Attachment_1_NER_Bermad_Pressure_Stations_Spare_Parts_Expanded_Diagram_Operations_Manual_Photos.pdf

Evron, 25235, Israel Tel: +972-4-985-7696, Fax: +972-4-985-7652

BERMAD

Water Control Solutions info@bermad.com ● www.bermad.com Application Engineering

6. PREVENTATIVE MAINTENANCE SCHEDULE

The following procedure suggestions are a maintenance guide. These procedure suggestions will vary depending on the type of fluid and operation conditions.

Description Norm Clean filter Annually

Seat inspection Annually

Seal inspection Biannually or longer

Indicator Stem freedom of rotation

Annually

Valve freedom of movement Annually

Sealing Annually

Needle valve operation Annually

Pressure gauge Semi Annually

Cavitation damage Annually

Inspect and/or replace diaphragm heavy duty

3 year

Inspect and/or replace diaphragm light duty

5 year

7. FIELD MAINTENANCE INSTRUCTIONS

Bermad valves require no lubrication, no packing tightening, and require a minimum of maintenance. A periodic inspection schedule should be established to determine how the flow, the erosion, the dissolved minerals and the suspended particles are affecting the valve.

VALVE OVERHAUL. After about three years of operation, replacement of important parts and diaphragm is recommended. Remove the actuator, clean the valve body from sediments, clean the control tubing entry holes, install a new diaphragm and other Elastomers.

FILTER CLEANING. The filter used in the valve is a Y pattern filter. The filter should be cleaned manually every time the valve is opened for internal inspection.

Bermad Highlight

Pressure Reducing Stations

Note: Read all instructions prior to system start-up

Inspection prior to filling system

1. Close and tighten all valve drain plugs. The drain plugs are brass or plated and located on the underside of the valve.

2. Visually inspect valves for cracks or other defects.

3. Tighten all flange nuts & bolts.

4. Remove and inspect all control filters elements for cleanliness & casing tightness.

5. Tighten all nuts on the control tubing

OPERATION

1. The brass pilot on the 6”, 8”, & 14” pressure reducing valves control the “downstream” pressure in the system. Turning the adjusting screw clockwise increases the downstream pressure, counterclockwise decreases the downstream pressure. One full turn of the adjusting screw, near the final set point, changes the pressure from 10-15 psi. Experience will dictate the speed at which the adjusting screw should be turned. Turning the adjusting screw too quickly will cause the valve to “swing” from full open to completely shut creating detrimental “water hammer” in the mainline. Slow adjustments are required.

2. The brass pilots on the 8” & 12” pressure relief valves control the upstream pressure in the system. The pressure relief valves exist to protect the system from pressure reducing valve failure or improper pilot adjustment. The pressure relief valves will be adjusted to pressures determined during system start-up. They are generally set to a pressure 5 psi above the pressure reducing valve setting.

3. Pressure Reducing Station 1 has 6” & 14” pressure reducing valves operating in parallel. This allows for smooth valve operation over a wide range of flow rates. The 6” valve provides pressure reducing during low system flows with the 14” valve coming on-line as the system demand increases. In order for this parallel system to operate properly the final settings on the control pilots will be adjusted to different settings. The final settings will be determined in the field. In general, however, the 6” valve will be set 5 psi above the 14” setting.

Purpose of Cock Valves

There are three 1/2 cock valve on each pressure control valve, they are identified as cock valve #1 and cock valve #2 in these documents and in the Bermad IOM included later in this manual. Cock valve #3 is only identified here. The open/closed configuration of the valve effects how the pressure control valve operates. The following functions are possible

Valve Open Closed Effect on Control Valve

1 X Control Valve is in the Regulating Mode

2 X

3 X

1 X Control Valve is in manual mode and is locked with the diaphragm in its current position

1 X Control Valve in manual mode and will close when pressure is applies to the upstream side of the valve

2 X this is the Initial Valve Setting for pressure reducing valves when filling the lines.

1 X Control Valve is in manual mode and will open when pressure is applies to the upstream side of the valve

X=OFF POSITION THE VALVE IS OFF WHEN THE YELLOW HANDLE IS

PREPENDICULAR TO THE CONTROL TUBING.

COMMON CONFIGURATIONS

Setting Cock Valve #3 to the Off Position locks the valve in its current state

NO REGULATION OCCURS.

MAINTENANCE

Check the control tubing connections, brass pilot adjusting screw locking nuts, up stream and downstream pressures and other components inside the pressure reducing station weekly.

1. The primary cause for failure of the pressure reducing valve during operation is a plugged control filter. When the filter plugs the valve “drifts” open causing an increase in the downstream pressure. Pressures increasing substantially above the design pressure could result in damaged equipment.

To clean the control filter:

1. Close cock valve 3 this locks the pressure control valve in its current state.

2. Close cock valves 1 & 2.

3. Loosen slightly the control filter nut and allow the pressure to decrease on the filter until it can be safely removed.

4. Clean the filter element, reinsert the filter element into the filter casing, and tighten the control filer nut.

5. Open cock valves 1 & 2.

6. Open cock valve 3

7. Check Pressure Reducing Valve operation

Note: The reason for closing cock valve 3 prior to cleaning the filter is to “manually” set the pressure in the system. During the time period that the filter is out of the pressure reducing valve, the pressure reducing valve is locked and provides the same downstream pressure reducing function as when regulating, provided the flow rate on the system does not change.

Monthly during irrigation season the pilot adjusting screw should be exercised to verify proper operation of the pressure reducing/relief valves. Slightly adjusting the pressure reducing valve pilots ¼ to ½ turn counterclockwise should show a reduction in downstream pressure. The time for pressure changes to occur during this exercise will vary for various reasons. It may take only a few seconds up to a minute to see a result of a pilot adjustment. BE PATIENT! When it is determined that the valve is operating properly return the pilot to its original setting and tighten the lock nut. To exercise the pressure relief valves follow the same procedure for pressure reducing valves. If the pressure relief valve is operating properly the valve will begin to open to discharge water to the sump or pond. Return the adjusting screw to its original setting to close the valve.

INLET SCREEN

The inlet screen’s maintenance requirement will vary during the irrigation season due to stream water quality and irrigation demands. The frequency at which the screens should be cleaned to maintain a full pipeline will be determined overtime by field personnel.

Debris inside the inlet box can be flushed as needed by through the Flush Gate.

WINTERIZATION SHUTDOWN PROCEDURE

Drain the system as described above

1. Winterize the pressure relief and pressure reducing valves as outlined below.

2. Open the drain valves at 4+61,94+69, 286+76,331+04, and any other mainline drains that have been installed along the mainline. Close Drains at stations 94+69, 286+73, 331+04 after 7-10 days. In order to prevent water that may leak past the inlet headgates from filling the pipe leave the drain 4+61 open.

3. Remove the screens from the inlet structure and store for winter.

PRESSURE REDUCING STATIONS – WINTERIZATION

1. At the conclusion of the irrigation season and after all pipelines have been drained, remove all of the threaded brass plugs and allow the valve chambers to completely drain. Drain plugs are located on the bottom of the valve body and on the bonnet or cover of the valve. Loosen the control tubing connections on the valve and pilot bodies to allow for draining of the pilot.

2. Remove and drain the large filter, after draining reinstall.

3. Re-install the brass plugs and tighten control tubing connections prior to filling the mainlines.

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E 8 i n f o @ b e r m a d . c o m • w w w . b e r m a d . c o m The information herein is subject to change without notice. BERMAD shall not be held liable for any errors. All rights reserved. © Copyright by BERMAD.

BERMAD Waterworks Accessories

PCXWE0F 14

The Large Control Filter is used for filtration of dirty control fluid that might quickly block a smaller filter element. The Large Control Filter increases the reliability of the control valve system and time between maintenance, while minimizing faulty operation.

Technical Data Filter Element: Disc Type, 60 mesh; 250 µm Filter types:

Large Control Filter (F) Extra Large Control Filter (F1) Pressure Rating:

25 bar; 350 psi (Standard) 40 bar; 600 psi (HP Model) Max Temperature: 80°C; 180°F Ports:

3/8” NPT female ½” NPT female

Materials:

Large Control Filter

Standard St. St. Ni-Al-Bronze Super Duplex Hastalloy

1 Body Carbon Steel, Epoxy Coated St. St. 316 Ni-Al-Bronze Super Duplex Hastalloy

2 Covers Brass St. St. 316 Ni-Al-Bronze Super Duplex Hastalloy

3 Stem (1) St. St. 304 St. St. 316 Ni-Al-Bronze Super Duplex Hastalloy

4 Nut St. St. 304 St. St. 316 St. St. 316 St. St. 316 St. St. 316

5 Filter Element Construction: Polypropylene, Grooved discs: Polyethylene

Seals (2) NBR

(1) For HP models stem might differ

(2) Optional Seals: EPDM and Viton

Type F1 – 315 m m

/ 12 3/8”

Type F – 190 m m

/ 7 1/2”

100 mm / 3 7/8”

Weight:

Type F - 2.7 kg; 6 lbs Type F1 - 5.3 kg; 11.7 lbs