Cla-Val 90-01KO User Manual

90-01KO/690-01KO

Anti-Cavitation Pressure Reducing Valve

High Pressure

Isolation Valve

Gauge

Constant Downstream Pressure

CLA-VAL 90-01BYKO

Pressure Reducing Valve

CLA-VAL 90-01ASKO

Pressure Reducing Valve

CLA-VAL Model

90-01KO

Anti-Cavitation Trim

for Excess Pressure Drop

Consult Cavitation Chart

Isolation Valve

Gauge

Constant Downstream Pressure

High Pressure

The "D" check feature on a vertically installed 6" and larger valves must be horizontally installed.

Typical Applications

Typical applications include pressure reducing valve station using Model 90-01BYKO and Model 90-01ASKO in parallel to handle wide range of flow rates. Larger Model 90-01BYKO valve meets requirements of peak loads and smaller Model 90-01ASKO handles low flows.

Schematic Diagram

Item Description

1 Hytrol (100-01KO Main Valve) 2 X58 Restriction Fitting 3 CRD Pressure Reducing Control

Optional Features

Item Description

A X46A Flow Clean Strainer B CK2 (Isolation Valve) C CV Flow Control (Closing)* D Check Valves with Isolation Valve P X141 Pressure Gauge S

CV Speed Control (Opening)

V

X101 Valve Position Indicator

Y X43 "Y" Strainer

*The closing speed control (optional) on this valve should

always be open at least three (3) turns off its seat.

• Virtually Cavitation Free Operation

•

Sensitive and Accurate Pressure Control

•

Easy Adjustment and Maintenance

•

Tamper Resistant

•

Optional Check Feature

•

Fully Supported Frictionless Diaphragm

The Cla-Val Model 90-01KO

Anti-Cavitation Hytrol

Pressure Reducing Valve automatically reduces a higher inlet pressure to a steady lower downstream pressure, regardless of changing flow rate and/or varying inlet pressure. This valve is an accurate, pilot-operated regulator capable of holding downstream pressure to a pre-determined limit. When downstream pressure exceeds the pressure setting of the control pilot, the main valve and pilot valve close drip-tight.

If a check feature is added, and a pressure reversal occurs, the downstream pressure is admitted in the main valve cover chamber, closing the valve to prevent return flow.

Cla-Val Model

90-01KO

Pressure Reducing Valve with Anti-Cavitation Trim provides for optimum downstream pressure control while reducing noise and eliminating damage associated with cavitation.

See Cavitation Guide to determine if the valve is a candidate for the KO Anti-Cavitation Trim.

90-01KO

MODEL

(Full Internal Port)

Materials

Pressure Ratings

(Recommended Maximum Pressure - psi)

Component Standard Material Combinations

Body & Cover Ductile Iron Cast Steel Bronze

100-01KO Available Sizes

1 1/4" - 36" 3" - 16" 3" - 16"

Disc Retainer & Diaphragm Washer

Cast Iron Cast Steel Bronze

Trim: Disc Guide, Seat & Cover Bearing

Bronze is Standard

Stainless Steel is Optional

Disc Buna-N

®

Rubber

Diaphragm Nylon Reinforced Buna-N®Rubber

Stem, Nut & Spring Stainless Steel

For material options not listed, consult factory. Cla-Val manufactures valves in more than 50 different alloys.

Valve Body & Cover

Pressure Class

Flanged Grooved Threaded

Grade Material

ANSI

Standards*

150

Class

300

Class

300

Class

End‡

Details

ASTM A536 Ductile Iron B16.42 250 400 400 400

ASTM A216-WCB Cast Steel B16.5 285 400 400 400

ASTM B62 Bronze B16.24 225 400 400 400

Note: * ANSI standards are for flange dimensions only.

Flanged valves are available faced but not drilled.

‡ End Details machined to ANSI B2.1 specifications.

Valves for higher pressure are available; consult factory for details

Model 100-01KO

Specifications

Operating Temp. Range

Pattern Globe Angle Grooved End

Size 1

1/4" - 36" 1 1/4" - 16" & 24" 1 1/4" - 8"

Fluids

-40°to 180°F

APPROVED

(4" - 24")

SELECTION GUIDELINE FOR KO ANTI-CAVITATION VALVES

400

350

300

200

150

100

50

0

010

20 30

40 60

50

70 80

OUTLET PRESSURE (psi)

250

INLET PRESSURE (psi)

Cavitation

Zone

90 100

Notes: On Operating Differential

1. For atmospheric discharge, the maximum inlet pressure cannot exceed 150 psi.

2. For pressure differentials greater than 300 psi, the maximum flow velocity should not exceed 18 ft/sec.

3. Flow velocities greater than 25 ft/sec are not recommended.

4. Recommended minimum flow velocity is 1 ft/sec.

5. Consult factory for conditions exceeding these recommendations.

100G-01KO ANTI-CAVITATION VALVE CURVES

100

10

1000

10000

FLOW RATE (gpm)

10

100

PRESSURE DROP (psi)

400

1

300

SOLID LINE IS FULL OPEN FLOW CURVES FOR 18 FT/SEC CONTINUOUS DUTY APPLICATIONS

DASHED LINE IS FULL OPEN FLOW CURVE FOR 25 FT/SEC INTERMITTENT DUTY APPLICATIONS

100000

3"

4"

6"

8"

10"

12"

2"

2 1/2"

1 1/2"

16"

14"

20"

36"

30"

18"

1 1/4"

24"

100-01KO (Main Valve)

Cla-Val Control Valves with KO ANTI-CAVITATION Trim operate with maximum efficiency when mounted in horizontal piping with the main valve cover Up. We recommend isolation valves be installed on inlet and outlet for maintenance. Adequate space above and around the valve for service personnel should be considered essential. A regular maintenance program should be established based on the specific application data. However, we recommend a thorough inspection be done at least once a year. Consult factory for specific recommendations.

GGGG

DDDD

Inlet

AAAA

X

100-01KO

Grooved

EE

CC

(MAX)

K

J

H

Inlet

Outlet

B

(Diameter)

G

GG

GGG

D

Inlet

DD

DDD

F

FF

X

100-01KO

Threaded &

Flanged

A

E

C

(MAX)

K

J

H

Inlet

Outlet

AA

AAA

B

(Diameter)

Note:

Consult Factory on 10",12", 16" angle pattern

Y

Z

Valve Size (Inches) 1 1/4 1 1/2 22 1/2 3468101214161820243036 A Threaded

7.25 7.25 9.38 11.00 12.50 — — — — — — — — ————

AA 150 ANSI

— 8.50 9.38 11.00 12.00 15.00 20.00 25.38 29.75 34.00 39.00 41.38 46.00 52.00 61.50 63.00 76.00

AAA 300 ANSI

— 9.00 10.00 11.62 13.25 15.62 21.00 26.38 31.12 35.50 40.50 43.50 47.64 53.62 63.24 64.50 76.00

AAAA Grooved End

— 8.50 9.00 11.00 12.50 15.00 20.00 25.38 — — — — — ————

B Dia.

5.62 5.62 6.62 8.00 9.12 11.50 15.75 20.00 23.62 28.00 32.75 35.50 41.50 45.00 53.16 56.00 66.00

C Max.

5.50 5.50 6.50 7.56 8.19 10.62 13.38 16.00 17.12 20.88 24.19 25.00 39.06 41.90 43.93 54.60 61.50

CC Max. Grooved End

— 4.75 5.75 6.88 7.25 9.31 12.12 14.62 — — — — — ————

D Threaded

3.25 3.25 4.75 5.50 6.25 — — — — — — — — ————

DD 150 ANSI

— 4.00 4.75 5.50 6.00 7.50 10.00 12.69 14.88 17.00 19.50 20.81 — — 30.75 — —

DDD 300 ANSI

— 4.25 5.00 5.88 6.38 7.88 10.50 13.25 15.56 17.75 20.25 21.62 — — 31.62 — —

DDDD Grooved End

— — 4.75 — 6.00 7.50 — — — — — — — ————

E

1.12 1.12 1.50 1.69 2.06 3.19 4.31 5.31 9.25 10.75 12.62 15.50 12.95 15.00 17.75 21.31 24.56

EE Grooved End

— 2.00 2.50 2.88 3.12 4.25 6.00 7.56 — — — — — ————

F 150 ANSI

— 2.50 3.00 3.50 3.75 4.50 5.50 6.75 8.00 9.50 10.50 11.75 15.00 16.50 19.25 22.50 25.60

FF 300 ANSI

— 3.06 3.25 3.75 4.13 5.00 6.25 7.50 8.75 10.25 11.50 12.75 15.00 16.50 19.25 24.00 25.60

G Threaded

1.88 1.88 3.25 4.00 4.50 — — — — — — — — ————

GG 150 ANSI

— 4.00 3.25 4.00 4.00 5.00 6.00 8.00 8.62 13.75 14.88 15.69 — — 22.06 — —

GGG 300 ANSI

— 4.25 3.50 4.31 4.38 5.31 6.50 8.50 9.31 14.50 15.62 16.50 — — 22.90 — —

GGGG Grooved End

— — 3.25 — 4.25 5.00 — — — — — — — ————

H NPT Body Tapping

.375 .375 .375 .50 .50 .75 .75 1111111122

J NPT Cover Center Plug

.25 .25 .50 .50 .50 .75 .75 1 1 1.25 1.5 2 1.5 1.5 1.5 2 2

K NPT Cover Tapping

.375 .375 .375 .50 .50 .75 .75 1111111122

Stem Travel

0.4

0.4 0.6 0.7 0.8 1.1 1.7 2.3 2.8 3.4 4.0 4.5 5.1 5.63 6.75 7.5 8.5

Approx. Ship Wt. Lbs.

15 15 35 50 70 140 285 500 780 1165 1600 2265 2982 3900 6200 7703 11720

X Pilot System 11 11 13 14 15 17 29 31 33 36 40 40 43 47 68 79 85 Y Pilot System 9 9 9 10 11 12 20 22 24 26 29 30 32 34 39 40 45 Z Pilot System 9 9 9 10 11 12 20 22 24 26 29 30 32 34 39 42 47

Valve Size (mm) 32 40 50 65 80 100 150 200 250 300 350 400 450 500 600 750 900 A Threaded

184184238279318————————————

AA 150 ANSI

— 216 238 279 305 381 508 645 756 864 991 1051 1168 1321 1562 1600 1930

AAA 300 ANSI

— 229 254 295 337 397 533 670 790 902 1029 1105 1210 1362 1606 1638 1930

AAAA Grooved End

—216228279318381508645—————————

B Dia.

143 143 168 203 232 292 400 508 600 711 832 902 1054 1143 1350 1422 1676

C Max.

140 140 165 192 208 270 340 406 435 530 614 635 992 1064 1116 1387 1562

CC Max. Grooved End

120120146175184236308371—————————

D Threaded

8383121140159————————————

DD 150 ANSI

— 102 121 140 152 191 254 322 378 432 495 528 — — 781 — —

DDD 300 ANSI

— 108 127 149 162 200 267 337 395 451 514 549 — — 803 — —

DDDD Grooved End

——121—152191———————————

E

29 29 38 43 52 81 110 135 235 273 321 394 329 381 451 541 624

EE Grooved End

—52647379108152192—————————

F 150 ANSI

— 64 76 89 95 114 140 171 203 241 267 298 381 419 489 572 650

FF 300 ANSI

— 78 83 95 105 127 159 191 222 260 292 324 381 419 489 610 650

G Threaded

484883102114————————————

GG 150 ANSI

— 102 83 102 102 127 152 203 219 349 378 399 — — 560 — —

GGG 300 ANSI

— 102 89 110 111 135 165 216 236 368 397 419 — — 582 — —

GGGG Grooved End

——83—108127———————————

H NPT Body Tapping

.375 .375 .375 .50 .50 .75 .75 1111111122

J NPT Cover Center Plug

.25 .25 .50 .50 .50 .75 .75 1 1 1.25 1.5 2 1.5 1.5 1.5 2 2

K NPT Cover Tapping

.375 .375 .375 .50 .50 .75 .75 1111111122

Stem Travel

10-32

10-32 10-32 10-32

1

⁄4-281⁄4-283⁄8-243⁄8-243⁄8-243⁄8-243⁄8-241⁄2-203⁄4-163⁄4-163⁄4-163⁄4-163⁄4-16

Approx. Ship Wt. Kgs.

10 10 15 18 20 28 43 58 71 86 102 114 130 143 171 190 216

X Pilot System 7 7 16 23 32 64 129 227 354 528 726 1027 1353 1769 2812 3494 5316 Y Pilot System 9 9 9 10 11 12 20 22 24 26 29 30 32 34 39 40 45 Z Pilot System 9 9 9 10 11 12 20 22 24 26 29 30 32 34 39 42 47

Model 100-01KO Dimensions

(Full Internal Port)

(In Inches)

Functional Data

CLA-VAL

Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice.

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

©

E-90-01KO (R-7/2011)

For assistance in selecting appropriate valve options or valves manufactured with special design requirements, please contact our Regional Sales Office or Factory.

K =

894d

4

C

2

v

L =

K 12 f

K Factor (Resistance Coefficient)

The Value of K is calculated from the formula: (U.S. system units)

Equivalent Length of Pipe

Equivalent lengths of pipe (L) are determined from the formula: (U.S. system units)

Fluid Velocity

Fluid velocity can be calculated from the following formula: (U.S. system units)

d

V =

.4085 Q

2

d

C

V

Factor

Formulas for computing C Factor, Flow (Q) and Pressure Drop

V

( P):

C

V

=

Q

P

C

V

=

Q

P

C

V

=

Q

P

2

V

Where:

U.S. (gpm) @ 1 psi differential at 60 F water

(l/s) @ 1 bar (14.5 PSIG) differential

or

at 15 C water

inside pipe diameter of Schedule 40 Steel Pipe (inches)

friction factor for clean, new Schedule 40 pipe

(dimensionless) (from Cameron Hydraulic Data,

18th Edition, P 3-119)

Resistance Coefficient (calculated)

Equivalent Length of Pipe (feet)

Flow Rate in U.S. (gpm) or (l/s)

Fluid Velocity (feet per second) or (meters per second)

Pressure Drop in (psi) or (bar)

=

P

V

Q

L

K

f

d

C

Valve Size

Inches 11⁄4 11⁄2 221⁄2 3468101214161820243036

mm.

32 40 50 65 80 100 150 200 250 300 350 400 450 500 600 750 900

C

V

Factor

Globe

Pattern

Gal./Min. (gpm.)

14 14 25 37 52 90 218 362 660 810 1100 1200 1550 1950 3900 6100 9150

Litres/Sec. (l/s.)

3.4 3.4 6.0 8.9 12.5 21.6 52 87 159 194 264 288 360 469 938 1466 2199

Angle

Pattern

Gal./Min. (gpm.)

15 15 26 39 55 95 232 388 479 790 1075 1175 —————

Litres/Sec. (l/s.)

3.6 3.6 6.2 9.4 13.2 22.8 56 93 115 190 258 282 —————

Equivalent Length of

Pipe

Globe

Pattern

Feet (ft.)

196 196 237 277 416 572 858 1315 2444 2118 1937 3022 3537 4199 4532 3897 3954

Meters (m.)

60 60 72 84 127 174 262 401 745 646 590 921 1078 1280 1381 1188 1205

Angle

Pattern

Feet (ft.)

171 171 219 250 372 514 757 1145 2133 2226 2021 3152 —————

Meters (m.)

52526776113157231349650678616961—————

K Factor

Globe Pattern

30.6 30.6 26.1 24.3 29.3 29.0 25.5 27.7 41.0 27.7 22.8 31.4 30.2 29.5 28.9 17.6 15.1

Angle Pattern

26.7 26.7 24.1 21.8 26.2 26.0 22.5 24.1 35.8 29.1 23.8 32.8 —————

Liquid Displaced from Cover Chamber When

Valve Opens

U.S. Gal.

0.2 0.2 .03 .04 .08 .17 .53 1.26 2.5 4.0 6.5 9.6 11 12 29 65 90

Litres

0.8 0.8 .12 .16 .30 .64 2.0 4.8 9.5 15.1 25.6 36.2 41.6 45.4 110 246 340

Adjustment Ranges

2 to 30 psi 15 to 75 psi 20 to 105 psi 30 to 300 psi*

*Supplied unless otherwise specified Other ranges available, please consult factory

Temperature Range

Water: to 180°F

Materials

Standard Pilot System Materials

Pilot Control: Bronze ASTM B62

Trim: Stainless Steel Type 303

Rubber: Buna-N

®

Synthetic Rubber

Optional Pilot System Materials

Pilot Systems are available with optional Aluminum, Stainless Steel or Monel materials.

Note: Available with remote sensing control.

When Ordering, Please Specify

1. Catalog No. 90-01KO

2. Valve Size

3. Pattern - Globe or Angle

4. Pressure Class

5. Threaded, Flanged or Grooved End

6. Trim Material

7. Adjustment Range

8. Desired Options

9. When Vertically Installed

Pilot System Specifications

90-01KO

Valve

Selection

100-01KO Pattern: Globe (G), Angle (A), End Connections: Threaded (T), Grooved (GR), Flanged (F) Indicate Available Sizes

Inches 11⁄4 11⁄2 221⁄2 3 4 6 8 10 12 14 16 18 20 24 30 36

mm 32 40 50 65 80 100 150 200 250 300 350 400 450 500 600 750 900

Basic Valve

100-01KO

Pattern

G, A G, A G, A G, A G, A G, A G, A G, A G, A G, A G, A G, A G G G, A G G

End Detail

T

T, F,

Gr*

T, F,GrT, F,

Gr*

T, F,GrF, GrF,

Gr*

F,

Gr*

FFFFFFFFF

Suggested

Flow

(gpm)

Max. Continuous

84 115 190 270 410 710 1620 2810 4420 6280 7590 9920 12550 14900 22600 37700 52450

Max. Intermittent

120 160 260 370 580 990 2250 3900 6150 8720 10540 13700 17500 21700 31300 48000 62500

Min. Continuous

10 10 15 20 30 50 115 200 300 400 500 650 560 1073 1577 2650 3150

Suggested

Flow

(Liters/Sec)

Max. Continuous

5.3 7.3 12 17 26 45 102 177 279 397 479 694 792 940 1427 2379 3309

Max. Intermittent

7.6 10 16 23 37 62 142 246 387 549 664 863 1104 1369 1972 3028 3940

Min. Continuous

.6 .6 .9 1.3 1.9 3.2 7.2 13 19 25 32 41 41 57 110 132 180

100-01KO Series is the full internal port Hytrol. For Lower Flows Consult Factory *Globe Grooved Only

Description

The CIa-VaI Model 100-01 Hytrol Valve is a main valve for CIa-VaI Automatic Control Valves. It is a hydraulically operated, diaphragm-actuated, globe or angle pattern valve.

This valve consists of three major components; body, diaphragm assembly, and cover. The diaphragm assembly is the only moving part. The diaphragm assembly uses a diaphragm of nylon fabric bonded with synthetic rubber. A synthetic rubber disc, contained on three and one half sides by a disc retainer and disc guide, forms a seal with the valve seat when pressure is applied above the diaphragm. The diaphragm assembly forms a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure.

Installation

1. Before valve is installed, pipe lines should be flushed of all

chips, scale and foreign matter.

2. It is recommended that either gate or block valves be

installed on both ends of the 100-01 Hytrol Valve to facilitate

isoIating the valve for preventive maintenance and repairs.

3. Place the valve in the line with flow through the valve in the

direction indicated on the inlet nameplate. (See “Flow Direction”

Section)

4. Allow sufficient room around valve to make adjustments and

for disassembly.

5. CIa-VaI 100-01 Hytrol Valves operate with maximum effici ency

when mounted in horizontal piping with the cover UP, however,

other positions are acceptable. Due to size and weight of the

cover and internal components of 8 inch and larger valves,

installation with the cover UP is advisable. This makes internal parts readily accessible for periodic inspection.

6. Caution must be taken in the installation of this valve to insure that galvanic and/or electrolytic action does not take place. The proper use of dielectric fittings and gaskets are required in all systems using dissimilar metals.

7. If a pilot control system is installed on the 100-01 Hytrol Valve, use care to prevent damage. If it is necessary to remove fittings or components, be sure they are kept clean and replaced exactly as they were.

8. After the valve is installed and the system is first pressurized, vent air from the cover chamber and pilot system tubing by loosening fittings at all high points.

Tight Closing Operation

When pressure from the valve inlet (or an equivalent independent operating pressure) is applied to the diaphragm chamber the valve closes drip-tight.

Full Open Operation

When pressure in diaphragm chamber is relieved to a zone of lower pressure (usually atmosphere) the line pressure (5 psi Min.) at the valve inlet opens the valve.

Modulating Action

Valve modulates when diaphragm pressure is held at an intermediate point between inlet and discharge pressure. With the use of a Cla-Val. "modulating control," which reacts to line pressure changes, the pressure above the diaphragm is varied, allowing the valve to throttle and compensate for the change.

Principles of Operation

Three Way

Pilot Control

Three Way

Pilot Control

Restriction

Modulating

Control

100-01

Hytrol Valve

MODEL

INSTALLATION / OPERATION / MAINTENANCE

2

Flow Direction

The flow through the 100-01 Hytrol Valve can be in one of two directions. When flow is “up-and-over the seat,” it is in “normal” flow and the valve will fail in the open position. When flow is “overthe seat-and down,” it is in “reverse” flow and the valve will fail in the closed position. There are no permanent flow arrow markings.

The valve must be installed according to nameplate data.

BRIDGEWALL INDlCATOR

Normal Flow Reverse Flow

Troubleshooting

The following troubleshooting information deals strictly with the Model 100-01 Hytrol Valve. This assumes that all other components of the pilot control system have been checked out and are in proper working condition. (See appropriate sections in Technical Manual for complete valve).

Three Checks

The 100-01 Hytrol Valve has only one moving part (the diaphragm and disc assembly). So, there are only three major types of problems to be considered.

First: Valve is stuck - that is, the diaphragm assembly is not free to move through a full stroke either from open to close or vice versa.

Second: Valve is free to move and can’t close because of a worn out diaphragm.

Third: Valve leaks even though it is free to move and the diaphragm isn’t leaking.

Closed isolation valves in control system, or in main line.

Lack of cover chamber pressure.

Diaphragm damaged. (See Diaphragm Check.)

Diaphragm assembly inoperative. Corrosion or excessive scale build up on valve stem. (See Freedom of Movement Check)

Mechanical obstruction. Object lodged in valve. (See Freedom of Movement Check)

Worn disc. (See Tight Sealing Check)

Badly scored seat. (See Tight Sealing Check)

Closed upstream and/or downstream isolation valves in main line.

Insufficient line pressure.

Diaphragm assembly inoperative. Corrosion or excessive buildup on valve stem. (See Freedom of Movement Check)

Diaphragm damaged. (For valves in "reverse flow" only)

After checking out probable causes and remedies, the following three checks can be used to diagnose the nature of the problem before maintenance is started. They must be done in the order shown.

Open Isolation valves.

Check upstream pressure, pilot system, strainer, tubing, valves, or needle valves for obstruction.

Replace diaphragm.

Clean and polish stem. Inspect and replace any damaged or badly eroded part.

Remove obstruction.

Replace disc.

Replace seat.

Open isolation valves.

Check upstream pressure. (Minimum 5 psi flowing line pressure differential.)

Clean and polish stem. Inspect and replace any damaged or badly eroded part.

Replace diaphragm.

Fails to Close

Fails to Open

CAUTION: Care should be taken when doing the troubleshooting checks on the 100-01 Hytrol Valve. These checks do require the valve to open fully. This will either allow a high flow rate through the valve, or the downstream pressure will quickly increase to the inlet pressure. In some cases, this can be very harmful. Where this is the case, and there are no block valves in the system to protect the downstream piping, it should be realized that the valve cannot be serviced under pressure. Steps should be taken to remedy this situation before proceeding any further.

(cast into side of valve body)

SYMPTOM PROBABLE CAUSE REMEDY

Recommended Tools

1. Three pressure gauges with ranges suitable to the installation to be put at Hytrol inlet, outlet and cover connections.

2. Cla-Val Model X101 Valve Position Indicator. This provides visual indication of valve position without disassembly of valve.

3. Other items are: suitable hand tools such as screwdrivers, wrenches, etc. soft jawed (brass or aluminum) vise, 400 grit wet or dry sandpaper and water for cleaning.

All trouble shooting is possible without removing the valve from the line or removing the cover. It is highly recommended to permanently install a Model X101 Valve Position Indicator and three gauges in unused Hytrol inlet, outlet and cover connections.

Diaphragm Check (#1 )

1. Shut off pressure to the Hytrol Valve by slowly closing upstream and downstream isolation valves. SEE CAUTION.

2. Disconnect or close all pilot control lines to the valve cover and

leave only one fitting in highest point of cover open to atmosphere.

3.With the cover vented to atmosphere, slowly open upstream isolation valve to allow some pressure into the Hytrol Valve body. Observe the open cover tapping for signs of continuous flow. It is not necessary to fully open isolating valve. Volume in cover chamber capacity chart will be displaced as valve moves to open position. Allow sufficient time for diaphragm assembly to shift positions. If there is no continuous flow, you can be quite certain the diaphragm is sound and the diaphragm assembly is tight. If the fluid appears to flow continuously this is a good reason to believe the diaphragm is either damaged or it is loose on the stem. In either case, this is sufficient cause to remove the valve cover and investigate the leakage. (See “Maintenance” Section for procedure.)

Freedom of Movement Check (#2)

4. Determining the Hytrol Valve’s freedom of movement can be

done by one of two methods.

5. For most valves it can be done after completing Diaphragm Check (Steps 1, 2, and 3). SEE CAUTION. At the end of step 3 the valve should be fully open.

6. If the valve has a Cla-Val X101 Position Indicator, observe the indicator to see that the valve opens wide. Mark the point of maximum opening.

7. Re-connect enough of the control system to permit the application of inlet pressure to the cover. Open pilot system cock so pressure flows from the inlet into the cover.

8. While pressure is building up in the cover, the valve should close smoothly. There is a hesitation in every Hytrol Valve closure, which can be mistaken for a mechanical bind. The stem will appear to stop moving very briefly before going to the closed position. This slight pause is caused by the diaphragm flexing at a particular point in the valve’s travel and is not caused by a mechanical bind.

9. When closed, a mark should be made on the X101 Valve position indicator corresponding to the “closed” position. The distance between the two marks should be approximately the stem travel shown in chart.

10. If the stroke is different than that shown in stem travel chart this is a good reason to believe something is mechanically restricting the stroke of the valve at one end of its travel. If the flow does not stop through the valve when in the indicated “closed” position, the obstruction probably is between the disc and the seat. If the flow does stop, then the obstruction is more likely in the cover. In either case, the cover must be removed, and the obstruction located and removed. The stem should also be checked for scale buildup. (See “Maintenance, section for procedure.)

11. For valves 6” and smaller, the Hytrol Valve’s freedom of movement check can also be done after all pressure is removed from the valve. SEE CAUTION. After closing inlet and outlet isolation valves and bleeding pressure from the valve, check that the cover chamber and the body are temporarily vented to atmosphere. Insert fabricated tool into threaded hole in top of valve stem, and lift the diaphragm assembly manually. Note any roughness. The diaphragm assembly should move smoothly throughout entire valve stroke. The tool is fabricated from rod that is threaded on one end to fit valve stem and has a “T” bar handle of some kind on the other end for easy gripping. (See chart in Step 4 of “Disassembly” Section.)

12. Place marks on this diaphragm assembly lifting tool when the valve is closed and when manually positioned open. The distance between the two marks should be approximately the stem travel shown in stem travel chart. If the stroke is different than that shown, there is a good reason to believe something is mechanically restricting the stroke of the valve. The cover must be removed, and the obstruction located and removed. The stem should also be checked for scale build-up. (See “Maintenance” Section for procedure.)

Tight Sealing Check (#3)

13. Test for seat leakage after completing checks #1 & #2 (Steps

1 to 12). SEE CAUTION. Close the isolation valve downstream of the Hytrol Valve. Apply inlet pressure to the cover of the valve, wait until it closes. Install a pressure gauge between the two closed valves using one of the two ports in the outlet side of the Hytrol. Watch the pressure gauge. If the pressure begins to climb, then either the downstream isolation valve is permitting pressure to creep back, or the Hytrol is allowing pressure to go through it. Usually the pressure at the Hytrol inlet will be higher than on the isolation valve discharge, so if the pressure goes up to the inlet pressure, you can be sure the Hytrol is leaking. Install another gauge downstream of isolating valve. If the pressure between the valves only goes up to the pressure on the isolation valve discharge, the Hytrol Valve is holding tight, and it was just the isolation valve leaking.

STEM TRAVEL

(Fully Open to Fully Closed)

Valve Size (inches) Travel (inches)

Inches MM Inches MM

1 1/4 32 0.4 10 1 1/2 40 0.4 10 250 0.615 2 1/2 65 0.7 18 380 0.820 4 100 1.1 28 6 150 1.7 43 8 200 2.3 58 10 250 2.8 71 12 300 3.4 86 14 350 4.0 100 16 400 4.5 114 20 500 5.6 143 24 600 6.7 165 30 800 7.5 190 36 900 8.5 216

COVER CHAMBER CAPACITY

(Liquid Volume displaced when valve opens)

Valve size (inches) Displacement

Gallons Liters

1 1/4 .020 .07 1 1/2 .020 .07 2 .032 .12 2 1/2 .043 .16 3 .080 .30 4 .169 .64 6 .531 2.0 8 1.26 4.8 10 2.51 9.5 12 4.00 15.1 14 6.50 24.6 16 9.57 36.2 20 12.00 45.4 24 29.00 109.8 30 42.00 197.0 36 90.00 340.0

3

Maintenance

Preventative Maintenance

The Cla-Val Co. Model 100-01 Hytrol Valve requires no lubrication or packing and a minimum of maintenance. However, a periodic inspection schedule should be established to determine how the operating conditions of the system are affecting the valve. The effect of these actions must be determined by inspection.

Disassembly

Inspection or maintenance can be accomplished without removing the valve from the line. Repair kits with new diaphragm and disc are recommended to be on hand before work begins.

WARNING: Maintenance personnel can be injured and equipment damaged if disassembly is attempted with pressure in the valve. SEE

CAUTION.

1. Close upstream and downstream isolation valves and independ- ent operating pressure when used to shut off all pressure to the

valve.

2. Loosen tube fittings in the pilot system to remove pressure from valve body and cover chamber. After pressure has been released from the valve, use care to remove the controls and tubing. Note and sketch position of tubing and controls for re-assembly. The schematic in front of the Technical Manual can be used as a guide when reassembling pilot system.

3. Remove cover nuts and remove cover. If the valve has been in service for any length of time, chances are the cover will have to be loosened by driving upward along the edge of the cover with a dull cold chisel.

On 6” and smaller valves block and tackle or a power hoist can be used to lift valve cover by inserting proper size eye bolt in place of the center cover plug. on 8” and larger valves there are 4 holes (5/8” — 11 size) where jacking screws and/or eye bolts may be inserted for lifting purposes. Pull cover straight up to keep from damaging the integral seat bearing and stem.

4. Remove the diaphragm and disc assembly from the valve body. With smaller valves this can be accomplished by hand by pulling

straight up on the stem so as not to damage the seat bearing.

On large valves, an eye bolt of proper size can be installed in the stem and the diaphragm assembly can be then lifted with a block and tackle or power hoist. Take care not to damage the stem or bearings. The valve won't work if these are damaged.

5. The next item to remove is the stem nut. Examine the stem threads above the nut for signs of mineral deposits or corrosion. If the threads are not clean, use a wire brush to remove as much of the residue as possible. Attach a good fitting wrench to the nut and give it a sharp “rap” rather than a steady pull. Usually several blows are sufficient to loosen the nut for further removal. On the smaller valves, the entire diaphragm assembly can be held by the stem in a vise equipped with soft brass jaws before removing the stem nut.

The use of a pipe wrench or a vise without soft brass jaws scars the fine finish on the stem. No amount of careful dressing can restore the stem to its original condition. Damage to the finish of the stem can cause the stem to bind in the bearings and the valve will not open or close.

6. After the stem nut has been removed, the diaphragm assembly breaks down into its component parts. Removal of the disc from the disc retainer can be a problem if the valve has been in service for a long time. Using two screwdrivers inserted along the outside edge of the disc usually will accomplish its removal. Care should be taken to preserve the spacer washers in water, particularly if no new ones are available for re-assembly.

7. The only part left in the valve body is the seat which ordinarily does not require removal. Careful cleaning and polishing of inside and outside surfaces with 400 wet/dry sandpaper will usually restore the seat’s sharp edge. If, however, it is badly worn and replacement is necessary, it can be easily removed.

Seats in valve sizes 1 1/4” through 6” are threaded into the valve body. They can be removed with accessory X109 Seat Removing Tool available from the factory. On 8” and larger valves, the seat is held in place by flat head machine screws. Use a tight-fitting, long shank screwdriver to prevent damage to seat screws. If upon removal of the screws the seat cannot be lifted out, it will be necessary to use a piece of angle or channel iron with a hole drilled in the center. Place it across the body so a long stud can be inserted through the center hole in the seat and the hole in the angle iron. By tightening the nut a uniform upward force is exerted on the seat for removal.

NOTE: Do not lift up on the end of the angle iron as this may force the integral bearing out of alignment, causing the stem to bind.

VALVE STEM THREAD SIZE

Valve Size Thread Size (UNF Internal)

1 1/4"

—2 1/2" 10—32 3"—4" 1/4—28 6"—14" 3/8—24

16" 1/2—20

20 3/4-16 24" 3/4-16 30” 3/4-16 36” 3/4-16

COVER CENTER PLUG SIZE

Valve Size Thread Size (NPT)

1 1/4"

—1 1/2" 1/4" 2"—3" 1/2" 4"—6" 3/4" 8"—10" 1"

12" 1 1/4" 14" 1 1/2"

16" 2" 20” & 24" 2" 30” & 36” 2”

NUT

ANGLE OR CHANNEL IRON

LONG STUD OR BOLT

NUT OR BOLT HEAD

DO NOT

LIFT

VALVE SEAT

VALVE BODY

4

Lime Deposits

One of the easiest ways to remove lime deposits from the valve stem or other metal parts is to dip them in a 5-percent muriatic acid solution just long enough for the deposit to dissolve. This will remove most of the common types of deposits. CAUTlON: USE EXTREME CARE WHEN HANDLING ACID. Rinse parts in water before handling. If the deposit is not removed by acid, then a fine grit (400) wet or dry sandpaper can be used with water.

Reassembly

1. Reassembly is the reverse of the disassembly procedure. If a

new disc has been installed, it may require a different number of spacer washers to obtain the right amount of “grip” on the disc. When the diaphragm assembly has been tightened to a point where the diaphragm cannot be twisted, the disc should be compressed very slightly by the disc guide. Excessive compression should be avoided. Use just enough spacer washers to hold the disc firmly without noticeable compression.

2. MAKE SURE THE STEM NUT IS VERY TIGHT. Attach a good fitting wrench to the nut and give it a sharp “rap” rather than a steady pull. Usually several blows are sufficient to tighten the stem nut for final tightening. Failure to do so could allow the diaphragm to pull loose and tear when subjected to pressure.

Test Procedure After Valve Assembly

There are a few simple tests which can be made in the field to make sure the Hytrol Valve has been assembled properly. Do these before installing pilot system and returning valve to service. These are similar to the three troubleshooting tests.

1. Check the diaphragm assembly for freedom of movement after all pressure is removed from the valve. SEE CAUTlON. Insert fabricated tool into threaded hole in top of valve stem, and lift the diaphragm assembly manually. Note any roughness, sticking or grabbing. The diaphragm assembly should move smoothly throughout entire valve stroke. The tool is fabricated from rod that is threaded on one end to fit valve stem (See chart in Step 4 of “Disassembly” section.) and has a “T” Bar handle of some kind on the other end for easy gripping.

Place marks on this diaphragm assembly lifting tool when the valve is closed and when manually positioned open. The distance between the two marks should be approximately the stem travel shown in stem travel chart. (See “Freedom of Movement Check” section.) If the stroke is different than that shown, there is a good reason to believe something is mechanically restricting the stroke of the valve. The cover must be removed, the obstruction located and removed. (See “Maintenance” Section for procedure.)

Inspection of Parts

After the valve has been disassembled, each part should be examined carefully for signs of wear, corrosion, or any other abnormal condition. Usually, it is a good idea to replace the rubber parts (diaphragm and disc) unless they are free of signs of wear. These are available in a repair kit. Any other parts which appear doubtful should be replaced. WHEN ORDERlNG PARTS, BE SURE TO GIVE COMPLETE NAMEPLATE DATA, ITEM NUMBER AND DESCRlPTlON.

NOTE: If a new disc isn’t available, the existing disc can be turned over, exposing the unused surface for contact with the seat. The disc should be replaced as soon as practical.

3. Carefully install the diaphragm assembly by lowering the stem through the seat bearing. Take care not to damage the stem or bearing. Line up the diaphragm holes with the stud or bolt holes on the body. on larger valves with studs, it may be necessary to hold the diaphragm assembly up part way while putting the diaphragm over the studs.

4. Put spring in place and replace cover. Make sure diaphragm is Iying smooth under the cover.

5. Tighten cover nuts firmly using a cross-over pattern until all nuts are tight.

6. Test Hytrol Valve before re-installing pilot valve system.

Due to the weight of the diaphragm assembly this procedure is not possible on valves 8” and larger. on these valves, the same determination can be made by carefully introducing a low pressure-less than five psi) into the valve body with the cover vented. SEE CAUTION. Looking in cover center hole see the diaphragm assembly lift easily without hesitation, and then settle back easily when the pressure is removed.

2. To check the valve for drip-tight closure, a line should be connected from the inlet to the cover, and pressure applied at the inlet of the valve. If properly assembled, the valve should hold tight with as low as ten PSI at the inlet. See “Tight Sealing Check” section.)

3. With the line connected from the inlet to the cover, apply full working pressure to the inlet. Check all around the cover for any leaks. Re-tighten cover nuts if necessary to stop leaks past the diaphragm.

4. Remove pressure, then re-install the pilot system and tubing exactly as it was prior to removal. Bleed air from all high

points.

5. Follow steps under “Start-Up and Adjustment” Section in

Technical Manual for returning complete valve back to service

.

5

1

5

8

10

14

16

6

17

7

9

OUTLE

T

INLET

GLOBE PATTERN

9

26

27

12

15

14

16

INLET

OUTLET

ANGLE PATTERN

22

23

13

12

14

10

11

15

23

TOP VIEW

8" - 24" SEAT DETAIL

1 1/4" - 6" SEAT DETAIL

16" COVER DETAIL

4

24

2

25

13

31

28

30

29

5

14

3

Item Description

1. Pipe Plug

2. Drive Screws (for nameplate)

3. Hex Nut (8” and larger)

4. Stud (8” and larger)

5. Cover Bearing

6. Cover

7. Stem Nut

8. Diaphragm Washer

9. Diaphragm

10. Spacer Washers

11. Disc Guide

12. Disc Retainer

13. Disc

14. Stem

15. Seat

16. Body

17. Spring

22. Flat Head Screws (8” and larger)

23. Seat O-Ring

24. Hex head Bolt (1 1/4” thru 4”)

25. Nameplate

26. Upper Spring Washer (Epoxy coated valves only)

27. Lower Spring Washer (Epoxy coated valves only)

28. Cover Bearing Housing (16” only)

29. Cover O-Ring (16’” only)

30. Hex Bolt (16” only)

31. Pipe Cap (16” only)

PARTS LIST

6

100-01

Hytrol Valve Service Data

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Description 100-01 Hytrol Valve

The CIa-VaI Model 100-01 Hytrol Valve is a main valve for

CIa-VaI Automatic Control Valves. It is a hydraulically operated,

diaphragm-actuated, globe or angle pattern valve.

This valve consists of three major components; body, diaphragm

assembly, and cover. The diaphragm assembly is the only

moving part. The diaphragm assembly uses a diaphragm of nylon

fabric bonded with synthetic rubber. A synthetic rubber disc,

contained on three and one half sides by a disc retainer and disc

guide, forms a seal with the valve seat when pressure is applied

above the diaphragm. The diaphragm assembly forms a sealed

chamber in the upper portion of the valve, separating operating

pressure from line pressure.

Description 100-20 600 Series Hytrol Valve

The CIa-VaI Model 100-20 Hytrol Valve (600 Series main valve)

have only one part -the body- that is different from standard 100

Series Cla-Val main valve parts. The remaining parts of the 600

series main valve are standard Cla-Val main valve parts. All serv-

ice and maintenance information for the standard 100 Series

main valves also apply to the 600 series main valves.

The most important thing to remember when ordering main

valve repair kits and replacement parts, except for the body, all

other parts are going to be for a smaller size main valve. Cla-

Val identifies main valve parts with the flange size of the stan-

dard 100 Series main valve. Refer to the "Main Valve Sizes”

chart below.

HYTROL Service Data

HYTROL SIZE

Stem

Travel

Cover Capacity

Displacement

Valve Stem

Thread

UNF-Internal

Cover

Center

Plug

NPT

Cover Nut or Bolt

Cover

Lifting

Holes

UNC

Cover Plug Cover Torque

Stem Nut**

Stem Nut Torque

(ft. Lbs.)

100-01

100-20

Thread

(Bolt)

Socket

Qty Thread

Socket ft. Lbs. in. Lbs.

Thread

Socket

(Long)

inches mm inches mm inches mm

Gallons

Liters

Lubed DRY

1"

25 0.3 8 1/4"

1/4" - 20 (B)

7/16" 8

4

48 3/8" - 24

4

6

1 1/4"

32

0.4

10

0.020

0.07

10 - 32

1/4" 5/16" - 18 (B) 1/2"

8

8 96 7/16" -20 6 10

1 1/2" 40 0.4 10 0.020 0.07

10 - 32

1/4" 5/16" - 18 (B) 1/2"

8

8 96 7/16" -20 6 10

2" 50 0.6 15 0.032

0.12 10 - 32

1/2" 3/8" - 16 (B) 9/16" 8 3/8" 7/16" 12

1/2" - 20

3/4" 10 15

2 1/2"

65 0.7 18

0.043 0.16

10 - 32

1/2" 7/16" - 14 (B) 5/8" 8 1/2" 9/16" 20

5/8" - 18 15/16" 21

30

3" 80 4" 100 0.8

20

0.080 0.30

1/4 - 28 1/2"

1/2" - 13 (B)

3/4" 8 1/2" 9/16" 30 5/8" - 18

15/16"

21 30

4" 100 6" 150 1.1 23

0.169 0.64

1/4 - 28 3/4"

3/4" - 10 (B)

1 1/8" 8 3/4" 5/8" 11 0 3/4" - 16

1 1/16"

40

60

6" 150 8" 200 1.7 43 0.531 2.00 3/8 - 24 3/4"

3/4" - 10 (B) 1 1/8"

12 3/4"

5/8" 110

7/8" - 14

1 5/16"

85 125

8"

200 10"

250

2.3 58

1.26 4.80 3/8 - 24

1"

3/4" - 10

1 1/4" 16 5/8" - 11

1" 13/16" 110

1 1/8" -12 1 13/16"

125

185

10" 250 12" 300 2.8 71 2.51 9.50

3/8 - 24

1" 7/8" - 9 1 7/16"

20

3/4" - 10

1"

13/16" 160 1 1/2" -12 1 7/8" 252 375

12" 300 16" 400 3.4 86 4.0 15.10

3/8 - 24

1 1/4" 1 1/8" - 7 1 13/16"

20

3/4" - 10

1" 13/16" 390 1 1/2" -12 2 1/2" 270 400

14" 350 3.9

99

6.5

24.60

3/8 - 24 1 1/2" 1 1/4" - 7

2" 20

1" - 8

1" 13/16" 545 1 1/2" -12

2 1/2"

280 420

16"

400

20", 24"

600

4.5

114

9.6 36.20

1/2 - 20

2" 1 1/4" - 7

2" 20

1" - 8

1" 13/16" 545 2" - 16 3" 500 750

20" 500 5.63

143

12 45.40

3/4 - 16 1 1/2" 1 3/8" - 6

2 1/8" 24

1" - 8

1" 13/16" 670

2 1/4" - 16

3 1/2" 930

N/R

24" 600

30"

800 6.75 165

29.0

108.80 3/4 - 16*

3/4"

1 1/2" - 12 2 3/8" 24

1 1/8"- 7

1" 13/16"

800

3" - 12

Special

1350

N/R

* Adapter

p/n 2594101E

inside 1/4" - 28"

Grade 5 Bolts

"Heavy" Grade Nuts

Tighten cover nuts in a "star" cross-over pattern

** Must Use ONLY

Cla-Val Supplied part

COVER

PIPE PLUG

COVER BEARING

SPRING

STEM NUT

DIAPHRAGM WASHER

DISC RETAINER

BODY

*

SPACER WASHERS

DISC GUIDE

SEAT

PIPE PLUG

STEM

SEAT O-RING

STUD

8" and Larger

*

DIAPHRAGM

*

DISC

*

Repair Parts

Seat Screw

8" and Larger

(Globe

or

Angle)

PIPE PLUG

HEX NUT

8" and Larger

Cover Bolt

6" and Smaller

KO

DISC GUIDE

KO

SEAT

KO Anti-Cavitation

Trim Option

N-100-01 (R-3/2011

CLA-VAL

Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice.

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

©

BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS

4

BOLTS

6

BOLTS

8

BOLTS

12

BOLTS

16

BOLTS

20

BOLTS

4

3

2

1

65

4

3

2

1

8

7

6

5

4

3

2

1

0

9

8

7

6

5

4

3

2

1

12

11

10

9

8

7

6

5

4

3

2

1

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

20

19

18

17

16

15

14

13

12

11

Follow this procedure when reassembling MAIN Valve:

1. Tightens bolts/nuts in a “Star” or “Cross-Over” pattern following the

numbers shown above to insure that cover seats evenly on the diaphragm

material and body.

2. Torque the bolt/nuts in three stages with a "Star" or "Cross-Over" pattern

for each stage:

A. To approximately 10% of final torque.

B. To approximately 75% of final torque.

C. To final required torque.

3. Valves that are to be tested to 375 PSI or higher should be retorqued

after 24 hours.

100-01 Hytrol Main Valve Assembly

Description

The CIa-VaI Model 100-01 Hytrol Valve is a main valve for CIa-VaI Automatic Control Valves. It is a hydraulically operated, diaphragm-actuated, globe or angle pattern valve.

This valve consists of three major components; body, diaphragm assembly, and cover. The diaphragm assembly is the only moving part. The diaphragm assembly uses a diaphragm of nylon fabric bonded with synthetic rubber. A synthetic rubber disc, contained on three and one half sides by a disc retainer and disc guide, forms a seal with the valve seat when pressure is applied above the diaphragm. The diaphragm assembly forms a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure.

Installation

1. Before valve is installed, pipe lines should be flushed of all chips, scale and foreign matter.

2. It is recommended that either gate or block valves be installed on both ends of the 100-01 Hytrol Valve to facilitate isoIating the valve for preventive maintenance and repairs.

3. Place the valve in the line with flow through the valve in the direction indicated on the inlet nameplate. (See “Flow Direction” Section)

4. Allow sufficient room around valve to make adjustments and for disassembly.

5. CIa-VaI 100-01 Hytrol Valves operate with maximum effici ency when mounted in horizontal piping with the cover UP, however, other positions are acceptable. Due to size and weight of the cover and internal components of 8 inch and larger valves,

installation with the cover UP is advisable. This makes internal parts readily accessible for periodic inspection.

6. Caution must be taken in the installation of this valve to insure that galvanic and/or electrolytic action does not take place. The proper use of dielectric fittings and gaskets are required in all systems using dissimilar metals.

7. If a pilot control system is installed on the 100-01 Hytrol Valve, use care to prevent damage. If it is necessary to remove fittings or components, be sure they are kept clean and replaced exactly as they were.

8. After the valve is installed and the system is first pressurized, vent air from the cover chamber and pilot system tubing by loosening fittings at all high points.

Tight Closing Operation

When pressure from the valve inlet (or an equivalent independent operating pressure) is applied to the diaphragm chamber the valve closes drip-tight.

Full Open Operation

When pressure in diaphragm chamber is relieved to a zone of lower pressure (usually atmosphere) the line pressure (5 psi Min.) at the valve inlet opens the valve.

Modulating Action

Valve modulates when diaphragm pressure is held at an intermediate point between inlet and discharge pressure. With the use of a Cla-Val. "modulating control," which reacts to line pressure changes, the pressure above the diaphragm is varied, allowing the valve to throttle and compensate for the change.

Principles of Operation

Three Way

Pilot Control

Three Way

Pilot Control

Restriction

Modulating

Control

100-01

Hytrol Valve

MODEL

INSTALLATION / OPERATION / MAINTENANCE

2

Flow Direction

The flow through the 100-01 Hytrol Valve can be in one of two directions. When flow is “up-and-over the seat,” it is in “normal” flow and the valve will fail in the open position. When flow is “overthe seat-and down,” it is in “reverse” flow and the valve will fail in the closed position. There are no permanent flow arrow markings.

The valve must be installed according to nameplate data.

BRIDGEWALL INDlCATOR

Normal Flow Reverse Flow

Troubleshooting

The following troubleshooting information deals strictly with the Model 100-01 Hytrol Valve. This assumes that all other components of the pilot control system have been checked out and are in proper working condition. (See appropriate sections in Technical Manual for complete valve).

Three Checks

The 100-01 Hytrol Valve has only one moving part (the diaphragm and disc assembly). So, there are only three major types of problems to be considered.

First: Valve is stuck - that is, the diaphragm assembly is not free to move through a full stroke either from open to close or vice versa.

Second: Valve is free to move and can’t close because of a worn out diaphragm.

Third: Valve leaks even though it is free to move and the diaphragm isn’t leaking.

Closed isolation valves in control system, or in main line.

Lack of cover chamber pressure.

Diaphragm damaged. (See Diaphragm Check.)

Diaphragm assembly inoperative. Corrosion or excessive scale build up on valve stem. (See Freedom of Movement Check)

Mechanical obstruction. Object lodged in valve. (See Freedom of Movement Check)

Worn disc. (See Tight Sealing Check)

Badly scored seat. (See Tight Sealing Check)

Closed upstream and/or downstream isolation valves in main line.

Insufficient line pressure.

Diaphragm assembly inoperative. Corrosion or excessive buildup on valve stem. (See Freedom of Movement Check)

Diaphragm damaged. (For valves in "reverse flow" only)

After checking out probable causes and remedies, the following three checks can be used to diagnose the nature of the problem before maintenance is started. They must be done in the order shown.

Open Isolation valves.

Check upstream pressure, pilot system, strainer, tubing, valves, or needle valves for obstruction.

Replace diaphragm.

Clean and polish stem. Inspect and replace any damaged or badly eroded part.

Remove obstruction.

Replace disc.

Replace seat.

Open isolation valves.

Check upstream pressure. (Minimum 5 psi flowing line pressure differential.)

Clean and polish stem. Inspect and replace any damaged or badly eroded part.

Replace diaphragm.

Fails to Close

Fails to Open

CAUTION: Care should be taken when doing the troubleshooting checks on the 100-01 Hytrol Valve. These checks do require the valve to open fully. This will either allow a high flow rate through the valve, or the downstream pressure will quickly increase to the inlet pressure. In some cases, this can be very harmful. Where this is the case, and there are no block valves in the system to protect the downstream piping, it should be realized that the valve cannot be serviced under pressure. Steps should be taken to remedy this situation before proceeding any further.

(cast into side of valve body)

SYMPTOM PROBABLE CAUSE REMEDY

Recommended Tools

1. Three pressure gauges with ranges suitable to the installation to be put at Hytrol inlet, outlet and cover connections.

2. Cla-Val Model X101 Valve Position Indicator. This provides visual indication of valve position without disassembly of valve.

3. Other items are: suitable hand tools such as screwdrivers, wrenches, etc. soft jawed (brass or aluminum) vise, 400 grit wet or dry sandpaper and water for cleaning.

All trouble shooting is possible without removing the valve from the line or removing the cover. It is highly recommended to permanently install a Model X101 Valve Position Indicator and three gauges in unused Hytrol inlet, outlet and cover connections.