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Maintenance Minders

Healthy Control Valves


Mark Gimson, Singer Valve

A simple maintenance routine can help ensure trouble-free valve operation.

W
hether the control valve in your
Basic Valve Troubleshooting
system is the rst one that has
Problem Probable Cause Verification Solution
required maintenance or if you are
experienced with maintaining multiple valves in Valve will not open
Ball valves in control circuit closed (if
equipped)
Check ball valve handle positions Open ball valves

your system, some simple guidelines can help Insufficient supply pressure to inlet of Check upstream and downstream Open upstream and downstream
main valve isolation valves
keep them operating at optimal performance.
Physically checking all valves at least every Cover chamber pressure not being
discharged through pilot system
Inspect pilot system
Correct as suggested in trouble
shooting section of Valve IOM

12 weeks is important, assuming that everything Diaphragm assembly not operating Clean or replace damaged parts as
Inspect diaphragm assembly
is running ne in the system. his inspection is properly (eg: stem binding guides) necessary

to look for any leaks in the tubing. he pres- Flow stabilizer not properly adjusted for Check that the adjustment screw is not Correct as suggested in trouble
control valve start-up turned all the way out shooting section of Valve IOM

sure gauges should be checked to ensure that the


valve is performing as designed. he inspection Problem Probable Cause Verification Solution

should make sure that nothing looks abnormal. Valve will not close
Cover chamber pressure not being
discharged through pilot system
Inspect pilot system
Correct as suggested in trouble
shooting section of Valve IOM
If something is wrong, always ensure that
Disconnect supply line at cover
the correct instruction manual for the valve is Strainer is clogged
chamber, check for flow
Remove and clean strainer

on hand. Today, many manufacturers have these Resilient disc is damaged Inspect resilient disc Flip the disc over or replace

available on their websites. As a note of cau-


Diaphragm failure (valve flow under the Pull cover, inspect diaphragm for
tion, valves are under pressure and care should seat) damage
Replace diaphragm

be taken to bleed pressure o the valve before Obstruction


Bleed bonnet until water stops flowing
to confirm diaphragm ok.
Disassemble valve and remove
blockage
taking any valve apart. (For example, in a 6-inch
valve with 100 psi in the line, at least 2,800 Problem Probable Cause Verification Solution

pounds of force is trying to push the cover o


Valve will not modulate Air in control circuit or pilots Bleed all air
the valve, so safety rst.) Regular maintenance
will ensure that valves remain healthy. Pilot is not adjusted correctly
Turn adjusting screw on pilot and
check response
Re-adjust pilot

Opening and/or closing speed controls Turn adjusting screws and check Adjust opening and/or closing speed
not adjusted correctly response needle valves
Pilot System Shut-Off Ball
Operating conditions do not fall within 1. Check tag on pilot for proper spring 1. Replace with pilot of correct spring
Valves the spring range of the pilot range range

2. Adjust the screw all the way in and


Exercise the three isolating cocks on the main all the way out to check for pilot
2. Replace with pilot of correct spring
range
response
valvelocated in front of the strainer on the 3. Read gauges/meters to ensure 3. Change operating conditions to
proper operating conditions desired range or change pilot set-point
upstream side of the valve, on the valve bonnet
on top of the valve and below the pressure-
reducing pilot on the valve downstream. Giving the isolating counter-clockwise. Otherwise, bleed the air from the high
cock a momentary quarter turn to the closed position, then point of the valve. If the water runs clear and no air bubbles
returning it to open is sucient. Open position is when the are seen in the glass of the position indicator, close the bleed
handle of the isolating cock is in-line with its body. cock. If air is present (the water will be foamy white) run the
water until the air is gone.
Air in the Pilot System
Air is the primary enemy in the pilot system because it will Strainers
give false readings and cause poor valve operation. Bleed air Pilot systems rely on a supply of clean water, usually taken
from the valve bonnet. If the valve is equipped with a posi- from the inlet of the valve. Either external or ush clean
tion indicator, on top of the position indicator is a bleed strainers can be installed. If an external strainer is installed, a
cock. Open the bleed cock slightly by turning the handle simple occasional ush is a good idea. Normally, three to ve
seconds is sucient to clean the strainer screen.

40 JULY 2011 www.pump-zone.com PUMPS & SYSTEMS


Experience will dictate if it needs to be ushed longer
than this. A number of water utilities install a ball valve on the
ushing plug of the strainer, allowing operators to give a short
ush every time they are in the valve station. A plugged strainer
can cause a valve to remain and result in major problems.

Reducing Pilot
Ensuring that the control valve pilot is operational is a simple
task. As a cautionary notebefore making any pressure
adjustmentensure that this is acceptable for the system and
that any SCADA alarm controls that may be triggered are
turned o. To exercise the pressure-reducing pilot, loosen the
lock nut on the pilot adjusting screw and turn clockwise to
increase the pressure 5 psi above the normal set point.
Check that the downstream pressure gauge is tracking
the adjustments made. hen turn the adjusting screw counter-
clockwise to reduce the pressure to 5 psi below the set point.
Finally, turn the adjusting screw clockwise to increase the pres-
sure back to the original set point, and tighten the lock nut.
If the pressure gauge does not move as you adjust the screw,
either the gauge is bad or a pilot should be examined.

Main Valve Flows


Just as we all like to take our cars out for an occasional run to
give them a good workout, valves also need to see some decent
ow occasionally. During a major re is not a good time to circle 137 on card or go to psfreeinfo.com
nd out that the main valve will not open fully. First, get some
ow through the valve station to open the peak demand/re- In-Stock Parts Ready To Go
ow valve. (his could be as simple as opening a hydrant on FOR ALL BRANDS OF PROGRESSIVE CAVITY PUMPS
the outside of the valve station).
Our large inventory of spare parts
If a station or vault has two valves in parallel, with one is available and ready for immediate
valve handling normal ow and the other handling large or delivery at Liberty Process Equipment,
re ows, the larger valve should be operated for a minimum Inc. Our complete selection includes
the most common progressive cavity
of ve minutes. his can be done by closing the isolating cock pump design models, sizes and
on the downstream side of the smaller valve pilot system (the materials in service in the USA.
cock below the pressure-reducing pilot). his will close the The genuine quality replacement
parts meet or exceed the
smaller valve and cause the larger valve to open and allow ow performance standards.
into the system. he above four steps can be followed for the
Call, fax or contact us online to
larger valve while it is in owing mode. order your pump parts or service.
his is also a good time to ensure that the main line con-
trol isolating valves are in good working order. he gate or Same Day Deliveries
buttery valves used to isolate the control valve should also be In-Stock Inventory
checked, in case they are needed. Following this routine can Return/Repair Service The #1 Source
help provide years of trouble-free service. Full Warranty for Progressive
P&S Complete Pump Packages Cavity Pumps!
Complete Seal Flush Systems
Mark Gimson is a certified trainer for ISO 9001
the B.C. AWWA, New York AWWA and Auto Cad Drawings
Virginia Rural Water. He also hosts Levels Full Technical Submittals
1 and 2 Control Valve Training Courses for Wobble Stator Pump &
Parts are also in stock
the Environmental Operator Certification Liberty Process
Equipment, Inc.
Program. He runs operator training sessions 2525 S. Clearbrook Drive
around the world with Singer Valve and has been with Arlington Heights, Illinois 60005-4623
Phone: 847-640-PUMP (7867) Fax: 847-640-7855
Singer Valve as account sales manager since 2002. He can be E-mail: info@libertyprocess.com
Web site: www.libertyprocess.com
reached at mgimson@singervalve.com or 604-594-5404.
circle 133 on card or go to psfreeinfo.com
PUMPS & SYSTEMS www.pump-zone.com JULY 2011 41

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