Cash Valve TYPE G-4 PILOT OPERATED PRESSURE REDUCING REGULATOR FOR STEAM, AIR AND GASES. ISSUED - MARCH 2001 CAVMC-0512-US-0208 ISO 9001 Certified
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1 Cash Valve TYPE G-4 PILOT OPERATED PRESSURE REDUCING REGULATOR FOR STEAM, AIR AND GASES ISSUED - MARCH 2001 CAVMC-0512-US-0208 ISO 9001 Certified
2 TYPE G-4 DESCRIPTION FIG Bronze FIG Bronze FIG 2044 FIG 2046 & Stainless Steel & Stainless Steel Cast Iron Cast Steel SIZE RANGE Ins MAXIMUM INLET 1/ 2 3/ / / / 2 3/ / / / / 2 3/ / / / PRESS/TEMP Pressure/Temperature ratings are strictly in accordance with the table below. RATINGS REDUCED 5*-300 5*-300 5* PRESSURE air & gases -175 RANGE psig 5*-175 steam FLANGES ANSI NPT CL150 and CL300 CL125 CL150 and CL300 per ANSI B16.24 per ANSI B16.1 per ANSI B16.5 *Note ( 1 / 2 ") and ( 3 / 4 ") sizes 1 to 5 psig REDUCED PRESSURE AVAILABLE WITH LOW PRESSURE TOP MAXIMUM INLET PRESSURE 100 psig restricted internals in 1" body. (1 1 / 4 ") and (1 1 / 2 ") sizes restricted internals in 2" body. FEATURES The G-4 regulator is a self-actuating pilot operated pressure reducing valve, and is the most versatile of its kind available. The G-4 handles a wide range of pressure reducing applications. Over 100 years of manufacturing experience under the IMI Bailey-Birkett, Ltd. trademark, and continuous improvement in design and performance provides Cash Valve G-4 users with the best regulator of its type. EXTREMELY COMPACT DESIGN In general the G-4 is much smaller than other types of regulators for the same duty. CONSTANT OUTLET PRESSURE is maintained right up to the maximum rated capacity of the valve, and is unaffected by changes in the flow rate or inlet pressure. VERY HIGH FLOW RATES can be achieved due to the full lift capability of the main valve assembly and the design of the valve body. POSITIVE SHUT OFF is ensured by accurate guiding of the pilot and main valve assemblies. Non-metallic trims are available to give dead tight shut-off on air and gas applications. INTERCHANGEABILITY of the pilot valve component parts simplifies maintenance and allows for greater flexibility of spare parts. THE FINEST MATERIALS are used throughout the construction of every G4 regulator and the highest standard of engineering skill is maintained by the use of modern machinery and closely PRESSURE TEMPERATURE RATINGS Material End Connection Pressure (psig) Description ASTM Spec. ANSI Class 0 to 250F 300F 400F 450F 500F 750F 150F Cast Iron A126 Class B CL125 (Iron) Bronze B62 Alloy 836 CL150 (Bronze) CL300 (Bronze) CL250 (Bronze Threaded) Carbon & A216 GR WCB CL150 (Steel) * Stainless Steel A351 CF8 (304) CL300 (Steel) CL250 (Steel Threaded) * 570F for 150 psig controlled manufacturing methods. AVAILABLE IN BRONZE, CAST IRON, STAINLESS STEEL AND STEEL construction to allow for pressures up to 600 psi and temperatures up to 800 F. ENGINEERING ASSISTANCE and additional technical service is available, including specially prepared parts kits to enable either routine servicing or complete overhauls to be carried out. OUTLET PRESSURE REGULATION up to 3" size ± 1 /2% (± 1 /2 psig below 100 psig); Above 3" size ± 1% (± 1 psig below 100 psig); Pressure rise to dead end = 1%. MINIMUM PRESSURE DIFFERENTIAL The pressure differential is the difference between the inlet pressure and outlet (reduced) pressure. The minimum allowable pressure differential varies depending upon both the inlet pressure and the size of the valves Valve Inlet Press. Minimum Press. Size Range (psig) Differential (psig) /2"-2" PLUS /2"-4" PLUS 15 5"-6" Refer to Refer to sales office sales office 2
3 PILOT OPERATED PRESSURE REDUCING REGULATOR APPLICATIONS Standard G-4 pressure regulators are fitted with stainless steel valves and seats to use on steam, air and gases up to a maximum temperature of 800 F. For air and gas applications where a positive shutoff is essential, non-metallic trims are available for temperatures up to 395 F. Typical Installations: Here are but a few of the many possible installations for the Type G-4: Dryers, ovens, oil heaters, molding machines, steam jacketed equipment, sterilizers, steam cookers, large capacity kilns, retorts, heat exchangers, paper and board machines, cookers, heating lines, steam driven auxiliaries blowers, centrifugal pumps, centrifuges, etc. TYPICAL INSTALLATION Safety Valve Shut Off Valve Inlet Strainer Inlet Pressure Gauge Outlet Pressure Gauge Inlet Pipe Outlet Pipe Type G-4 Remote Sensing Connection Not less than 6' Dirt Pocket and Steam Trap The G-4 regulator is primarily designed for use on steam although it works equally well with air and gases. It will maintain a constant pressure irrespective of variations in inlet pressure or steam demand from the system. Steam at inlet pressure passes through the inlet relay port (G) to the pilot valve (D). Both pilot and main valves (H) initially are closed by the action of the pilot and main valve springs (E & I). The pilot valve is opened by clockwise rotation of the adjusting screw (A) which compresses the adjusting spring (B) and applies load to the topside of the diaphragm (C), pushing open the pilot valve. Steam at inlet pressure now passes through the pilot valve and a relay port (K) to the piston (F), which pushes open the main valve. The inlet steam is reduced in pressure as it passes through the open main valve and seat to the valve outlet. At the same time Bypass Valve Globe Type Needle Valve OPERATION SECTION VIEW OF VALVE steam at outlet pressure passes up the relay port (L) to the underside of the diaphragm. The opening of the main valve determines the outlet pressure and this in turn is controlled by the pilot valve. The outlet pressure is a result of balancing the action of the adjusting spring on the top of the diaphragm against the reduced pressure acting on the underside, thus controlling the opening of the pilot valve. The sensitivity of the diaphragm and adjusting spring ensure that any variation in reduced pressure will cause the pilot valve to open or close sufficiently to move the piston and main valve between the fully open and closed positions. Thus the out-let pressure is accurately maintained under all operating conditions. Outlet pressure is increased by clockwise rotation of the adjusting screw, or decreased by counterclockwise rotation. SECTION VIEW OF VALVE D E A C B F G INLET H I A. Adjusting Screw B. Adjusting Spring C. Diaphragm D. Pilot Valve E. Pilot Valve Spring F. Piston J K L OUTLET G. Inlet Relay Port H. Main Valve I. Main Valve Spring J. Remote Control Port K. Piston Relay Port L. Reduced Pressure Relay Port 3
4 PILOT OPERATED PRESSURE REDUCING REGULATOR SPECIFICATIONS DIMENSIONS Fig 2042 Fig 2043 Fig 2044 Fig 2046 Size 1/ 2 3/ / / 2 2 1/ 2 3/ / / / / A 4 1 / / / / / / / / / / / / / / / / / / 2 B / / / / / / / / / / / / / / / / / / / / / 2 C 2 3 / / / / / / / / / / / / / / / / / / / / 4 Wt.lb STANDARD ASSEMBLY LOW PRESSURE TOP ASSEMBLY REMOTE CONTROL *See Note *NOTE: We recommend a remote sensing connection be fitted whenever: 1. The outlet pressure is below 55% of the inlet pressure. 2. A low pressure top assembly is fitted. 3. Difficult outlet pipework conditions occur. Please refer to factory for more details. *See Note SPECIFICATIONS MATERIALS OF CONSTRUCTION PART No. PART FIGURE 2042 & 2043 FIGURE 2044 FIGURE Body Bronze or Stainless Steel Cast Iron Cast Steel 2 Main Valve* Stainless Steel Stainless Steel Stainless Steel 3 Main Valve Seat Stainless Steel Stainless Steel Stainless Steel 4 Bottom Plug Cover Manganese Bronze Cast Iron/Aluminum Bronze Stainless Steel 5 Piston Brass Bronze Steel 6 Piston Rings Phosphor Bronze Phosphor Bronze Chrome Iron 7 Liner Stainless Steel Stainless Steel Stainless Steel 8 Piston Guide Stainless Steel Stainless Steel Stainless Steel (6" Monel ) 21 Main Valve Spring Stainless Steel Stainless Steel Stainless Steel 25 Pilot Valve Top Bronze Bronze Steel 26 Pilot Valve* Stainless Steel Stainless Steel Stainless Steel 27 Pilot Valve Plug Stainless Steel Stainless Steel Stainless Steel 29 Diaphragm Stainless Steel Stainless Steel Stainless Steel 31 Pilot Valve Spring Stainless Steel Stainless Steel Stainless Steel 33 Adjusting Spring Steel Steel Steel 49 Diaphragm for low Phosphor Bronze Phosphor Bronze pressure top Gaskets-Steam-Non Asbestos Material. Air & Gases-Teflon (2" & below) Rubber Bonded Cork (2 1 /2" & above) *Main and pilot valves are fitted with elastomeric inserts for use on air and gases when tight shut-off is required. Note: For full parts list please refer to installation & maintenance instructions available on request. TRIM SELECTION Duty Trim Steam Stainless Steel Standard Valve Compressed air, carbon dioxide, nitrogen, hydrogen, helium Nitrile Oxygen Fig. 2043/3 only Oxygen, methane Viton 4
5 PILOT OPERATED PRESSURE REDUCING REGULATOR SPECIFICATIONS SPRINGS VALVE SIZE 1/2" - 4" 5 and 6"* 5-50 (Yellow) (Black) (White) (Green) (Red) *Not Color Coded A special Low Pressure Top assembly should be fitted for outlet pressures from 1 up to 5 psig. Low Pressure Tops are available for valves up to 4 size. Larger valves are not suitable for outlet pressures of less than 5 psig. The Low Pressure Top is supplied as a complete conversion unit for fitting to the existing pilot valve assembly. It incorporates a large diaphragm, thus providing a greater effective area and improved sensitivity to very low outlet pressure conditions. NOTE: It is advisable to select a spring which will ensure that there is at least 10% extra adjustment available above the required reduced set pressure. The spring with the lowest pressure range should be used whenever possible. SPECIFICATIONS CAPACITIES STEAM - POUNDS PER HOUR INLET OUTLET 1 /2 3 / /4 1 1 / / PRESS. PRESS. Flow Coefficient (C v ) These capacities are based on a 3% variance from the regulator s set point. 5
6 TYPE G-4 SPECIFICATIONS CAPACITIES AIR (SCFM) INLET OUTLET 1 /2 3 / /4 1 1 / / PRESS. PRESS. Flow Coefficient (C v ) These capacities are based on a 3% variance from the regulator s set point. GAS OXYGEN NITROGEN HYDROGEN HELIUM CO 2 ARGON METHANE FACTOR To find valve capacities for gases at ambient temperatures multiply required flow rate by Approximate factor. Use chart above for valve capacity. HOW TO ORDER Specify Cash Valve Type G-4 and state: 1. Pipe Size; 2. End Connections; 3. Inlet Pressure; 4. Outlet Pressure range and setting; 5. Maximum flow rate desired. 6. Service; 7. Trim; 8. Body Material; 9. Operating Temperature; 10. For remote sensing-order remote control adapter. Cash Valve 953 Old U.S. Highway 70 Black Mountain, NC Phone: Fax: CAVMC-0512-US Tyco Valves & Controls
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