Watts Flowrite II 596 SI - Type SI 2-Way Installation guide

Watts Flowrite II 596 SI - Type SI 2-Way Installation guide
®
UTILITY IRON BODY CONTROL VALVES
Form TI 596SI v2
TECHNICAL INSTRUCTIONS
Iron Body Series 596 SI
UTILITY IRON BODY SERIES
DESCRIPTION
The rugged Powers Type SI (single seat iron body) valve is primarily used for
steam and water modulating applications with moderate pressure drops. The
equal percent plug provides excellent control characteristics and is more
tolerant of oversizing than linear or quick-opening plugs. The SI’s control and
close off characteristics are particularly well-suited to commercial water
heaters, boilers, and industrial utility applications. The SI valve is available
with the Powers 46 in.2. and 100 in.2. actuators. Actuator selection depends
on valve size and flowing system pressure drop across the valve.
SPECIFICATIONS
VALVE
Body Sizes:
Body Material:
End Connections:
Trim:
Packing:
Seat Leakage:
Cv Range:
Rangeability:
Characteristics:
Maximum Pressure:
Max. Differential Press.:
Temperature Range:
ACTUATOR
Housing Construction:
Diaphragm Construction:
Diaphragm Area:
Maximum
Pressure and Temp.:
Ambient Shipping Limits:
Ambient Operating Limits:
Air Connection:
Position Indication:
Mounting:
2 1/2" – 6"
Cast Iron (per ASTM A126-93 Class B)
125 # Flanged (per ANSI B16.1–1993)
Bronze Composition Disc or Stainless Steel Teflon disc
Spring loaded TFE packing
ANSI Class IV < 0.01% leakage
56-350
75:1
Equal Percent
200 psi @ Temp. <150°F
50 psi for Bronze, 100 psi for Stainless Steel
40° – 281° F
Normally-closed 596SI with 46 in. 2 actuator shown
Sizes
2 1/2”
3”
4”
5”
6”
Actuators Available
46 in.2 or 100 in.2 Diaphragm
46 in.2 or 100in.2 Diaphragm
46 in.2 or 100 in.2 Diaphragm
100 in.2 Diaphragm
100 in.2 Diaphragm
TABLE OF CONTENTS
Die cast aluminum
Replaceable molded neoprene
46 in.2, 100 in.2
35 psi and 200°F
- 40 to 220° F
- 20 to 220° F
46 in.2 1/4” NPT
100 in.2 1/8” NPT
1/8” increments
In any upright position with actuator head
above 45° of the center line of the valve
body. Actuator head may be swiveled to any
convenient position.
Description............................................................................
1
Specifications............................................................................... 1
Application Information ............................................................... 2
Theory of Operation..................................................................... 2
Valve Sizing and Selection ............................................................. 3-4
Close Off Data .......................................................................... 5
Temperature/Pressure Ratings .................................................... 5
Dimensional Data ........................................................................... 6
Installation .................................................................................... 7
Maintenance ................................................................................. 7
Ordering Information....................................................................... 8
CALIFORNIA PROPOSITION 65 WARNING
WARNING: This product contains chemicals
known to the State of California to cause cancer
and birth defects or other reproductive harm.
(California law requires this warning to be given
to customers in the State of California.)
For more information: www.wattsind.com/prop65
Page 2
Form TI 596SI v2
APPLICATION INFORMATION
Flowrite II Single Seated SI Valves are generally recommended for steam,
hot water and chilled water applications. They are particularly suited for
installations requiring tight shutoff and quick response.
THEORY OF OPERATION
On normally closed valve assemblies, the valve stem will start to open
whenever the control air pressure applied against the actuator diaphragm
area and the lower housing exceeds the holding force of the springs. A
further increase in control air pressure will initiate a continued upward
travel of the valve steam until the valve has fully opened.
Figure 1 B- Push to Close
Figure 1 A- Push to Open
When the valve is at its’ "full open" position there is maximum flow
potential through the valve. At this position, valves are compared based
on flow that is directly related to the valve flow coefficient (see Cv
equations in table 1). The 596 SI valves are designed so that equal changes
in valve stem position provide equal percentage changes in existing flow
through the valve. This is otherwise know as an equal percent valve which
has a typical flow curve (figure 2) that can be used to determine flow based
on stem position, pressure drop, and Cv. As you can see from the graph,
these valves are less sensitive at the low end, which gives both high
rangeability and high flows. These types of valves are used extensively to
compensate for fluctuating system requirements (pressure, flow, load, etc.).
Valve actuators equipped with positioners provide feedback for enhanced
control strategies and, as an example, are required for valve staging. Valves
with positioners can utilize full control air pressure at any point in stem
travel to initiate stem movement or to maintain stem position. However,
the actuator springs still provide the necessary force to move the stem in
the opposite direction. Use of a positioner will tend to provide faster
response and ensure repeatability of stem position regardless of the load on
the actuator. However, in a system where available pressure and flow
requirements are relatively consistent, control valves can usually perform
adequately without a positioner.
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
The air pressure change to initiate full stem travel is known as the spring
range or span. This spring span is factory set and will vary slightly as the
pressure drop across the valve changes.
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Percent Flow
On normally open valve assemblies, the stem will start to close whenever
the control air pressure applied against the actuator diaphragm area and
upper housing exceeds the holding force of the springs. A further increase
in control air pressure will initiate a continued downward travel of the
valve stem until the valve has fully closed.
Fully
Closed
Percent Travel
Figure 2
Fully
Open
Form TI 596SI v2
Page 3
VALVE SIZING AND SELECTION (WATER)
The sizing of a valve is very important if it is to render good service. If it
is "undersized", it will not have sufficient capacity. If it is "oversized", the
controlled variable may cycle, the trim can be exposed to excessive wear or
wire drawing, and you could expect reduced valve life. To help select the
right valve, it is important to understand your application and its variables
(controlled fluid, temperatures, pressures, min/max load, etc.). When
your system variables are known and you have calculated actual demand, it
is possible to select the right Powers valve for your application. The
following technical data should help you in selecting a valve for your water
control applications. For fluid applications other than water, contact
Powers’ application engineering.
On/Off Control:
These types of applications are normally line sized to reduce pressure drop
and pump size. In these applications it is important to verify valve seat
leakage will not result in system overheat or damage. If this is a concern, it
is necessary to take precautions to alleviate this potential problem.
Proportional Control:
In applications where the close-off pressure at the valve is below 20psig,
use a pressure drop of 5psi.
In applications where the close-off pressure at the valve is above 20psig, it
is generally recommended to take 25-50% of the system pressure drop at
the control valve to maintain good valve/system performance. Certain
applications can successfully utilize lower pressure drops across the valve
(5-25%) if system fluctuations are kept to a minimum. If not, the valve is
considered oversized it will not effectively throttle until it is nearly closed
thereby resulting in poor control.
Refer to the following table for flow….
Table - 1 Water Capacity in Gallons Per Minute
Valve
Size
2.5
3
4
5
6
Cv
Rating
65
85
145
235
350
5
145
190
324
525
783
10
206
269
459
743
1107
20
291
380
648
1051
1565
Differential Pressure (∆P in psi)
30
40
50
60
356
411
460
503
466
538
601
658
794
917 1025 1123
1287
1486 1662 1820
1917
2214 2475 2711
70
544
711
1213
1966
2928
80
581
760
1297
2102
3130
90
617
806
1376
2229
3320
100
650
850
1450
2350
3500
125
727
950
1621
2627
3913
CAVITATION LIMITATIONS ON VALVE PRESSURE DROP
A concern in high temperature water systems is the potential for cavitation/flashing, which is caused by the downstream pressure being lower than that of the
vapor pressure of the fluid. This basically causes the water to "boil" and can result in reduced flow/capacity, excessive noise, vibration, wear and should be
avoided if possible. Use the following equation to estimate the maximum allowable pressure drop across the valve:
Table-2 Vapor Pressure of Water Table
Pmax = 0.5 (P1 – Pv)
Where:
Pmax = Maximum allowable pressure drop
P1 = Absolute inlet pressure (psia)
Pv = Absolute vapor pressure (refer to psia - Table 2)
Absolute pressure = gage pressure + 14.7
Water
Temp.
(°F)
Vapor
Pressure
(psia)
Water
Temp.
(°F)
Vapor
Pressure
(psia)
40
50
60
0.12
0.18
0.26
140
150
160
2.89
3.72
4.74
70
80
90
0.36
0.51
0.70
170
180
190
5.99
7.51
9.34
100
110
120
0.95
1.28
1.69
200
210
220
11.53
14.12
17.19
130
2.22
230
20.78
Page 4
Form TI 596SI v2
VALVE SIZING AND SELECTION (STEAM)
Steam:
One can use the same reasoning for selecting a valve in steam applications
as would be used for water applications. Once again, pressure drop
selection is a major determining factor for good control and system
performance. In general, for steam applications, the largest possible
pressure drop should be taken without exceeding the critical pressure ratio.
Proportional Control:
For pressures less than 15 psig, use an 80% of the gauge inlet pressure as a
differential. For pressures above 15psig, use 50% of the absolute inlet
pressure. In those cases where the required Cv falls between two valves,
select the larger size.
One may be concerned about steam entering a heating coil at 0 psig when
these large pressure drops are taken at the valve. However, flow will
continue as the pressure in the coil will drop to vacuum pressures due to
the steam condensation. It is essential to use proper condensate piping
and steam trapping in these applications.
On/Off Control:
These types of applications are normally line sized to reduce pressure drop.
In these applications it is important to verify valve seat leakage will not
result in system overheat or damage. If this is a concern, it is necessary to
take precautions to alleviate this potential problem.
Table - 3 Steam Capacity in Pounds Per Hour
Steam Inlet Pressure (psig)
Pressure Drop
Across Valve (psi)
Valve
Cv
Size
Rating
2
0.5
5
1
2
10
1
2
3
4
5
2
4
6
8
10
2.5
65
554
777
1082
846
1181
1426
1624
1790
1329
1839
2203
2484
2709
3
85
724
1016
1415
1106
1544
1865
2124
2341
1738
2405
2880
3249
3543
4
145
1235
1733
2413
1887
2634
3182
3623
3993
2965
4103
4914
5542
6044
5
235
2002
2809
3911
3058
4268
5157
5872
6472
4805
6650
7964
8981
9796
6
350
2981
4184
5825
4555
6357
7681
8746
9639
7156
9905
11861
13376
14589
Steam Inlet Pressure (psig)
Pressure Drop
Across Valve (psi)
Valve
Cv
Size
Rating
15
25
50
(max)
(max)
(max)
3
6
9
12
15
5
10
15
20
10
20
30
2.5
65
1776
2443
2907
3255
3523
2633
3596
4242
4705
4717
6385
3
85
2322
3195
3802
4257
4607
3443
4702
5548
6152
6168
8350
9747
10017
4
145
3961
5450
6485
7262
7858
5873
8022
9464
10495
10522
14243
16628
17088
5
235
6419
8834
10511
11770
12736
9518
13001
15338
17010
17053
23084
26949
27694
6
350
9561
13156
15654
17529
18968
14176
19363
22844
25334
25397
34380
40137
41247
Steam Inlet Pressure (psig)
Pressure Drop
Across Valve (psi)
Valve
Cv
Size
Rating
75
100
25
(max)
35
45
10
7660
125
(max)
10
7454
32.5
25
36
58
(max)
20
50
70
2.5
65
5618
8481
9704
10615
6394
9758
11390
13610
9832
14619
16526
3
85
7347
11090
12690
13882
8361
12760
14894
17797
12857
19117
21611
4
145
12533
18918
21647
23681
14263
21767
25408
30360
21932
32611
36866
5
235
20312
30661
35084
38379
23116
35277
41178
49205
35546
52853
59748
6
350
30251
45665
52252
57160
34428
52541
61329
73284
52940
78717
88987
Steam Inlet Pressure (psig)
Pressure Drop
Across Valve (psi)
Valve
Cv
Size
Rating
150
175
(max)
200
(max)
(max)
25
50
83
50
70
95
50
75
108
2.5
65
11908
16134
19521
17518
20088
22437
18800
22254
25431
3
85
15572
21098
25527
22908
26269
29340
24585
29102
33256
4
145
26563
35990
43546
39078
44812
50051
41939
49644
56731
5
235
43051
58329
70574
63334
72627
81117
67971
80457
91944
6
350
64118
86873 105111
94327
108167
120813
101233
119830
136937
Form TI 596SI v2
Page 5
CLOSE OFF DATA
In all cases requiring greater close off, a preload adjustment is possible. Consult with factory for your application.
Close Off Ratings for Normally Closed Valves
Close Off ( ∆ P in psi)
Signal-to-Actuator
Valve Size
Actuator
(in)
5
(in2)
46
100 (1U)
46
100 (1U)
46
100 (1U)
100 (1U)
3-15 PSI
26
96
15
63
6
32
19
1-17 PSI
53
125
34
92
16
48
29
0-30 PSI
106
125
70
92
36
48
29
6
100 (1U)
12
19
19
2.5
3
4
(Positioner)
Close Off Ratings for Normally Open Valves
Close Off ( ∆ P in psi)
Signal-to-Actuator
Valve Size
(in)
2.5
3
4
5
6
Actuator
(in2)
46
100 (1L)
46
100 (1L)
46
100 (1L)
100 (1L)
100 (1L)
3-15 PSI
49
125
32
90
15
48
29
19
(Positioner)
0-30 PSI
125
125
125
125
77
125
105
72
1-17 PSI
86
125
58
118
30
64
39
26
169 psig
TEMPERATURE/PRESSURE RATINGS
Maximum Media
Temperature
281¡F
300
Temperature — ¡F
In all cases, do not exceed the temperature/pressure
ratings of the valve (see figure 3). Acceptable region is
shown by the shaded area.
250
200
150
596SI
100
Minimum Media
Temperature
40¡F
50
50
150
100
200
Pressure — psig
Figure 3 - Temperature and Pressure Ratings
Page 6
Form TI 596SI v2
DIMENSIONAL DATA
Table-4 Dimensions for 596 SI Series Valves
Nominal Pipe Size
3”
4”
5”
A
STROKE
8.500
0.938
2-1/2”
9.500
0.938
11.500
0.938
13.000
1.938
14.000
1.938
6”
B1
B2
C1
C2
D
E
F
G
Valve Weight (lbs)
Weight w/46”
Weight w/100”
4.125
3.500
4.125
3.875
10.375
10.000
16.625
10.313
52.00
65.00
77.00
4.125
3.750
4.375
4.250
10.375
10.000
16.625
10.313
65.00
78.00
90.00
5.063
4.500
5.000
4.875
10.375
10.000
16.625
10.313
90.00
103.00
115.00
6.750
5.000
5.500
5.500
N/A
N/A
19.000
10.313
150.00
N/A
180.00
7.375
5.500
6.500
6.375
N/A
N/A
19.000
10.313
225.00
N/A
255.00
Figure 4 - 2-1/2” to 6” Valve Bodies
G
E
100" Actuator
F
46" Actuator
D
C2
Normally
Open Valve
C1
Normally
Closed Valve
B1
B2
A
Table - 5 Flange Detail for American Standard 125 lb. Cast Iron Pipe Flanges
Valve
Size
Flanges
Flange
Diameter
Flange
Thickness
Drilling
Diameter of
Bolt Circle
A
B
C
D
2-1/2"
3"
4"
5"
6"
7"
7-1/2"
9"
10"
11"
11/16"
3/4"
15/16"
15/16"
1"
5-1/2"
6"
7-1/2"
8-1/2"
9-1/2"
3/4"
3/4"
3/4"
7/8"
7/8"
Diameter of
Bolt Holes
Bolting
Number
of Bolts
Diameter
of Bolts
E
4
4
8
8
8
5/8"
5/8"
5/8"
3/4"
3/4"
E
Figure 5
D
B
C
A
Length of
Machine
Bolts
2-1/2"
2-1/2"
3"
3"
3-1/4"
Form TI 596SI v2
Page 7
INSTALLATION
Inspection
Inspect the package for damage. If damaged, notify the appropriate carrier
immediately.
If undamaged, open the package and inspect the device for obvious
damage. Return damaged products.
Requirements
• Pipe wrenches
• Flange gaskets, bolts/nuts
• Installer must be a qualified, experienced technician
CAUTION!
• Install the valve with the flow in the direction of the flow arrow.
• Do not exceed the ratings of the device.
• Avoid locations where excessive moisture, corrosive fumes, or
vibration are present.
Mounting/Orientation
1. The valve should be mounted in a location that is within the
ambient limits of the actuator. When selecting a location, allow
sufficient room for valve linkage, actuator, and other accessories
and for service of the product.
2. The preferred mounting position for the valve is with the valve
stem vertical above the valve body. Avoid mounting the valve so
that the valve stem is below horizontal.
3. On steam applications where the ambient temperature
approaches the limit of the actuator, the valve stem should be
mounted 45° from vertical.
Figure 6 - Installation of
Flanged End Valves
Valve
Body
Gasket:
Supplied
by Others
Companion
Flange
Flanged Connection
The 596SI series flanged valve bodies conform to American Standard 125
Lb. Cast Iron Pipe Flanges. The companion flanges (not provided) should
be the same specification as the valve. The 125 lb. flanges have plain flat
faces and should not be bolted to a raised faced flange.
1.
2.
3.
4.
All parts should be clean to assure the best results.
The pipe with the companion flanges installed should be
properly supported and aligned. Be sure the companion flange is
flush with the face of the valve body flange and lined up
squarely.
Use a gasket material (not provided) that is recommended for
the medium being handled.
CAUTION! Do not apply pipe dope to the valve flange, gasket,
or companion flange.
See Figure-5 for flange and flange bolt details.
Figure-6 shows the proper way a flanged valve should be
mounted.
MAINTENANCE
Regular maintenance of the total system is recommended to assure sustained performance. See Table-6 for maintenance kit part numbers.
Table - 6 Maintenance Kits for 596SI Valves
Valve Description
Replacement
Packing Assembly
2.5 Normally Closed
596 Pack
3 Normally Closed
4 Normally Closed
5 Normally Closed
6 Normally Closed
2.5 Normally Open
3 Normally Open
4 Normally Open
5 Normally Open
6 Normally Open
* Kit includes replacement packing and stem & plug assembly.
Water System Maintenance
All systems are susceptible to valve and system problems caused by improper
water treatment and system storage procedures. These guidelines are
provided to help avoid valve and water system problems resulting from
improperly treated water or storage procedures and to obtain maximum life
from the valves.
Durability of valve stems and packings is dependent on maintaining nondamaging water conditions. Inadequate water treatment or filtration can
result in corrosion, scale, and abrasive particle formation. Scale and
Replacement
Gaskets
Valve Repair Kit*
596250G
596300G
596400G
596500G
596600G
596250G
596300G
596400G
596500G
596600G
SIGOBCTK
SIHOBCTK
SIJOBCTK
SIKOBCTK
SILOBCTK
SIGOBXTK
SIHOBXTK
SIJOBXTK
SIKOBXTK
SILOBXTK
particulates can result in stem and packing scratches and can adversely affect
packing life and other parts of the hydronic system.
To maintain non-damaging conditions, follow these guidelines:
• Clean the system prior to start up.
• Use filtration equipment where needed.
• Properly store off-line systems and monitor water treatment results.
• Follow the advice of a water treatment professional.
Page 8
Form TI 596SI v2
ORDERING INFORMATION
596– S
Size
2 1⁄2″
3″
4″
5″
6″
I
Order Code
250
300
400
500
600
End Connections
125# Flange
F
Valve Trim
Bronze
Stainless Steel
B
S
Action
Fail Open (Air-to-Close)
Fail Closed (Air-to-Open)
X
C
Packing
Teflon
T
ACCESSORIES
SELECT CODE
(see below)
ACTUATOR
SELECT CODE
(see below)
ACTUATOR SELECT CODE
CODE
PNEUMATIC DIAPHRAGM ACTUATORS
46
46 Sq. In., 1” Max Valve Stroke with Stainless Steel Springs,
adjustable start w/ 7 ~ 12 lb. Fixed span.
4X
46 Sq. In., 1” Max Valve Stroke with Extended Springs
(requires positioner), adjustable start w/22 lb. span.
1U
100 Sq. In; 8-13 psi Spring Range, (Normally Closed Valves)
1L
100 Sq. In; 3-8 psi Spring Range, (Normally Open Valves)
ACCESSORIES SELECT CODE
CODE
IS
TS
US
DESCRIPTION
Bellofram 1000 I/P’S
3–15 psi
1–17 psi
3–27 psi
ES
CONTROL/AIR TYPE 900X I/P
0–30 psi
BS
UTILITY POSITIONER AND I/P
4–20 mA
PS
RS
SS
UTILITY POSITIONER
3-15 psi
3-9 psi
9-15 ps
OS
NO ACCESSORIES
No Accessories
I/P TRANSDUCERS
The “standard” 3-15 psi signal was originally designed as a transmission
signal, not a valve actuation signal. The Fluid Controls Institute (in
Standard 87-2) has recommended that a 1–17 psi air signal range be used
when directly actuating a control valve without a positioner. Powers
concurs with this recommendation, and therefore, offers a 1–17 psi I/P
transducer and a 0–30 psi I/P transducer and the Accritem pneumatic
controller for maximum close-off. 3-15 psi I/P transducers should be used
in conjunction with positioners.
POSITIONERS
Positioners are used for one or more of the following reasons:
1) To split range valves.
2) To eliminate unwanted valve movement caused by line pressure
variations
3) To minimize the effects of “stick-slip”
4) To speed response time and/or
5) To increase close-off rating when I/Ps are used.
© 2004 Powers, a division of Watts Water Technologies, Inc.
USA Phone: 1.800.669.5430 • Fax 1.847.824.0627
Canada Phone: 1.888.208.8927 • Fax 1.888.882.1979
www.powerscontrols.com
Form TI 596SI v2 0403
EDP# 6512248
Printed in U.S.A.
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