Cashco POSR-2 - Manual (Page 12)

IOM-POSR-2 12
57. Rig the reassembled main valve (MV) for
over head hoisting. Re move temporary duct
tape. Lift and remove from vise.
E. Joining:
1. Place main valve body (1) into vise, oriented
to allow correct positioning of pilot valve (PV)
and interconnecting piping. See Figures 6, 7
& 8.
SECTION VII
VII. LEAK TESTING
A. General:
1. A POSR-2 is a metal-to-metal seated de sign
with standard hardened trim in main valve
(MV) and pilot valve (PV).
2. Both pilot valve (PV) and main valve (MV)
are of a fl ow-to-close design, and can be seat
leakage tested without extensive setup.
3. There are two design pressures for a
POSR-2; one for the higher inlet pressure
zone, and another for the lower outlet pres-
sure zone.
Recommended Test Pressures –
Inlet: 100 psig (7.0 Barg).
Outlet: 15 psig (1.03 Barg) for Pilot with
5–15 psig (0.34–1.03 Barg) spring
range.
Outlet: 40 psig (2.7 Barg) for Pilots with
(Cont.) 15–150 psig (1.03–10.3 Barg) spring
ranges.
B. Seat Leakage – Pilot Valve (PV):
1. Separate pilot valve (PV) from main valve
(MV), see Section VI, subsection B.
2. Install a temporary 1/4" - NPT pipe plug into
the (P
Int
) connection.
3. Install a hose fi tting and hose into the 1/2"
FNPT connection port of the pilot valve (PV)
body (1). Place other “open” end of the hose
at the bottom of a glass container having
approximately 1/8" (3 mm) of water depth.
NOTE: Pilot valve (PV) and glass container
should be at about the same elevation.
4. Relax the range spring (15) by rotating the
ad just ing screw (19) CCW (viewed from above
ad just ing screw) until fully loose. Keep track of
the num ber of rev o lu tions in the box below:
2. Place thread sealant on threaded ends of pipe
nipples (19, 29 and 30) and on street elbow
(27). Ensure that excess material is removed
and not allowed to enter the regulator upon
start-up.
3. Reconnect pilot valve (PV) to main valve (MV)
using appropriate pipe nipple(s) and fi ttings
(19, 26, 27, 28, 29 & 30). Using a pipe wrench,
ensure that all connections are tight and in
proper orientation.
4. Reinstall interconnecting tubing (21) be tween
main valve (MV) cylinder head (4) and pilot
valve (PV) body (1).
5. Leak test the combined unit per Section
VII.D.
No. of Revolutions adjusting screw ro tat ed:
__________________
Main Valve
Body Size
Torque
in (DN) ft-lbs (N-M)
1" (25) 25–30 (33-40)
1-1/2" (40) 25–30 (33-40)
2" (50) 70–75 (94-101)
3" (65) 100–110 (135-149)
4" (100) 150–160 (203-216)
5. Connect temporary air supply with in-line ad-
just able airset regulator to P
2
outlet of pilot.
Slow ly pres sur ize the pilot valve (PV) while
ob serv ing the jar with water. Bring pres sure
to 50 psig (3.4 Barg). Wait a min i mum of fi ve
min utes. Ob serve for leak age of bubbles in the
water jar. If the number of bub bles is greater
than one (1) per minute, the leakage is at the
point where trim re place ment is rec om mend ed.
(Rec om mend pres sure in teg ri ty test per sub-
section D. herein.)
6. Remove leak test apparatus. Reconnect pilot
valve (PV) to main valve (MV) using ap pro -
pri ate pipe nipples, tubing and fi ttings (19, 20,
26, 27, 28, 29 & 30). Ensure all connections
are tight and in proper orientation.