flucon Pump Control Booster Pump Control Valves Deep Well Pump Control Valves Relief Valves Surge Anticipating Valves

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1 Pump Booster Pump Valves Deep Well Pump Valves Relief Valves Surge Anticipating Valves Hydraulic Electric Electronic Systems Continuous innovation

2 flucon pump control booster Pump Valves deep well Pump Valves relief valves surge anticipating Valves flucon PUMP CONTROL / RELIEF If a pumping system is not correctly designed it can result in serious damage and injury. We have the right solution for pump control equipment including the new Flucon 09.EL-PI the electronic surge antecipating relief valve to protect against power failure surges or overpressure. Pump control valves are the right solution to control your pump station. This catalogue presents the most common models. If your application requires a different solution please fill out the TS-TS enquiry form, which is available at and send it to us by post or . You may also use the valve specifications CD to help you in the selection of the correct valve. FLUCON 00 FLUCON 00 is the standard main valve in almost Valcon automatic control valves. It is a hydraulically operated, diaphragm actuated globe type valve. It consists of three major components: body, diaphragm assembly and cover. The diaphragm assembly containing the stem is fully guided at both ends by a bearing in the valve cover and an integral bearing in the replaceable seat. The diaphragm assembly is the only moving part and forms a sealed chamber separating the operating pressure from the line pressure. A resilient EPDM disc contained in the disc retainer forms a drip tight seal against the valve seat. The diaphragm is made of nylon fabric bonded with EPDM. PILOT SYSTEM The pilot system is of modular type and the control pilots are in stainless steel 316L of Integral Balanced Pressure design, which means that a change in pressure in the system does not alter the pressure set point. The filter in the pilot system is of high capacity (filtering area 50cm² with body in stainless steel 316L and transparent bowl. The dirt is trapped on the outside of the screen and collects in the bowl. The collected dirt can be flushed directly out to drain by opening the blow down valve. This drain valve can be equipped with solenoid control and electronic programmable timer. Standard valves are supplied with opening - closing speed control OCS. If required the valves can be equipped with OSCS allowing independent opening and closing speed control. These controllers are also made of SS 316L All the non-stainless steel accessories are nickel plated brass as standard, or SS 316. Note: Please see main valve materials and pilot system materials on page 6. hydraulic, electric electronic systems working principle There is a restriction orifice in the connection between the upstream section of pilot system and the control chamber, which will limit the flow rate that will cause the valve to open. Clearly, the valve will open, close or remain in the same position depending upon the decreasing or increasing of flow rate (pressure in the control chamber. In order to make sure that the valve is able to close, the maximum flow rate allowed through the pilot is greater than the maximum flow rate allowed through the restriction orifice. Taking A as the wetted area on the surface of the plug, the diaphragm area is approximately 3A. Therefore the diaphragm area that is exposed to P at outlet of main valve is equal to A. The on/off or modulating pilot controls the main valve by controlling the pressure P 3 in control chamber. Disregarding the mass of the diaphragm assembly, the forces that will cause the valve diaphragm assembly to move are:.a - Upstream pressure applied on area A at the bottom of the disc P.A - Downstream pressure P exerted on area A at the lower side of the diaphragm P 3.3A - Upper chamber pressure P 3 pushing down the diaphragm on area 3A F spring - Spring force orifice P1 a P3 a 3a fspring Opening operation The valve will open when the following condition is met..a + P.A > P 3.3A + F spring a pilot closing operation In the same way, if the valve is open, it will move towards closing when:.a + P.A < P 3.3A + F spring modulating operation If the sum of the forces applied on the top side of the diaphragm is equal to the sum of the forces on the bottom side the valve plug will remain stationary, allowing a modulation regime..a + P.A = P 3.3A + F spring no flow - no pressure If there is no pressure is in the valve, the spring force and the weight of the diaphragm assembly hold the valve closed. = P = P 3 F spring + (W DA W DA Diaphragm assembly weight (only for horizontally installed valves. p

3 pump control Booster pump control Flucon 00.07(BP Mounted downstream of a pump this type of valve will open and close slowly. It eliminates the transient pressure surges that are associated with the starting and stopping of pumps. The opening and closing speed are independently adjustable. These valves also include a non-return feature that is activated in case of power failure (reverse flow. RELIEF, SURE CONTROL, SAFETY Pressure relief flucon F (A Mounted in a tee on the main pipeline downstream of a pump or pressure reducing station. Opens when inlet pressure exceeds a predetermined setting. Deep well pump control Flucon 00.07(DW Mounted in a T on main line. Discharges air and silt to the atmosphere. Opening and closing speeds are adjustable indepently. The main valve is normally open, single chamber with spring lift. This valve can be installed together with a booster pump control valve. Surge anticipating relief Flucon Automatically opens to dissipate the excess energy of a surge in the starting and stopping of a pump. Opens quickly to relieve high pressure (relief function and opens under pressure to antecipate the return of a surge wave. Hydraulic check Flucon Permits one-way flow only and is supplied with opening and closing speed controls. When pressure is reversed there is a brief reverse flow and the valve closes tightly. This feature can be supplied in all type of control valves. Surge anticipating electronic Flucon EL-PI Automatically opens to dissipate the excess energy of a surge in starting and stopping a pump. Opens quickly to relieve high pressure (relief function and opens under low pressure to antecipate the surge wave. This is an electronic valve and is supllied with a pressure transmitter, a controller and the valve is connected to a UPS. PUMP CONTROL When pumps are present in a pipeline it is extremely important to avoid the damage caused by hydraulic surges, which happen whenever pumps start or stop suddenly. In the case of power failure it is important to divert the hydraulic energy carried by the downstream water column as it returns towards the pump. We have developed systems that attenuate or eliminate the destructive effect of these phenomena. The example shown on page 5 explains one of the most cutting edge solutions [Flucon 07(BP + Flucon 09.EL-PI]. OTHER FLUCON MODELS In certain situations, the pump control valves may incorporate a pressure sustaining system. This application is very useful, for example, when a pump delivers a head higher than the network requirements. In this case, the use of a pressure sustaining feature will prevent cavitation and will cause the pump to work within the range that is recommended by its manufacturer. PRACTICAL ADVICE Valcon provides inline filters to be used with Flucon valves. If the fluid is not free from solid particles, please make sure that there is a strainer upstream; otherwise the use of a filter is compulsory. Please check the electrical specifications before connecting any electrical elements. Pilot SYMBOLs IMPORTANT NOTE HD Electric 03 Position Transmitter Pressure Transmitter The outlet pipe of pressure relief and surge anticipating valves should be submerged in water, in order to prevent air from getting into the pipeline. This way, if vacuum is present in the main line, water will be sucked into the system instead of air. If the valves discharge to the atmosphere please make sure that the fluid exit is not directed in a way, that may be liable to causing damage or injury. Remember that we are dealing with high pressures.

4 valves selection The information contained in this section should be regarded as a general guide for the selection of valves and network design. Please gather all the required parameters, in order to define the service conditions: Q - Volume flow rate (minimum, maximum and regular values - Upstream pressure P - Downstream pressure P - Target pressure Is the electrical valve normally open or normally closed? What are its voltage and current? Please use the formulas below and take into account the cavitation graph. Remember to apply the safety factors, which are shown on the table at the bottom of this page. If you need assistance please do not hesitate to contact us. Our team will analyse your application and will give you the best solution. Please make use of the valve selection CD. You may also fill out the enquiry form (TS-TS available at The standard valves are shown in Red Specification of control valves for public water distribution systems full lift, full bore DN < DN15. Remember: fire tighting systems are connected to the public water distribution network. This is the reason why Flucon standard valves are full lift and full bore from DN50 to DN100. Usually select valves with the same size of pipeline up to DN00. For larger valves or high P use the calculation formulas. Flucon 00 Full lift, full port, single chamber Flucon 00R Full lift, reduced port, single chamber Flucon 00W Full lift, full port, double chamber Flucon 00WR Full lift, reduced port, double chamber model kv values DN F F. 00R F. 00W F 00WR Kv = Cubic meters of water, a5º celsius flowing through a valve in one hour with a P of one bar. Other sizes, please contact us. water Q - m 3 /h P - bar Kv Q = kv kv = Q P = P P SAFETY FACTORS kv versus stroke Q ( For selection for a control valve the following rules must be applied. MAXIMUM LIFT The maximum Kv value can only be used in ON-OFF valves. For proportional control valves use the following safety factors. Kv SAFETY FACTORS Multiply the Kv values of the table to avoid control failure in momentary high flow. Model factor kv CAVITATION downstream pressure 5 A X EXAMPLE B % Lift C EXAMPLE 1 upstream pressure ON - OFF valves valves A,B,C EXAMPLE 3 Safety factor Y Minimum Lift C bar Minimum lift When a valve is correctly specified for continuous flow verify if intermittent low flow is present for brief periods of time. As velocity increases between the seat and the plug the risk of cavitation increases. For this reason do not oversize valves. Use anti-cavitation trim, or valves in parallel. HEAD LOSS Use the formula P = Q ( F00WR. kv for F00, F00R, F00W, A Standard plug or B Parabolic plug C Anticavitation System (ACS, or two valves in series. Note: The table above is only a general guide. Maximum cavitation value is not proportional to the square root of P. For special applications, please contact us. CAVITATION P

5 FLUCON SYSTEM - Booster Pump control + Electronic surge antecipating relief flucon STANDARD - Motorized valve (butterfly + relief valve + check valve + pneumatic vessel e c B e d ups f A - Pump B - Flucon 07(BP C - Flucon 00.EL.09 D - Flucon LS3300 E - Transmitter F - UPS - Panel f a B c M d A - Pump B - Check valve C - Pneumatic vessel D - Mot. valve E - Relief valve F - Panel a Valve B in the figure above is a Flucon 00.07(BP, with local regulation of opening and closing speed for better system performance. The Flucon 00.07(BP also integrates an automatic closing system, which is adjustable for protection against water column return. Valve C is a normally open wave anticipating valve. The model is Flucon 00.EL-PI.09. The opening and closing commands are achieved with the use of a 4VDC electric impulse version pilot (latch coil. The pilot is commanded by electric pulses, which only take place when changing the valve state is required and that means power consumption is low. The system includes an analogue pressure transmitter and a Flucon LS3300 PID controller. The controller s programme keeps the valve closed between two predefined ranges. In case of power failure, the water column will keep moving downstream towards a higher level for a short while. When this happens the pressure downstream of the pump decreases rapidly and when the predefined level of low pressure is detected, the controller opens the valve in order to anticipate the expected surge of high pressure. When gravity brings the water column back towards the pump a high pressure wave is generated and the valve will open in order to relief the high pressure and allow fluid to escape out of the pipeline. When the flow is reversed the pressure goes up sharply. At this stage the valve is completely open and will channel out most of the pressure surge energy. If the pressure again reaches the high preset level there will be a new opening command. This process is repeated until all the energy of the pressure surge has dissipated. The Flucon LS3300 controller, the pressure transmitter and the Flucon valve are connected to a UPS. Valve B in the figure above, is a motorized butterfly valve, which opens as the pump starts to run. The opening and closing speed is not adjustable, and the regulation may not be ideal to avoid pressure surges. In case of power failure when the pump is running, the network downstream of the pump will undergo a violent pressure surge. If the water speed is high the pressure may become too low and cause pipes to implode if they are not prepared for vacuum situations. pressure Bar vacuum In red Conventional System power failure In black Flucon System Flucon EL-PI O Open C Closed ExaMPLeS of sizing of the main valve ExAmple 1 Booster Pump 0V, gauge Service Conditions: Pump Pressure: 14 bar Flow rate: 360m 3 /h Head: 110 m Pipe diameter: DN00 Step 1: To minimize head loss specify the same size of installed pipe. Installed pipe - DN00 Step : See if head loss + pumping head is correct Q= 360m 3 /h, Kv (Flucon 00R DN00 = 416 ( ( P= Q <=> P= 360 kv 416 <=> P= 0,74 bar = 7,4 mwc ExAmple Electronic surge antecipating and relief valve 4V DC for service conditions of example 1 Step 1: Calculation of surge is complex and depends upon pipeline design and service conditions. If necessary the DN of the valve is one size lower than installed pipe. Step : Max discharge flow for the indicated working conditions: Kv (Flucon 00R DN150 = 30 P= 14 bar Q = kv P <=> Q = <=> Q = 860 m 3 /h = 38 lt/s Correct selection Flucon 00R DN mwc + 7,4 mwc = 117,4 mwc 14 bar = 140 mwc 140 mwc > 117,4 mwc Correct selection Flucon 00R DN00.

6 DIMENSIONS IN MILIMETERS DN A B C D E F /8 3/8 3/8 1/ 1/ 1/ 1/ 1/ 3/4 3/4 3/4 3/4 3/4 H 3/8 3/8 3/8 3/8 3/8 3/8 1/ 1/ 1/ 1/ 1/ 1/ 1/ NOTE: For valves Flucon 06(OC A must be increased (thickness of two s of respective DN and PN. Distance B and C - Maximum PN 5/40. E - Maximum VPIA / VPIB / Air drain / Automatic air drain F - Maximum width of pilot system Fluid E Liquids. B C MATERIALs Main valve ITEM material Ductile iron 40 Bronze 1400 L 1, Body and cover Steel SC5 ST Steel 304/316 3 Seat ST Steel 316L Ductile iron 40 4 Valve plug ST Steel 304/316 5 Valve seat ST Steel 316L Ductile iron 40 6 Top spring plate ST Steel 304/316 7 Stem ST Steel Lock nut ST Steel 316 EPDM EPDM + Belt 9 Diaphragm Viton Viton + Belt EPDM EPDM 10 Disc PTFE (TCF PTFE (TCF 11 Bolts and nuts ST Steel Stem guide Bronze 1400 L 13 Air vent Brass MS MS 14 Spring ST Steel In Red alternative material A D F H Pilot System MAX. service CONDITIONS Body PN 10, 16 and 5. Max. operation temperature 75ºC. Body test pressure 40 Bar. SIZES AND CONNECTIONS Threaded BSP DN 3 - DN 80 Flanged DN 50 - DN 500 ASA 150, 300, DIN BS 4504, PN 10, 16 and 5. Other sizes on request. ITEM material 1 Pressure Reducing ST Steel 316L Pressure Sustaining (03/09 ST Steel 316L 3 Float Level (04 ST Steel 316L 4 Altitude Level (05 ST Steel 316L 5 Differential Pressure (06 ST Steel 316L 6 Negative Pressure (0(I/09 ST Steel 316L 7 Electric (HD/07 ST Steel/Bronze 316L 8 Non return (08 ST Steel 316L 9 Speed control ST Steel 316L 10 High capacity filter ST Steel 316L 11 Restriction orifice ST Steel Ball valve VS Nickel Plated brass/st Steel L/ Pressure auge (M ST Steel (oil filled Position indicator (VPI.B ST Steel Limit switches (MS Idec Izumi 16 Position transmitter (PT Camille Bauer 17 Fittings Nickel Plated brass/st Steel Serto 18 Compound Locktite FAC Filter 0 Pressure Reducing 03 Pressure Sustaining/ Relief 06 Flow 05 Altimetric Level HD Electric Oscs 04(N/P Float Level 04(DI Differential Level

7 Specifications - PUMP CONTROL - BOOSTER, DEEP WElL RELIEF, SURE ANTICIPATIN Main Valve MODEL body/cover disc retainer diaphragm disc plug connections size DN ductile iron ductile iron epdm epdm flat r threaded bsp dn50 dn65 cs cast steel ss ST steel v viton T ptfe P parabolic pn10 din pn10 dn80 dn100 ss ST steel bz bronze acs anti cavitation pn16 din pn16 dn15 dn150 bz bronze pn5 din pn5 dn00 dn50 00 FULL LIFT, FULL PORT asa150 asa150 dn300 dn350 00r FULL LIFT, REDUCED PORT asa300 asa300 dn400 dn450 00w FULL LIFT, FULL PORT, DOUBLE CHAMBER dn500 00wr FULL LIFT, REDUCED PORT, DOUBLE CHAMBER Pilot System Main system INCORPORAtIoNs main function MATERIAL spring electric control filter pressure electric control non return 03(A Pressure Relief stainless steel (03 R bar p 1 4 AC 4v AC manual 09 Anticipating Relief SS Total S.steel (03 R 3-1 bar p 1 4 AC P 4v AC pet 4v AC 03(S(R 1 p bar HD(Nc 4AC nc 4v AC 08 HIDRAU. CHECK 09(el 07(bp 07(dw 08 Anticipating Relief Electronic Booster Pump Deep well Pump Hidraulic Check 0 V 0v P 4v AC P 0 V pet pet 0v 03(S(R PET - Programmable electronic drain 03(A and 09 - Not compatible with sustaining D and 08 - Only 03(A and 09 (Incorporation Spring - Only 03(A and EL - Only 4V DC p bar hd(nc 4DC hd(nc 0 hd(no 4AC hd(no 4DC hd(no 0 nc nc 0v no no no 0v Accessories UPSTREAM pressure gauge DOWNSTREAM pressure gauge PRESSURE TRANSMITTER p 1 PRESSURE TRANSMITTER p POSITION INDICATOR LIMIT SWITCHES POSITION TRANSMITTER ( bar m ( bar ( bar t ( bar vpia ms 1 LIMIT SWITCH pt (0-10 ( bar 0-16 bar m (0-10 m ( bar 0-16 bar (0-10 ( bar 0-16 bar t (0-10 t ( bar 0-16 bar vpib ms.ms LIMIT SWITCHES ( bar m ( bar ( bar t ( bar ( bar m ( bar ( bar t ( bar 09(el-PI - Specify pressure transmitter 07(BP, 07(DW - Specify position indicator and limit swiches Specifications on page 5: Example 1 Flucon 00R.07(BP(0V.M 1 (0-5.VPIB.MS DN00 PN16 Example Flucon 00R EL-PI.09(4V DC.T 1 (0-5 DN150 PN16

8 Hydraulic Automatic Valves Tecnilab Portugal, SA Avenida Columbano B. Pinheiro, 97 ºDto Lisboa - Portugal Tel.: * Fax: geral@tecnilab.pt * Distributor: catalogo CM e 805 c - Inglês - gabinete comunicação e imagem 04/007 Flucon is a registered trade mark of Valcon, Lda