Forbes Marshall FMPRV41 Manuale
Forbes Marshall Pilot Operated Pressure
Reducing Valve
FMPRV41
Installation and Maintenance Manual
Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com
1. Preface .................................................................................1
2. Important Safety Notes ........................................................1
3. Brief Product Information .....................................................3
4. Product Working Principle .....................................................9
5. Installation Guidelines ........................................................10
6. Startup and Commissioning.................................................15
7. Maintenance Guidelines ....................................................16
8. Troubleshooting ..................................................................28
9. Available Spares ................................................................31
10. Warranty Period .................................................................33
Table of Contents
PLEASE NOTE - Throughout this manual this cautionary symbol is used to
describe a potential damage or injury that might occur if the safety
considerations are overlooked. This symbol denotes CAUTION, WARNING or
DANGER.
Forbes Marshall Pilot Operated Pressure ReducingValve
1
1.
2.
Preface:
This manual is intended for anyone using, commissioning, servicing, or disposing the below
mentionedproductssafelyandefficiently.
ForbesMarshallPilotOperatedPressureReducingValve[FMPRV41]
Sizes: DN15(1/2“),DN20(3/4”),DN25(1”),DN40(1¾”)andDN50(2”)
PLEASENOTE:
Throughout this manual the following cautionary symbol is used to describe a potential damage
orinjurythatmightoccurifthesafetyconsiderationsareoverlooked.
ImportantSafetyNotes:
Read this section carefully before installing/operating/maintaining the product. The
precautions listed in this manual are provided for personnel and equipment safety.
Furthermore, Forbes Marshall accepts no responsibility for accidents or damage
occurring as a result of failure to observe these precautions. Note that the product is
designedtoperformfornon-contaminatedfluidsonly.Acontaminationintheformof
chemical,foreignparticleetc.canleadtoproblemwithproductperformanceandlifeof
theproduct.
If these products in compliance with the operating instructions are, properly installed,
commissioned, maintained and installed by qualified personnel (refer Section 2.7) the safety
operationsoftheseproductscan be guaranteed. General instructions for properuseoftoolsand
safetyofequipments,pipelineandplantconstructionmustalsobecompliedwith.
2.1 Intendeduse:
Check if the product is suitable for intended use/ application by referring to the installation
andmaintenanceinstructions,nameplatesandtechnicalinformationsheets.
i) Theproductissuitableforuse asdefinedin thetechnicalinformation sheet.Incase the
need arises to use the product on any other fluid please contact Forbes Marshall for
assistance.
ii) Checkforthesuitabilityinconformancetothelimitingconditionsspecifiedintechnical
informationsheetoftheproduct.
iii) Thecorrectinstallationanddirectionoffluidflowhastobedetermined.
iv) Forbes Marshall products are not intended to resist external stresses, hence necessary
precautionstobetakentominimizethesame.
2.2 AccessibilityandLighting:
Safeaccessibilityandworkingconditionsaretobeensuredpriortoworkingontheproduct.
FMPRV41
2
2.3 Hazardousenvironmentandmedia:
The product has to be protected from hazardous environment and check to ensure that no
hazardousliquidsorgasespassthroughtheproduct.
2.4 Depressurizingofsystemsandnormalizingoftemperature:
Ensure isolation and safety venting of any pressure to the atmospheric pressure. Even if the
pressure gauge indicates zero, do not make an assumption that the system has been
depressurized.
Toavoiddangerofburnsallowtemperaturetonormalizeafterisolation.
2.5 Toolsandconsumables:
Ensure you have appropriate tools and / or consumables available before starting the work.
UseoforiginalForbesMarshallreplacementpartsisrecommended.
2.6 Protectiveclothing:
Consider for the requirement of any protective clothing for you/ or others in the vicinity for
protection against hazards of temperature (high or low), chemicals, radiation, dangers to
eyesandface,noiseandfallingobjects.
2.7 Permitstowork:
All work to be carried out under supervision of a competent person. Training should be
imparted to operating personnel on correct usage of product as per Installation and
Maintenance instruction. “Permit to work” to be complied with (wherever applicable), in
case of absence of this system a responsible person should have complete information and
knowledgeon whatwork isgoingonandwhererequired,arrangetohaveanassistantwith
his primary goal and responsibility being safety. “Warning Notices” should be posted
wherevernecessary.
2.8 Handling:
There is a risk of injury if heavy products are handled manually. Analyze the risk and use
appropriatehandling method by taking into consideration the task, individual, the working
environmentandtheload.
2.9 Freezing:
Provision should be made to protect systems which are not self-draining, against frost
damage(inenvironmentwheretheymaybe exposedtotemperaturesbelowfreezingpoint)
tobemade.
2.10 Returningproducts:
CustomersandStockistareremindedthat,whenreturningproductstoForbesMarshallthey
must provide information on any hazards and the precautions to be taken due to
contamination residues or mechanical damage which may present a health, safety or
environmentalrisk.
This information must be provided in writing including Health and Safety data sheets
relatingtoanysubstancesidentifiedashazardousorpotentiallyhazardous.
Forbes Marshall Pilot Operated Pressure ReducingValve
3
FMPRV41
PMO-Maximum allowable pressure 17 bar g
TMO-Maximum allowable temperature 232°C
Cold hydraulic test pressure 34 bar g
Spring range 0.3 to 17 bar g
3. Brief Product Information:
3.1 Description:
TheForbesMarshallPilotOperatedForbesMarshallPilotOperatedPressureReducingValve,
FMPRV41isaSGironpilotoperatedForbesMarshallPilotOperatedPressureReducingValve
suitableforsteamorcompressedair.
3.2 Sizes and End Connections:
DN 15, 20, 25, 40 and 50
Screwed: BSPT / NPT for DN 15, 20, 25
Flanged: BS 10 table “F/H” for DN 40 and 50
DN15 FMPRV41 LC versions available
3.3 Limiting Conditions:
3.4 Pressure Sensing Pipe:
The FMPRV41 controls the pressure by sensing the downstream pressure through a
pressure sending pipe taken to the union (item L ) or through the internal sensing pipe
(item M). Fitting of the external pressure sensing pipe is described in the user manual
supplied with the valve.Note: Capacity is reduced and there is a possibility of hunting if
an external pressure sensing pipe is not fitted.
3.5 Operating Range:
KV Values
The Kv values are full capacities and should be used for safety valve sizing purpose
only
SIZE DN15 DN20 DN25 DN40 DN50
KV 2.8 5.5 8.1 17 28
For conversion Cv (UK)=Kv x 0.963
Cv (US)=Kv x 1.156
The product must not be used in this region.
Pressure bar g
Temperature °C
A
E
Steam
saturation
curve
C
F
BD
G
0515 20
10 17
100
150
50
200
232
4Forbes Marshall Pilot Operated Pressure ReducingValve
Figure 1: Forbes Marshall Pilot Oprated Presure Reducing valve - FMPRV41 steam.
5
FMPRV41
No Part Material Standard
1 Adjustments screw Carbon Steel IS1367Gr14
2 Adjustment lock nut SS Type 304
3 Spring housing SG iron EN-JS1025 DIN EN 1563
4 Top spring pad C-20 IS2062
5 Pressure adjustment Spring SS Type 302 IS4454 Part IV Gr.1
6 Bottom spring pad SS Type 304 ASTM A276
7 Spring housing
Securing nut Carbon Steel HT IS 1367
Securing studs Carbon Steel HT IS 1367
DN 15-32 M10x95mm
DN 40, 50 M12x95mm
8 Pilot diaphragms SS Type 304 ASTM A240
9 Pilot valve chamber SG iron EN-JS1025 DIN EN1563
10 Pilot valve plunger SS Type 304
11 Pilot valve seat with SS BS 970 431 S29
integral seal +PTFE
12 Pilot valve ball SS AISI 420
13 Pilot valve Spring SS BS 2057 302 S26
14 Pilot Valve clip SS ASTM A240 Type 301
15 Pilot filter cap gasket SS BS 1449-304-S16
16 Pilot filter cap SS ASTM A743Gr. CA 40
17 Pilot filter element Bronze
18 Internal strainer SS ASTM A240 Type 304
19 Body gasket SS forced
exfoliated graphite
20 Main valve return spring Stainless Steel BS 2056 302 S26
21 Main valve Stainless Steel ASTM A276 Type 420
22 Main valve seat Stainless Steel ASTM A276 Type 420
23 Balance pipe assembly Stainless Steel ASTM A213 Type 304
24 Main Valve body SG iron EN JS1025 DIN EN 1563
25 Lower diaphragm chamber SG iron EN-JS1025 DIN EN 163
26 Lower diaphragm chamber
Securing nuts Carbon steel S1367
Securing Bolts Carbon steel S 1367
DN 15 - 25 M12x50mm
DN 40, 50 M12x50mm
27 Main diaphragm pad SS Type 304 ASTM A240
28 Lower diaphragm pad SS Type 304 ASTM A276
29 Pushrod SS Type 431
30 Lock nut SS Type 316
31 Control pipe assembly SS Type 304 ASTM A213
32 Name plate SS
Materials:
6Forbes Marshall Pilot Operated Pressure ReducingValve
3.6 Product Dimension and Drawing:
Dimensions (approx.) in mm
Size Screwed A Flanged A1 B D E
DN15 160 ..... 181 410 130
DN15 LC 160 ..... 181 410 130
DN20 160 ..... 181 410 130
DN25 180 ..... 203 430 144
DN40 ..... 212 251 450 149
DN50 ..... 232 251 480 174
FMPRV41 (Steam)
FMPRV41 STEAM
M
FMPRV41 AIR
Size Screwed A Flanged A1 B D E
15 160 ..... 181 360 130
DN15 LC 160 ..... 181 360 130
DN20 160 ..... 181 360 130
DN25 180 ..... 203 383 144
DN40 ..... 212 251 415 149
DN50 ..... 232 251 415 174
DN
FMPRV41 (Air)
Figure 2: Dimensional drawing of FMPRV41-STEAM
Figure 3: Dimensional drawing of FMPRV41-Air
3.6 Steam Capacity Chart:
Note
The capacities quoted below are based on valves fitted with an external pressure
sensing pipe. Reliance on the internal pressure sensing pipe will mean that
capacities may be reduced. In the case of low downstream pressure this reduction
couldbeupto30%ofthevalvecapacity.
3.6.1 How to Use the Chart (for steam application):
Saturated Steam
Avalveisrequiredtopass600kg/hreducingfrom6bargto4barg.Findthepoint
at which the curved 6 bar g upstream pressure line crosses the horizontal 4 bar g
downstream pressure line. A perpendicular dropped from this point gives the
capacitiesofallFMPRV41sizesundertheseconditions.
Superheated steam
Because of the higher specific volume of superheated steam a correction factor
must be applied to the figure obtained from the chart above. For 55°C of
superheatthefactoris0.95andfor100°Cofsuperheatthefactoris0.9.
Using the example given for saturated steam, the DN40 valve would pass
1150X0.95=1092kg/hr. if the steam had 55°C superheat. It is still big enough to
passtherequiredloadof600kg/hr.
Upstream pressure bar g
Figure 4: FMPRV 41 Sizing (Steam application)
7
FMPRV41
3.6.2. How to Use the Chart: (for air application)
3
Capacities are given in cubic decimeters of free air per second (dm /s). The use of
thecapacitychartcanbebestexplainedbyanexample.
3
Required,avalvetopass100dm /soffreeairreducingfrom12bargto8barg.
Find the point at which the curved 12 bar g upstream pressure line crosses the
horizontal 8 bar g downstream pressure line. A perpendicular dropped
3
fromthis point shows that, a DN15 valve will pass approximately 120 dm /s under these
conditionsandisthecorrectvalvesizetochoose.
KV Values
The Kv values are full capacities and should be used for safety valve
sizing purpose only.
SIZE DN15 DN20 DN25 DN40 DN50
KV 2.8 5.5 8.1 17 28
For conversion Cv (UK)=Kv x 0.963
Cv (US)=Kv x 1.156
Compressed Air Capacity Chart
Upstream pressure bar g
Downstream pressure bar g
Figure 5: FMPRV 41 Sizing (air application)
8Forbes Marshall Pilot Operated Pressure ReducingValve
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