INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-C-BPV
12-13
MODEL C-BPV
BACK PRESSURE / RELIEF REG U LA TOR
SECTION l
I. DESCRIPTION AND SCOPE
Model C-BPV is a self-contained back pressure / relief regulator utilized in sanitary biotechnological process piping
systems and is used to control upstream (inlet or P
This angle style regulator is only suit able for liquids and gases at temperatures less than 300°F (149°C). Refer to
Technical Bulletin C-BPV-TB for specifi c design con di tions.
This is not a safety device and must not be substituted for a code approved pressure safety relief valve or a rupture disc.
) pressure. Inlet and outlet sizes are 3/4", 1", 1-1/2", 2" and 3".
1
CAUTION
CAUTION
SECTION II
II. INSTALLATION
A. General:
1. A diaphragm valve should be installed up stream of the regulator.
2. An inlet pressure gauge should be located
ap prox i mate ly ten pipe diameters upstream
and within sight.
3. All installations should include an upstream
relief device if the inlet pressure could exceed
the pressure rating of any equip ment or the
maximum inlet pressure rating of the unit.
4. Flow Direction: Install so fl ow enters through
the side connection and exits the bottom connection.
5. Install with spring chamber (2) in the vertical
up po si tion to allow for proper draining.
CAUTION
Installation of adequate overpressure pro tec tion is recommended to pro tect the reg u la tor from overpressure and
all down stream equip ment from damage in the event of
regulator failure.
SECTION III
III. PRINCIPLE OF OPERATION
A. General:
1. Movement occurs as pressure variations reg is ter on the diaphragm. The registering pres sure is the inlet, P
range spring opposes diaphragm movement.
or upstream pressure. The
1
As the inlet pressure drops, the range spring
pushes the diaphragm down, closing the port;
as inlet pressure increases, the diaphragm
pushes up and the port opens.
2. A complete diaphragm failure may cause the
regulator to fail close, and process fl uid will
discharge from the spring chamber vent hole.
SECTION IV
IV. START-UP
A. General:
1. Ensure that lock-open pin (10) and quick
release pin (15) are in proper position. See
Section VII.
2. Confi rm that the proper range spring is in di -
cat ed to be within the regulator by inspection
of the unit’s nameplate. Apply setpoint pres sures that are only within the stated range.
3. When stating direction of rotation of the
ad just ing screw, the view is with respect to
looking down towards the spring chamber or
its normal location.
B. For systems utilizing an upstream block
valve:
1. Start with the block valve closed. A bypass
valve may be used to maintain inlet pressure
in the upstream system without chang ing the
fol low ing steps.
2a. For range springs 2 - 75 psig - Relax range
spring (7) by turning adjustment nut (6) or
handle (36) counter-clockwise (CCW) until
rotation stops. Rotate adjustment nut (6)
clockwise (CW) three (3) full revolutions to
maintain spring (7) to di a phragm-plug assembly (14) contact. This reduces the inlet
(upstream) pressure set point.
5. If the inlet (upstream) pressure exceeds the
desired setpoint pressure, rotate the adjustment nut (6) or han dle (36) CCW until the
pressure decreases.
6. When fl ow is established steady enough that
the block valve is fully open, begin to slowly
close the bypass valve, if installed.
7. Develop system fl ow to a level near its ex-
pect ed normal rate and reset the regulator
setpoint by turning the adjustment nut (6) or
handle (36) CW to increase inlet pressure or
CCW to reduce inlet pressure.
8. Reduce system fl ow to a minimum level and
ob serve setpoint. Inlet pressure will rise from
the setpoint of Step 6. (Ensure that this rise
does not exceed the stated upper limit of
the range spring by greater than 30%, i.e.
20-60 psig (1.38-4.14 Barg) range spring, at
max i mum fl ow the inlet pressure should not
ex ceed 1.3 x 60 psig (4.14 Barg) or 78 psig
(5.4 Barg). If it does, consult the factory.)
9. Increase fl ow to maximum level, if possible.
Inlet (upstream) pressure should fall off. Re ad just setpoint as necessary at the normal
fl ow rate.
C. For systems not utilizing an upstream block
valve:
2b. For range spring 60 - 125 psig - Relax range
spring (7) by turning handle (36) counterclockwise (CCW) until rotation stops. Rotate
handle (36) clockwise (CW) three (3) full revolutions to maintain spring (7) to di a phragm-plug
assembly (14) contact. This reduces the inlet
(upstream) pressure set point.
3. Slowly open the block valve until fully open.
4. Observing the inlet (upstream) pressure
gauge, rotate the adjustment nut (6) or handle
(36) clockwise (CW) slowly until the inlet
pressure begins to rise. Rotate CW until the
desired setpoint is reached.
V. SHUTDOWN
1. On systems with a bypass valve, and where system pressure is to be maintained as the reg u la tor
is shutdown, slowly open the bypass valve while
closing the inlet (up stream) block valve. Fully
close the inlet (upstream) block valve. (When on
bypass, the system pressure must be con stant ly
observed and manually reg u lat ed.)
1. Refer to instructions B. 2a and 2b previous.
2. Closely monitor inlet (upstream) pressure,
via gauge, to ensure not over-pressurizing as
system fl ow is established. Rotate adjustment
nut (6) or handle (36) CW slowly until the inlet
pressure begins to rise to desired setpoint.
Slowly close the bypass valve, if installed.
3. If the inlet pressure exceeds the desired
set point pressure, rotate the adjustment nut
(6) or handle (36) CCW until the pres sure
decreases.
4. Follow instructions in “B”, Steps 7 thru 9.
SECTION V
CAUTION
Do not walk away and leave a bypassed regulator unattended.
2. If the regulator and system are both to be shut down, slowly close the inlet (up stream) block
valve.
IOM-C-BPV2
AUTION
VI. MAINTENANCE
WARNING
SECTION VI
2. Ensure that the lever (16) is in standard
horizontal position. Relax range spring (7)
by turning adjustment nut (6) or han dle (36)
CCW until rotation stops.
SYSTEM UNDER PRESSURE. Prior to performing any
maintenance, isolate the regulator from the system and
relieve all pressure. Failure to do so could result in personal injury.
A. General:
1. Unit’s lock-open feature allows this regulator
to be cleaned in-line; see Section VII.
2. Maintenance procedures hereinafter are
based upon removal of regulator unit from
the pipeline where installed.
3. Owner should refer to owner’s procedures
for re mov al, handling and disposal of nonreusable parts.
4. After dis-assembly, inspect, replace and clean
parts in accordance to owner's specifi cations.
CAUTION
Owner’s cleaning solution must be compatible with regulator’s trim materials.
NOTE: For those fl uids which could create a
potential hazard to personnel working on this unit,
owner must provide an OSHA approved MSDS
(Material Safety Data Sheet), and a signed state ment at test ing to the fact that the unit has been
fl ushed out, for a specifi c period of time, using an
OSHA acceptable neu tral iz ing agent. The name
of the agent, man u fac tur er’s name and total con cen tra tion level must also be included for both the
ser vice medium as well as the neutralizing agent.
Returns WILL NOT BE AC CEPT ED by Cash co,
Inc. without an MSDS form at tached to the outside
of ship ping carton.
4. Refer to Figures 3 and 4 for item numbers ().
B. Trim Replacement:
1. Securely install the body (1) in a vise with the
spring chamber (2) directed upwards. Ensure
that the body (1) is not held in the vise by the
edge of the end connection fl ange.
WARNING
SPRING UNDER COMPRESSION. Prior to re mov ing the clamp (13), relieve spring com pres sion by
rotating the adjustment nut (6) or handle (36) CCW
when viewed from above. Fail ure to do so may result in fl ying parts that could cause personal injury.
IOM-C-BPV
3a. For range springs 2 - 75 psig - pull ring on
pin (15) to remove pin, lever (16), nut (6) or
handle (36) and collar (19).
3b. For range spring 60 - 125 psig - pull ring on
pin (15) to remove pin, cam (16), slide base
(24) assembly, bearing plate (29) and collar
assembly (28).
a. Use a small round punch to tap and remove
spring pin (32). Note the location of the eye
nut (27). Count the number of revolutions
(CCW) to remove eye nut (27) from top of
guide post assembly (22). Record the count
here.
No. of Revolutions to
remove eye nut.
4. Loosen clamp (13) and remove.
a. For Opt. -80 2-piece clamp design See
Fig 1: Loosen and remove clamp nuts (13B),
washers (13D), bolts (13C) and clamps (13A).
5. Lift spring chamber (2) up off body (1) and set
aside. Remove bearing seal (23). Lift up to
remove adjusting screw assembly (5), spring
button (4) and spring (7) off guide post (22).
6. Grasp cap (5.1) of adjusting screw assembly
with hand and lift up to separate and remove
cap (5.1) and two u-cup seals (5.4). Do Not
remove dowel pin (5.2).
7. Install two new u-cup seals (5.4) into the adjusting screw cap (5.1). Insert the fi rst u-cup
with the open side with the spring showing into
the hole in the cap. Ensure that the u-cup is
pressed all the way in. Look into the hole to
confi rm that the white seal material is show-
ing and not the spring material. Then press
second u-cup seal with white seal material
side in fi rst into the hole all the way in next to
the fi rst u-cup. (Spring side of u-cup should
be visible.
8. Slide adjusting screw cap (5.1) with new u-cup
seals (5.4) and adjusting screw (5.3) together,
use the dowel pin (5.2) for alignment. NOTE;
Top end of pin (5.2) should be fl ush with top
surface of adjusting screw cap (5.1). Place
new seal (23) on adjusting screw cap (5.1).
Set parts aside.
9. Grasp the guide post (22) and lift upwards to
remove diaphragm (14) and plug (18) subassembly.
______
3
10A. For Sizes 3/4"-1-1/2" w/lower spring
ranges:
Clamp the plug (18) at the fl ats on the plug in
a smooth jawed vice.
a. Place a wrench at the fl ats on the adapter
(20) and rotate CCW to remove adapter
(20), and guide post (22) from the plug
(18).
b. Remove pressure plate (3), diaphragm
(14) and diaphragm spacer (38). NOTE:
Correct orientation of spacer (38) has
the side with the I.D. radius towards the
clamping surface of the plug.
c. Install diaphragm spacer (38) on plug (18).
Place new diaphragm (14) with convolution side facing up, onto plug (18) and fi t
it around the diaphragm spacer (38).
d. Lay pressure plate (3) on top of diaphragm
(14).
e. Apply Loctite 242 or equivelant to the
threads of the adapter (20) and thread
adapter (and guide post (22))through parts
and into plug (18) and tighten to 60 in-lbs
of torque.
f. Replace plug/guide post assembly of parts
back into body (1). Align tab on diaphragm
with the tab slot cut in the body fl ange lip.
g. Place spring (7) over guide post (22) and
fi t it around adapter (20).
h. Return spring button(4) with adjusting
screw assembly (5) and bearing (23) down
over guide post (22) onto spring (7). Align
one tab (ear) on spring button (4) directly
above tab slot in the body fl ange lip.
i. Align the two ribs inside the spring cham-
ber (2) with the tabs on the spring button
(4) and place the spring chamber (2) over
assembled parts directly on body (1).
j. Position the Tri-Clamp (13) around the
mating fl anges of the body (1) and the
spring chamber (2) with the threaded
fastener aligned with the tab slot cut in the
body fl ange lip. Clamp should be tightened
to approximately 4 to 6 ft-lbs. (Apply same
torque for Opt.-80) - See Figure 1.
k. Place load collar (19) and adjustment nut
(6) or handle (36) over guide post (22).
l. Place lever (16) over guide post (22) and
insert quick release pin (15) through holes
in lever and post.
m. See Section IV for start up and adjustment
of set point and Section VII for Cleaning.
10B. For Sizes 1-1/2"- 3" w/lower spring range:
Clamp the lower end of the plug (18) in a
smooth jawed vice, around the outside edges
of the winged design.
a. Remove set screw (37) from guide post
assembly (22).
b. Rotate guide post (22) CCW and remove
from plug (18).
c. Turn adapter (20) CCW and remove
pressure plate (3), diaphragm (14) and
diaphragm spacer (38). NOTE: Correct
orientation of spacer (38) has the side
with the I.D. radius towards the clamping
surface of the plug.
d. Reinstall diaphragm spacer (38) on plug
(18). Place new diaphragm (14) with
convolution side facing up, onto plug (18)
and fi t it around the diaphragm spacer
(38).
e. Lay pressure plate (3) on top of diaphragm
(14).
f. Apply Loctite 242 or equivelant to the
threads on the plug (18) and secure
adapter (20) to plug (18). Tighten to 60
in-lbs of torque.
g. Secure guide post (22) to threaded end of
plug (18) hand tight. Adjust fi nal rotation
to ensure that the set screw (37) will lock
fi rmly against one of the surface fl ats on
the plug (18).
h. Apply Loctite 242 or equivelant to threads
of set screw (37) and thread tight into
guide post.
i. Replace plug/guide post assembly of parts
back into body (1). Align tab on diaphragm
with the tab slot cut in the body fl ange lip.
j. Place spring (7) over guide post (22) and
around adapter (20).
k. Return spring button(4) with adjusting
screw assembly (5) and bearing (23) down
over guide post (22) onto spring (7). Align
one tab (ear) on spring button (4) directly
above tab slot in the body fl ange lip.
l. Align the two ribs inside the spring cham-
ber (2) with the tabs on the spring button
(4) and place the spring chamber (2) over
assembled parts directly on body (1).
m. Position the Tri-Clamp (13) around the
mating fl anges of the body (1) and the
spring chamber (2). Align the threaded
fastener with the tab slot cut in the body
fl ange lip. The clamp should be tightened
to approximately 4 to 6 ft-lbs. (Apply same
torque for Opt.-80) - See Figure 1.
n. Place load collar (19) and adjustment nut
(6) or handle (36) over guide post (22).
o. Position lever (16) over guide post (22)
and insert quick release pin (15) through
holes in lever and post.
p. See Section IV for start up and adjustment
of set point and Section VII for Cleaning.
IOM-C-BPV4
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