Ratermann Manufacturing, Inc. Customer Service 1-800-264-7793 y Email [email protected] y Order Online at Web Store www.rmiorder.com 34A-31 GRPV SERIES: RESIDUAL PRESSURE CYLINDER VALVES WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov S H E R W O O D M A S T E R D I S T R I B U T O R DISASSEMBLY OF VALVE 1. Place the valve assembly into a vise or similar holding fixture, taking care not to damage the inlet or outlet threads. The holding fixture must securely grip the valve body on the wrench flats so that no damage is done to the internal bores, external threads, out- let, or pressure relief device. 2. Chamber a. Using a 13 mm socket, remove the handwheel nut from the handwheel by turning it counter clockwise. b. Remove the handwheel from the stem square. c. Using an 11/16” socket wrench or hex box wrench, remove the bonnet by turning it counter clockwise. The stem subas- sembly with o-ring and back-up o-ring may remove with the bonnet. If not, remove the stem subassembly from the valve after the bonnet. d. Being careful not to scratch the bonnet sealing surface in the valve body, use a square drive to remove the lower plug from the valve chamber, by turning it counter clockwise. 3. Pressure Relief Device a. Being careful not to scratch the sealing surface of the valve body, remove the pressure relief device by turning it counter clockwise using a 5/8” hex box wrench or socket. INSPECTION OF VALVE AND COMPONENTS 1. Valve Body a. Inspect the valve body chamber for dirt, debris or damage. Where possible, blow out the valve body chamber using clean, dry, Compressed Air or Nitrogen to remove any foreign particles. b. If the valve body is damaged, do not attempt to repair. Order a new valve assembly. 2. Components a. Always discard the bonnet and stem subassembly and the lower plug. Order replacement parts. NOTE: The lower plug replacement must correspond with the valve body and its relative application. For example, standard valves have a .125” or .156” through hole in the body which uses a nylon seat diameter that is relative to that size, part number 1400-40. Carbon dioxide and manifold valves – except for oxygen – have a .272” through hole in the body and use a nylon seat that is relative to that size, part number 1400-40A. b. Handwheels should only be reused if in good condition. Discard handwheels if damaged. c. Inspect the pressure relief device threads for damage. Inspect the rupture disc and the webbed washer for scratches. Discard this component if damaged and order replacement parts. ASSEMBLY OF VALVE 1. Chamber a. Apply 3 dabs of lubricant around the perimeter of the lower plug threads, approximating the size of a pencil eraser for each. Locate lubricant toward the lower most threads closest to the crimped seat but using care not to get lubricant on the nylon seat. NOTE: Use Turmoxygen LC027 lubricant for oxygen service. Use Christo-Lube MCG-111 lubricant for all other gas applications. b. Being careful not to damage the bonnet sealing surface in the valve body, install the new lower plug into the chamber, seat first and tighten using a square drive until it is fully seated. c. Engage the new bonnet and stem subassembly into the valve body and hand tighten by turning clockwise. Rotate stem square until it becomes engaged in the lower plug. d. Using an 11/16” hex torque wrench, tighten the bonnet to 50-60 ft. lbs. NOTE: A properly calibrated torque wrench must be used. Over torquing will damage the bonnet. e. Place the handwheel over the stem square. Thread the handwheel nut onto the stem thread and tighten to 15-35 in. lbs. f. To ensure free and smooth operation, open and close the valve several times by turning the handwheel. 2. Pressure Relief Device (PRD) a. NOTE: Refer to CGA S-1.1 latest edition to select the correct pressure relief device type according to the cylinder pres- sure and application. b. Thread the proper pressure relief device on the PRD port until hand tight. c. Using a 5/8” socket and a calibrated torque wrench, tighten the PRD to 25-35 ft. lbs. Over torquing will damage the PRD. TESTING OF ASSEMBLED VALVE 1. Thoroughly test each repaired valve assembly by inserting and tightening the valve assembly into a cylinder or suitable test fixture. 2. Pressurize the valve assembly with an inert gas to the working pressure of the cylinder of intended use. 3. With outlet suitably plugged, open the valve assembly by turning the handwheel counter clockwise. Using leak detection solu- tion or equipment, check the bonnet, stem, and PRD for leaks. 4. Close the valve assembly by turning the handwheel clockwise. Remove the outlet plug and check for seat leakage through the outlet using proper leak detection solution or equipment. 5. If any leakage is detected, in the open or the closed position, the necessary repairs must be made before using the valve as- sembly. REPAIR INSTRUCTIONS FOR GRPV SERIES RESIDUAL PRESSURE VALVES Industrial Gas Valves GRPV Series: Repair Instructions
