove item 304

nozzle. Replace item 306 nozzle gasket. Reinstall
Thread the item 117 blowdown needle completely in,
then back out 3 full turns, and lock the item 114 jam

nut.

To replace soft goods of the main valve actuator:

item 305 o-ring seat into item 304 nozzle. Be sure the

o-ring is completely in the nozzle, and that the exposed

surface is at. Bolt item 304 nozzle back into item 301

body with items 308 bolts and 309 lockwashers and

tighten. Install item 303 seat plate assembly. Install
Remove the items 208 washers, 205 bolts, 206
lockwashers, and 207 nuts. Lift pilot assembly off and
set to the side. Replace item 203 actuator diaphragm.

new item 307 cover gasket and reinstall item 202

cover/lower case weldment with the item 310 bolts and

item 311 lockwashers.
Reassemble in reverse order.

TABLE 1

Soft Goods Kit Part Numbers

Soft goods kits, consisting of all the non-metallic components (o-rings, sense diaphragm, gaskets, etc) are available.
The drawings indicate which components are included in the kit. For other replacement parts, specify by item
number and description plus material, if the part number is not known.

Always provide the model number, size if applicable, and the serial number when ordering kits/replacement parts.

Soft Good Kit Numbers

Line Size Spring Range

4” - 1.5 psig 31452033 31452055 31452044

2” x 3”

3” x 4”

4” x 6”

6” x 8”

8” x 10”

10” x 12”

12” x 16”

1.5 - 3 psig 31452933 31452955 31452944

3.2 -14 psig 31452133 31452155 31452144

4” - 1.5 psig 31453033 31453055 31453044

1.5 - 3 psig 31453933 31453955 31453944

3.2 -14 psig 31453133 31453155 31453144

4” - 1.5 psig 31454033 31454055 31454044

1.5 - 3 psig 31454933 31454955 31454944

3.2 -14 psig 31454133 31454155 31454144

4” - 1.5 psig 31456033 31456055 31456044

1.5 - 3 psig 31456933 31456955 31456944

3.2 -14 psig 31456133 31456155 31456144

4” - 1.5 psig 31458033 31458055 31458044

1.5 - 3 psig 31458933 31458955 31458944

3.2 -14 psig 31458133 31458155 31458144

4” - 1.5 psig 31451033 31451055 31451044

1.5 - 3 psig 31451933 31451955 31451944

3.2 -14 psig 31451133 31451155 31451144

4” - 1.5 psig 31459033 31459055 31459044

1.5 - 3 psig 31459933 31459955 31459944

3.2 -14 psig 31459133 31459155 31459144

Buna-N EPDM Viton

O-RING MATERIAL

5IOM-1049

SECTION VI

VII. TROUBLE SHOOTING GUIDE

1. Model 1049 opens below set point.

Possible Cause Remedy

A. Sense line is clogged. A1. Check sense line and sense port for blockage. Clean as

needed

B. Incorrect set pressure. B1. Adjust set pressure screw to proper set pressure.

C. Pilot or actuator diaphragm failure. C1. Disassemble and check diaphragms. Replace if required.

D. Loss of external air/N2 source for air/N2 assist pilot. D1. Check external source.

2. Model 1049 will not open.

Possible Cause Remedy

A. Incorrect set pressure. A1. Adjusting set pressure screw to proper set pressure.

B. Pilot exhaust plugged. B1. Check pilot exhaust for blockage. Clean as needed.

C. Sense line clogged. C1. Check sense line and sense port for blockage. Clean as

needed.

3. Vapor leaking from pilot spring bonnet.

Possible Cause Remedy

A. Pilot diaphragm failure. A1. Disassemble and check pilot diaphragm. Replace if re-

quired.

4. Seat Leakage

Possible Cause Remedy

A.

O-ring seat has failed.

B.

Foreign particles trapped between seat and seat

plate.

C.

Sense line clogged.

D.

Back pressure higher than tank pressure.

A1.

Disassemble and check o-ring seat. Replace if required.

B1.

Check and clean as needed.

C1.

Check sense line and sense port for blockage. Clean as

needed.

D1.

Vent operating properly

6 IOM-1049

Model 1049 Pilot Assembly

ITEM NO. QUANTITY PART NAME

101 1 Pilot Body

102 1 Upper Diaphragm Case

103 1 Lower Diaphragm Case

104 1 Spring Bonnet

105 1 Cap

106 2 Support Plate

107‡ 1 Diaphragm

108 1 Spindle Assembly

109 17 Nut

110 20 Lockwasher

111 2 Lower Spring Guide Washer

112 1 Spring Button

113 1 Adjusting Screw

114 2 Jam Nut

115 1 Set Pressure Spring

116 1 Bug Screen Vent

117 1 Blowdown Needle

118‡ 1 O-Ring - TFE

119 1 C-Ring

120 20 Bolt

121 16 Washer

122‡ 1 Round Gasket

124‡ 1 Seal Diaphragm

125‡ 1 Body Gasket

126‡ 3 Bolt Gasket

127 1 Spacer

128 2 Wrenching Washer

131 1 Nipple

133‡ 1 O-Ring Seat

134‡ 1 Ring Gasket

‡Parts are included in the Soft Goods Kit

7IOM-1049

Model 1049 Main Valve Body & Actuator

ITEM NO. QUANTITY PART NAME

201 1 Upper Case Weldment

202 1 Cover/Lower Case Weldment

203 ‡ 1 Actuator Diaphragm

204 1 Support Plate Weldment

205 16 Bolt

206 16 Lockwasher

207 16 Nut

208 16 Washer

301 1 Body

303 1 Seat Plate Assembly

304 1 Nozzle

305 ‡ 1 O-Ring Seat

306 ‡ 1 Nozzle Gasket

307 ‡ 1 Cover Gasket

308 6 Bolts

309 6 Lockwashers

For 2” x 3” Size Only

310 6 Bolts

311 6 Lockwashers

For 3” x 4” Size Only

310 8 Bolts

311 8 Lockwashers

For 4” x 6” Size Only

310 8 Bolts

311 8 Lockwashers

For 6” x 8” Size Only

310 8 Bolts

311 8 Lockwashers

For 8” x 10” Size Only

310 12 Bolts

311 12 Lockwashers

For 10” x 12” Size Only

310 16 Bolts

311 16 Lockwashers

For 12” x 16” Size Only

310 16 Bolts

311 16 Lockwashers

‡Parts are included in the Soft Goods Kit

Valve Concepts, Inc.
3644 Westchase Drive
Houston, TX 77042-5224
PH [phone]
Fax. # [phone]

www.valveconcepts.com

email: [e-mail]
Printed in U.S.A. Model 1049 IOM

8 IOM-1049