Control valve repair process

1. Open the tubing connection 

• Filter Regulator air supply
• Valve positioner air supply

• Valve positioned outlet to valve diaphragm 
• Valve positioned inlet signal 

2. Open filter regulator and valve positioned

3. Open Linkage, actuator jointed and scale pointer

4. Open yoke from valve

5. Open the valve cover

6. Clean up valve plug

7. Closed again by taking into account the possible leakage

Aux Condenser Controller Dump(Automatic Level Controller)

Aux Controller can't Dump a Condenser with separate Level Controllers for Aux Condenser. An interconnected system.

Technically we could explain it as follows.

On the Condenser Controller is Dump the Aux Valve 3 Way which serves to maintain the water level in the tank, in a condenser water shortage Aux Condenser Controller Dump will give supply to the tank (the valve in position and under/aux), otherwise in a State of full or more will in the exhaust to cascade (valve in position over/cascade). Adjustable valve position signal setting of Automatic Level Controller which has a range of 0 s/d 1.4 kg/cm2. I explained in the diagram below:

	Range Supply	Range Output	0%	25%	50%	75%	100%
ALC Filter Regulator	Max. 10kg/cm2	0 – 3 kg/cm2
ALC Difragm			0 kg/cm2	0,01499kg/cm2	0,02998kg/cm2	0,04497kg/cm2	0,05996kg/cm2	From Diferential  pressure
ALC	Max 1,4kg/cm2	0 – 1,4kg/cm2	0 kg/cm2	0,35 kg/cm2	0,7 kg/cm2	1,05 kg/cm2	1,4 kg/cm2	To valve positioner
Valve Positioner Filter Regulator	Max.     10 kg/cm2	3 kg/cm2
Valve Positioner	Max. 2 kg/cm2		0,4 kg/cm2	0,8 kg/cm2	1,2 kg/cm2	1,6 kg/cm2	2 kg/cm2	To valve Diafragm

A. The results of the Inspection system Aux Condenser Dumb Controller are:

1. Automatic Level Control

a. Filter Regulator Automatic Level Controller

-Brand: SMC

-Max. Supply: 10 MPa

-Output: 0.02 – 0,5 MPa/0-60 PSI

-MPa range 0 – 4 kg/cm2

Filter regulator for Automatic Level Controller in good condition physically and functionally.

Figure 1. Filter Regulators and Automatic Level Controller

-A Pressure Filter Regulator Gauge Automatic Level Controller

• Brand: SMC

• Scale Range: 0 – 4 kg/cm2

• Diameter: 1.65 "

• Connector Diameter: 0.4 "

• Type: rear Connector

• Condition: Good

Figure 2. Calibration Of Pressure Gauges Filter Regulator Automatic Level Controller

b. Automatic Level Controller

-Brand: Nakakita Seisakusho

-Max. Supply: 1,4 kg/cm2

-Output Range: 0 – 1,4 kg/cm2

-Condition: there are indications of leaks on device (info from the federal party II that it is reasonable, as the disposal of excess pressure on the position of the settings that have been set up)

-Supply Pressure Gauge

• Brand: NKS

• Scale Range: 0 – 3 kg/cm2

• Diameter: 2 "

• Connector: 0.5 "Diameter

• Condition:

Figure 3. ALC Pressure Gauge Supply Calibration

I. The linear, no change value when done beats

II. Results of the benchmarking with master kalibrator already not suitable are:

• Master kalibrator): 3, 0kg/cm2
• Supply Pressure Gauge ALC: 3, 2 kg/cm2

III. need replacement, because setting the determination already does not work.

-Output Pressure Gauge ALC

• Brand: NKS

• Scale Range: 0 – 2 kg/cm2

• Diameter: 2 "

• Connector: 0.5 "Diameter

• Condition:

Figure 4. Calibration Of The Output Pressure Gauge ALC

I. The linear, no change value when carried out beats.

II. Results of the benchmarking with master kalibrator already not suitable are:

• Master kalibrator: 2.0 kg/cm2
• The Output Pressure Gauge ALC): 2.2 kg/cm2

III. Need replacement, due to the setting of the make the right is not working.

2. Valve Controller

Figure 5. Filter regulators and Stationer Valve

a. Filter regulator for Valve controller

-Brand: Nakakita Seisakusho

-Max. Supply: 10 kg/cm2

-Output: 0 – 3 kg/cm2

-Condition: works well

b. The Valve Positioners

-Brand: Nakakita Seisakusho

-Supply: Max. 3 kg/cm2

-Output: 0.4 – 2.0 kg/cm2

-Signal Input: 0 – 1,4 kg/cm2

-Supply Pressure Gauge Valve Positioners

• Brand: NKS

• Scale Range: 0 – 3 kg/cm2

• Diameter: 1.65 "

• Connector Diameter: 0.25 "

• Type: bottom/side Connector

• Condition:

Gambar 6. Kalibrasi Positioner Valve Supply Pressure Gauge

I. is not linear, changed when done percussion.

II. Comparison with master kalibrator are:

• Master Kalibrator: 2.0 kg/cm2
• Supply Pressure Gauge: 1,9 kg/cm2

III. replacement because it does not need to be linear and setting the assignment was not functioning.

-Output Pressure Gauge Valve Positioners

• Brand: NKS

• Brand: NKS

• Range: 0 – 2 kg/cm2

• The Diameter of the face: 1.65 "

• Connector Diameter: 0.25 "

• Type: bottom/side Connector

• Condition:

Figure 7. Calibration Of The Output Pressure Gauge Valve Positioners

I. is not linear, changed when done percussion.

II. Comparison with master kalibrator are:

• Master Kalibrator: 2.0 kg/cm2
• Supply Pressure Gauge: 1,9 kg/cm2

III. Replacement because it does not need to be linear and setting the assignment was not functioning.

-Input Pressure Gauge Valve Positioners

• Brand: NKS

• Range: 0 – 2 kg/cm2

• The Diameter of the face: 1.65 "

• Connector Diameter: 0.25 "

• Type: bottom/side Connector

• Condition:

Figure 8. Calibration Of Pressure Gauge Input Valve Positioners

I. Is not linear, changed when done percussion.

II. Comparison with master kalibrator are:

• Master Kalibrator: 2.0 kg/cm2
• Supply Pressure Gauge: 2.1 kg/cm2

III. Replacement because it does not need to be linear and the determination of the setting already does not work.

c. The diaphragm Valve

-Brand: Nakakita Seisakusho

-Range: 0.4-2.0 kg/cm2

-Condition: works well

d. Actuator Valve and parts

Figure 9. Actuator and its parts

-Brand: Nakakita Seisakusho

-Conditions:

• Actuator Shaft is a little rusty, it needs cleanup.

• Shock/Stem Actuator connector corroded

• Nice Yoke

• Spring works fine

B. Repairs performed

a. Flashing tubing by using compressor

-Tubing from Mainline supply to ragulator,

-Tubing from the regulator to the Automatic Level Controller

-Tubing from regulators to valve Positioners

-Tubing of the output level control to automatic input valve positioned

-Tubing from the diaphragm positioned output

-Tubing from HP to tank diaphragm ALC

-Tubing from the LP tank to the diaphragm ALC

b. calibration of Pressure gauges, All in detail described above

c. Setting with ALC: Diaphragm Actuator

-Put the pressure with a range of 0-0, 05996kg/cm2 by using a Handpump/Testpump air pressure in a position ready. The range obtained from the calculation of the pressure tank as follow:

• ρ = mass of weight = 1000 kg/m³

• g = force of gravity = 9.8 m/s²

• h = height of the tank = 0.6 m

• P2 = ρ × g × h

• P2 = 1000 kg/m × 9.8 m/s² × 0.6 m

• P2 = 5880 kg/m ³ × m × m/s²

• P2 = 5880 kgmm m³/s ²

• P2 = kgm/s 5880 m² m2

• P2 = 5880 Nm m2

• P2 = 5880 Pascal

• P2 = 5.88 kilopascals = 0,852821897676 PSI = 0.0599593133244 kg/sq cm = 0, 05996kg/cm2

1 a) kilopascals = 0.1450377377 PSI (pounds per square inch)

b kilopascals) = 0.01019716213 kg/sq cm

-Sensitivity Setting on ALC with actuator kopler difragma hopes right generate the output pressure signal between 0 – 1,4 kg/cm2

-Setting valve Positioners with a calculation of the ratio between the input scale of 0 – 1,4 kg/cm2 output valve Positioners with between 0.4-2.0 kg/cm2 (according to diaphragm valve range of 0.4 – 2.0 kg/cm2).

• Comparison of scale in explained in the diagram above.

C. Repairing which has not been made

a. Cleaning the actuator

b. Checking the feasibility of 3Way valve,

c. Final Calibration by providing load pressure of the tank is a condenser in actual/charging the water.

Condition of Auxiliary Condenser Dump Valve

Condition of Auxiliary Condenser Dump Valve

Signal from the condenser gravitational pressure tank to the automatic level control is not right, necessary to test tap of the tank condenser

Pressure gauge out automatic level control signal from the input signal on the pressure gauge valve positioner is not worth the same, needs to be calibrated pressure gauge out automatic level control signal and the valve positioner input signal

Signal range of automatic level control has not ruled or open the right scale on the pressure out of the positioner to the valve diaphragm, need calibration accuracy trigger input signal with the output pressure of the positioner valve to the diaphragm valve.

Pressure gauge on the incoming supply valve positioner is not working, need replacement pressure gauge.

There are leaks air pressure in the automatic level control unit, need further improvement

 Repairing and Calibration Auxiliary Condenser Dump Valve

Data equipment as follows:

1. Automatic Level Control Filter Regulator (need to be calibrated because the effect on supply pressure effect on the sensitivity of the signal settings and setting levels)

• Brand : SMC
• Type : IW 215-02
• Max. input press : 1,0MPa
• Output press : 0,02 ~ 0,5MPa
• Pressure Gauge : SMC, range 0 – 4 kg/cm2 or 0 – 60PSI, dia 1,65”, connection 0,4” back connection type (need to be calibrated). 

2. Automatic Level Control 

• Brand : Nakakita Seisashuko
• Type
• Supply Pressure Gauge : NKS, range 0 – 3 kg/cm2, dia 2”, connection 0,5” back connection type (need to be calibrated)
• Output Pressure Gauge: NKS, range 0 – 2 kg/cm2, dia 2”, connection 0,5” back connection type(need to be calibrated) 

Positioner Valve/ Level Control Valve for Aux Condenser

3. Positioner Valve Filter Regulator (need to be calibrated).

• Brand : Nakakita Seisashuko
• Type : NS770C
• Connection : PT1/4
• Inlet pressure : 10kg/cm2(max)
• Outlet pressure : 3 kg/cm
• Not pressure gauge 

4. Positioner Valve/ Level Control Valve for Aux Condenser (need to be calibrated).

• Brand : Nakakita Seusashuko
• Type : NS 7345 D
• Loading Press : 0,2 – 1.0 Kg/cm2
• Air Supply Press: 2,4 Kg/cm2
• Output Press : 0,4 – 2 Kg/cm2
• Supply Pressure Gauge: NSK, range 0 – 3 kg/cm2, dia. 1,65”, connection 0,3”, under connection type (need to be calibrated).
• Outlet Pressure Gauge : NSK, range 0 – 2 kg/cm2, dia. 1,65”, connection 0,3”, under connection type (need to be calibrated).
• Inlet Signal Pressure Gauge: NSK, range 0 – 2 kg/cm2, dia.1,65”, connection 0,3”, under conection type (need to be calibrated). 

5. Valve

• Brand : Nakakita Seusashuko (need to be calibrated).
• Nominal Bore : 80A
• Body rating : 5
• Body Trim : MTLFC20/S.STL
• Construction : 5 K
• Rated : AB 46/ AC 36
• Serial Number : 89K3364
• Caracteristic : LTN
• Travel : 30mm
• Airless : CASCAD.TK.OPEN
• Supply press. : 2,4 kg/cm2
• Sprink Range : 0,4 – 2 kg/cm2