Emerson Daniel 788DVC User Manual
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Emerson Daniel 788DVC User Manual

Emerson Daniel 788DVC User Manual

Digital control valve, nps 2 through 8/class 150-300
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User manual
P/N 3-9008-556, Rev AF
October 2019
™
Daniel
Model 788DVC Digital Control Valve
NPS 2 through 8 / Class 150-300
Table of Contents
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Summary of Contents for Emerson Daniel 788DVC

  • Page 1 User manual P/N 3-9008-556, Rev AF October 2019 ™ Daniel Model 788DVC Digital Control Valve NPS 2 through 8 / Class 150-300...
  • Page 3 Email • Customer Service: [email protected] • Customer Support: [email protected] • Field Lifecycle Services: [email protected] • Asia-Pacific: [email protected] • Europe: [email protected] Return Material Authorization (RMA) A Return Material Authorization (RMA) number must be obtained prior to returning any equipment for any reason. Access and fill in the RMA form for Daniel products clicking on the link below.
  • Page 4 Important Important is a statement the user needs to know and consider. Tip provides information or suggestions for improved efficiency or best results. Note Note is “general by-the-way” content not essential to the main flow of information.
  • Page 5 • Verify that this is the correct instruction manual for your Daniel product. If this is not the correct documentation, contact Daniel at 1-713-827-6314. You may also download the correct manual from: https://www.emerson.com/en-us/automation/ daniel. • Save this instruction manual for future reference.
  • Page 6 • Verify that this is the correct instruction manual for your Daniel product. If this is not the correct documentation, contact Daniel at 1-713-827-6314. You may also download the correct manual from: https://www.emerson.com/en-us/automation/ daniel. • Read and understand all instructions and operating procedures for this product.
  • Page 7 Notice THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES ONLY, AND WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO BE CONSTRUED AS WARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED, REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY. ALL SALES ARE GOVERNED BY DANIEL'S TERMS AND CONDITIONS, WHICH ARE AVAILABLE UPON REQUEST.
  • Page 8 Warranty and Limitations 1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein, Daniel Measurement & Control, Inc. (“Daniel”) warrants that the licensed firmware embodied in the Goods will execute the programming instructions provided by Daniel, and that the Goods manufactured by Daniel will be free from defects in materials or workmanship under normal use and care and Services will be performed by trained personnel using proper equipment and instrumentation for the particular Service provided.

  • Page 9: Table Of Contents

    User manual Contents P/N 3-9008-556 October 2019 Contents Chapter 1 Introduction.........................11 1.1 Purpose of this manual........................11 1.2 Description of the Model 788DVC Digital Control Valves..............11 1.3 Agency certifications for control valves Models 788DVC Digital............. 46 Chapter 2 Operating conditions and specifications...............49 2.1 Operating conditions for the control valve..................49 2.2 Specifications for the control valve....................
  • Page 10 Contents User manual October 2019 P/N 3-9008-556 10.1 Control valve troubleshooting...................... 83 10.2 Verify the return to operational condition..................84 Chapter 11 Spare parts........................85 11.1 Recommended spare parts......................85 Chapter 12 Decommission......................89 12.1 Shut down the control valve......................89 12.2 Shipment of the control valve.......................89 Appendix A Needle valve........................

  • Page 11: Chapter 1 Introduction

    User manual Introduction P/N 3-9008-556 October 2019 Introduction Purpose of this manual This manual provides guidance to owners and personnel in the installation, operation and maintenance of the Daniel Series 788DVC Digital Control Valves manual, 3-9008-556. It is imperative that product owners and operation personnel read and follow the information contained in this manual to ensure that the control valve is installed correctly and is operating according to the design certifications and safety considerations.
  • Page 12 Introduction User manual October 2019 P/N 3-9008-556 CAUTION EQUIPMENT DAMAGE Read the entire recommended procedure for all installation operations and maintenance procedures before attempting to install or disassemble the valve. Disassembly of this cylinder assembly is different from previous Daniel Control Valves and requires strict adherence to the procedures outlined in this manual.
  • Page 13 User manual Introduction P/N 3-9008-556 October 2019 Closed position The normally closed solenoid is closed. The normally open solenoid is open. Y-port (P3) to Z-port (p2) is closed. X-port (P1) and Y-port (P3) pressures are balanced. The main valve spring being the differential force, closes the position and keeps it seated. (See below.) Figure 1-1: Closed position Open - control position The normally closed solenoid is closed.
  • Page 14 Introduction User manual October 2019 P/N 3-9008-556 Figure 1-2: Open - control position Open position (no control) The normally closed solenoid is open. The normally open solenoid is closed. Y-port (P3) is open to Z-port (P2). X-port (P1) is closed off by the normally open solenoid. The pressure on the bottom of the piston (P1) is greater than the pressure at (P3) plus the spring force;...
  • Page 15 User manual Introduction P/N 3-9008-556 October 2019 Figure 1-3: Open position (no control) User manual...
  • Page 16 Introduction User manual October 2019 P/N 3-9008-556 1.2.4 Parts list for the Series 788DVC Control Valves Figure 1-4: Part description for a series 788DVC Control Valve NPS 2-8 NOTICE Item numbers are not meant to be consecutively numbered. Table 1-1: Part description for a Series 788DVC Control Valve NPS 2 Item number Description Part number...
  • Page 17 User manual Introduction P/N 3-9008-556 October 2019 Table 1-1: Part description for a Series 788DVC Control Valve NPS 2 (continued) Item number Description Part number Quantity 2 inch Seat ring Standard 520026-690 Piston Standard 520024-690 AP option 520024-693 O-ring Buna-N 152073 152073-005 FFKM...
  • Page 18 Introduction User manual October 2019 P/N 3-9008-556 Table 1-1: Part description for a Series 788DVC Control Valve NPS 2 (continued) Item number Description Part number Quantity 2 inch Cylinder head Standard 520056-510M Screw 151066 Jack-out screws 150691 Indicator stem visual 520183-690 Indicator stem micro-switch 520183-691...
  • Page 19 User manual Introduction P/N 3-9008-556 October 2019 Table 1-1: Part description for a Series 788DVC Control Valve NPS 2 (continued) Item number Description Part number Quantity 2 inch Seal retainer 540188-500 O-ring Buna-N 152096 152096 152096-005 FFKM 152096-075 NBR (Low-swell) 152096-120 152096-116 152096-022...
  • Page 20 Introduction User manual October 2019 P/N 3-9008-556 Table 1-1: Part description for a Series 788DVC Control Valve NPS 2 (continued) Item number Description Part number Quantity 2 inch 520575-692 FKM GFLT 520575-69G FKM V1289 520575-69M With standard indicator Buna-N 520175-690 520175-697 FFKM 520175-695...
  • Page 21 User manual Introduction P/N 3-9008-556 October 2019 Table 1-2: Part description for a Series 788DVC Control Valve NPS 3 (continued) Item number Description Part number Quantity 3 inch NBR (Low-swell) 152075-120 152075-116 152075-022 FKM GFLT 152075-027 FKM V1289 152075-029 Backup ring 157186 O-ring Buna-N...
  • Page 22 Introduction User manual October 2019 P/N 3-9008-556 Table 1-2: Part description for a Series 788DVC Control Valve NPS 3 (continued) Item number Description Part number Quantity 3 inch Magnet 1500410 Retaining ring 153946 Indicator adapter 540081-690M Cap plug 154769 Ring magnet 1500409 Indicator housing 540082-690...
  • Page 23 User manual Introduction P/N 3-9008-556 October 2019 Table 1-2: Part description for a Series 788DVC Control Valve NPS 3 (continued) Item number Description Part number Quantity 3 inch FKM GFLT 152096-027 FKM V1289 152096-029 Backup ring 157172 Upper bearing 540189-500 Indicator guard 540082-400 Lock washer...
  • Page 24 Introduction User manual October 2019 P/N 3-9008-556 Table 1-2: Part description for a Series 788DVC Control Valve NPS 3 (continued) Item number Description Part number Quantity 3 inch NBR (Low-swell) 530175-696 530175-693 530175-692 FKM GFLT 530175-690G FKM V1289 530175-69M Table 1-3: Part description for a Series 788DVC Control Valve NPS 4 Item number Description Part number...
  • Page 25 User manual Introduction P/N 3-9008-556 October 2019 Table 1-3: Part description for a Series 788DVC Control Valve NPS 4 (continued) Item number Description Part number Quantity 4 inch FFKM 152094-075 NBR (Low-swell) 152094-120 152094-116 152094-022 FKM GFLT 152094-027 FKM V1289 152094-029 Retaining ring 1500408...
  • Page 26 Introduction User manual October 2019 P/N 3-9008-556 Table 1-3: Part description for a Series 788DVC Control Valve NPS 4 (continued) Item number Description Part number Quantity 4 inch Bal-seal 159715 Nuts 151547M Valve body class 150 541001M class 300 543001M DIN PN 16 541001-016M DIN PN 40...
  • Page 27 User manual Introduction P/N 3-9008-556 October 2019 Table 1-3: Part description for a Series 788DVC Control Valve NPS 4 (continued) Item number Description Part number Quantity 4 inch Cap plug 154774 Set Screw 150975 Cylinder Without indicator assembly class Buna-N 540075-690 150 and 300 540075-697...
  • Page 28 Introduction User manual October 2019 P/N 3-9008-556 Table 1-4: Part description for a Series 788DVC Control Valve NPS 6 Item number Description Part number Quantity 6 inch Cylinder Standard 560471-590 High-pressure 566471-590 O-ring Buna-N 1500407 1500407-005 FFKM 1500407-075 NBR (Low-swell) 1500407-120 1500407-116 1500407-022...
  • Page 29 User manual Introduction P/N 3-9008-556 October 2019 Table 1-4: Part description for a Series 788DVC Control Valve NPS 6 (continued) Item number Description Part number Quantity 6 inch Retaining ring 156488 Spring Light (blue) 560031 Medium (bronze) 560029 O-ring Buna-N 159576 159576-005 FFKM...
  • Page 30 Introduction User manual October 2019 P/N 3-9008-556 Table 1-4: Part description for a Series 788DVC Control Valve NPS 6 (continued) Item number Description Part number Quantity 6 inch Cap plug 154774 O-ring Buna-N 157012 157012-005 FFKM 157012-075 NBR (Low-swell) 157012-120 157012-116 157012-022 FKM GFLT...
  • Page 31 User manual Introduction P/N 3-9008-556 October 2019 Table 1-4: Part description for a Series 788DVC Control Valve NPS 6 (continued) Item number Description Part number Quantity 6 inch 560075-692 FKM GFLT 560075-69G FKM V1289 560075-69M With visual indicator Buna-N 560575-690 560575-697 FFKM 560575-695...
  • Page 32 Introduction User manual October 2019 P/N 3-9008-556 Table 1-5: Part description for a Series 788DVC Control Valve NPS 8 (continued) Item number Description Part number Quantity 8 inch 157006-022 FKM GFLT 157006-027 FKM V1289 157006-029 Seat ring Standard 580026-500 High-pressure 580026-600 Piston Standard...
  • Page 33 User manual Introduction P/N 3-9008-556 October 2019 Table 1-5: Part description for a Series 788DVC Control Valve NPS 8 (continued) Item number Description Part number Quantity 8 inch FKM GFLT 157074-027 FKM V1289 157074-029 Cylinder head Standard 580056-514M Screw Standard 151072 High-pressure 151038...
  • Page 34 Introduction User manual October 2019 P/N 3-9008-556 Table 1-5: Part description for a Series 788DVC Control Valve NPS 8 (continued) Item number Description Part number Quantity 8 inch FKM V1289 152096-029 Backup ring 157172 Upper bearing 540189-500 Indicator guard 580082-400 Lock washer 152119 Screws...
  • Page 35 User manual Introduction P/N 3-9008-556 October 2019 WARNING EQUIPMENT HAZARD When the process fluid is liquid ammonia, use this equipment ONLY with CR elastomers. Consult a Daniel representative for assistance. Failure to comply may result in death or serious injury. Table 1-6: Reference for differential pressure and voltage Functio Elasto...
  • Page 36 Introduction User manual October 2019 P/N 3-9008-556 Table 1-6: Reference for differential pressure and voltage (continued) Functio Elasto Maxim Approv Voltage mers 110VA 220VA 440VA 12VDC 24VDC 48VDC Operta tional Pressur Differe ntial (Psi) FKM For 458815 458815 458815 458815 458815 458815 -019...
  • Page 37 User manual Introduction P/N 3-9008-556 October 2019 Table 1-6: Reference for differential pressure and voltage (continued) Functio Elasto Maxim Approv Voltage mers 110VA 220VA 440VA 12VDC 24VDC 48VDC Operta tional Pressur Differe ntial (Psi) 456960 456960 456960 456960 456960 -X10 -X20 -X40 -X70...
  • Page 38 Introduction User manual October 2019 P/N 3-9008-556 Table 1-6: Reference for differential pressure and voltage (continued) Functio Elasto Maxim Approv Voltage mers 110VA 220VA 440VA 12VDC 24VDC 48VDC Operta tional Pressur Differe ntial (Psi) 456960 456960 -XA5 -XB5 456960 456960 -XA5 -XB5 FKM For...
  • Page 39 User manual Introduction P/N 3-9008-556 October 2019 Figure 1-5: Parts description of 1710 (456910) Control Valve pilot Table 1-7: Parts list for 1710 (456910) pilot used with the 788DVC Control Valve Item Number Description Part Number Quantity O-ring, NBR 152071 O-ring, EPR 152071-005 O-ring, FFKM...
  • Page 40 Introduction User manual October 2019 P/N 3-9008-556 Table 1-7: Parts list for 1710 (456910) pilot used with the 788DVC Control Valve (continued) Item Number Description Part Number Quantity O-ring, FKM GFLT 152071-027 O-ring, FKM V1289 152071-029 O-ring, NBR 152076 O-ring, EPR 152076-005 O-ring, FFKM 152076-075...
  • Page 41 User manual Introduction P/N 3-9008-556 October 2019 Table 1-7: Parts list for 1710 (456910) pilot used with the 788DVC Control Valve (continued) Item Number Description Part Number Quantity Manual Operator FFKM 455525-005 Manual Operator EPR 455525-007 Manual Operator NBR (Low- 455525-008 swell) Manual Operator FKM GFLT...
  • Page 42 Introduction User manual October 2019 P/N 3-9008-556 Table 1-8: Voltages for the 1710 (456910) pilot (continued) Type Elastomer Voltage 110VAC 220VAC 440VAC 12VDC 24VDC 48VDC Atex 456810-0 456810-0 456810-0 456810-0 456810-0 FFKM 456810-0 456810-0 WARNING EQUIPMENT HAZARD When the process fluid is liquid ammonia, use this equipment ONLY with CR elastomers. Consult a Daniel representative for assistance.
  • Page 43 User manual Introduction P/N 3-9008-556 October 2019 Figure 1-6: Parts description of 1711 (456960) Control Valve pilot Table 1-9: Parts list for 1711 (456960) pilot used with the 788DVC Control Valve Item Number Description Part Number Quantity O-ring, NBR 152071 O-ring, EPR 152071-005 O-ring, FFKM...
  • Page 44 Introduction User manual October 2019 P/N 3-9008-556 Table 1-9: Parts list for 1711 (456960) pilot used with the 788DVC Control Valve (continued) Item Number Description Part Number Quantity O-ring, FKM GFLT 152071-027 O-ring, FKM V1289 152071-029 O-ring, NBR 152076 O-ring, EPR 152076-005 O-ring, FFKM 152076-075...
  • Page 45 User manual Introduction P/N 3-9008-556 October 2019 Table 1-9: Parts list for 1711 (456960) pilot used with the 788DVC Control Valve (continued) Item Number Description Part Number Quantity Manual Operator FFKM 455525-005 Manual Operator EPR 455525-007 Manual Operator NBR (Low- 455525-008 swell) Manual Operator FKM GFLT...

  • Page 46: Agency Certifications For Control Valves Models 788Dvc Digital

    Introduction User manual October 2019 P/N 3-9008-556 Table 1-10: Voltages for the 1711 (456960) pilot (continued) Type Elastomer Voltage 110VAC 220VAC 440VAC 12VDC 24VDC 48VDC Red Hat II 478935-2 478935-2 478935-2 478935-2 478935-2 (CSA) 478935-2 478935-2 478935-2 478935-2 478935-2 478935-2 478935-2 478935-2 478935-2...
  • Page 47 User manual Introduction P/N 3-9008-556 October 2019 Table 1-11: Agency certifications for control valves (continued) Certification type Description INMETRO certification Electrical • Certificate number — UL-BR 19.1331X • INMETRO marking — Ex mb IIB T4 Gb (16,1 W) — Ex mb IIB T3 Gb (20,1W) (-15 °C ≤...
  • Page 48 Introduction User manual October 2019 P/N 3-9008-556 Model 788DVC Digital Control Valve...

  • Page 49: Operating Conditions And Specifications

    User manual Operating conditions and specifications P/N 3-9008-556 October 2019 Operating conditions and specifications Operating conditions for the control valve Table 2-1: Operating conditions for the control valve Condition type Description Fluid phase Liquid Process temperature -26°C to 66°C (-15°F to 151°F) Optional process -46°C to 121°C (-51°F to 250°F) temperature...
  • Page 50 Operating conditions and specifications User manual October 2019 P/N 3-9008-556 Table 2-1: Operating conditions for the control valve (continued) Condition type Description Maximum safe working Flange connections/Ratings (DIN) for valve sizes DN50 and DN400: pressure • DIN PN16 MWP at 120 °C: 16 bar •...
  • Page 51 User manual Operating conditions and specifications P/N 3-9008-556 October 2019 Condition type Voltage Current (Inrush) Current holding Solenoid electrical data 110/50 Vac 0.71 amps 0.37 amps (150 lb. MOPD) 120/60 Vac 0.65 amps 0.34 amps 220/50 Vac 0.36 amps 0.19 amps 240/60 Vac 0.33 amps 0.17 amps...

  • Page 52: Specifications For The Control Valve

    Operating conditions and specifications User manual October 2019 P/N 3-9008-556 Table 2-2: Environmental conditions (continued) Parameter type Description Additional severe service The valves are designed to be used on liquid applications for conditions crude oil and refined products. The use of aggressive additives or oxygenates requires the use of the Aggressive Products (AP) option.
  • Page 53 User manual Operating conditions and specifications P/N 3-9008-556 October 2019 Table 2-3: Interface requirements Requirements Description Hydraulic lines External hook up: • ANSI class 150 and 300: — NPS 2-6: Carbon steel/Stainless steel 10 mm (0.375") — NPS 8-16 Carbon steel/Stainless steel 13 mm (0.5") —...
  • Page 54 Operating conditions and specifications User manual October 2019 P/N 3-9008-556 Figure 2-1: Valve orientation WARNING EQUIPMENT HAZARD Never use this equipment for any purpose other than its intended use. Failure to comply may result in death, serious personal injury and/or property damage. Model 788DVC Digital Control Valve...
  • Page 55 User manual Operating conditions and specifications P/N 3-9008-556 October 2019 2.2.3 Minimum clearances for installation, operation and maintenance For certified prints, consult the factory. Figure 2-2: Dimensions of the control valve Table 2-4: Weight and volume table for the control valve (Approximate) Size 150 lb.
  • Page 56 Operating conditions and specifications User manual October 2019 P/N 3-9008-556 Table 2-5: Dimensions for the control valve Valve size 150# ANSI 300# ANSI No indicator With indicator 2" 10-1/4" 10-1/2" 9" 11" 8.252" 260mm 267 mm 229 mm 279 mm 210 mm 3"...

  • Page 57: Control Valve Handling

    User manual Control valve handling P/N 3-9008-556 October 2019 Control valve handling Receive the control valve WARNING EQUIPMENT HANDLING AND OPERATING HAZARD Wear personal protective equipment appropriate to the situation when working with the control valve. Adhere to all safety standards and best practices for operating the equipment.
  • Page 58 Control valve handling User manual October 2019 P/N 3-9008-556 3.2.3 Storage conditions Store the control valve in a safe area to avoid damage. WARNING CRUSHING HAZARD During installation or removal of a control valve, always place the unit on a stable platform or surface that supports its assembled weight.

  • Page 59: Prepare The Control Valve For Use

    User manual Prepare the control valve for use P/N 3-9008-556 October 2019 Prepare the control valve for use Lifting conditions WARNING CRUSHING HAZARD During installation or removal of a control valve, always place the unit on a stable platform or surface that supports its assembled weight. Failure to comply may allow the control valve to roll, resulting in death, serious injury or equipment damage.

  • Page 60: Lifting Requirements For Personnel

    Prepare the control valve for use User manual October 2019 P/N 3-9008-556 Lifting requirements for personnel 4.2.1 Safety precautions using appropriately rated lifting slings WARNING LIFTING HAZARD The lifting instructions are for installation and removal of a Daniel control valve only and do not address lifting the control valve while it is attached or bolted to piping.
  • Page 61 User manual Prepare the control valve for use P/N 3-9008-556 October 2019 Figure 4-1: Correct sling attachment • Only use slings with ratings that exceed the weight to be lifted. Reference all safety standards for safety factors that must be included when calculating the load rating. CAUTION SLING HAZARD Never allow the slings to come in contact with the visual indicator, position indicator,...

  • Page 62: Configure The Control Valve

    Prepare the control valve for use User manual October 2019 P/N 3-9008-556 • Never apply shock loads to the valve. Always lift the control valve gradually. If shock loading occurs, inspect the slings per manufacturer's procedures before reuse. WARNING EQUIPMENT HANDLING AND OPERATING HAZARD Wear personal protective equipment appropriate to the situation when working with the control valve.
  • Page 63 User manual Prepare the control valve for use P/N 3-9008-556 October 2019 Figure 4-2: Control valve flow direction WARNING EQUIPMENT HAZARD Never use this equipment for any purpose other than its intended use. Failure to comply may result in death, serious personal injury and/or property damage. 4.3.2 Piping recommendations NOTICE...
  • Page 64 Prepare the control valve for use User manual October 2019 P/N 3-9008-556 Important Ensure that piping or other attachments connected to the control valve are not under stress. Important Provide fire prevention measures and equipment per local regulations. Model 788DVC Digital Control Valve...

  • Page 65: Chapter 5 Installation Prerequisites

    User manual Installation prerequisites P/N 3-9008-556 October 2019 Installation prerequisites Pre-start checks Ensure that the pipeline is completely free of all foreign material before installing the valve. The design of the control valve has not been assessed for the effects of traffic, wind or earthquake loading.

  • Page 66: Torque Values (Flanges)

    Installation prerequisites User manual October 2019 P/N 3-9008-556 • One final time - clockwise or counter clockwise sequentially around the flange Torque values (flanges) Table 5-1: Reference torque values for Daniel Control Valve (ft-lb) flange connections Nominal pipe size (NPS) ANSI class 150 ANSI class 300 Torque pattern sequences...

  • Page 67: Chapter 6 Installation Procedure

    User manual Installation procedure P/N 3-9008-556 October 2019 Installation procedure External components assembly Install the external components (e.g., flanges) onto the pipeline. The control valve is assembled at the factory. The components do not need to be uninstalled or reinstalled unless maintenance is required. CAUTION SURFACE TEMPERATURE HAZARD The control valve body and piping may be extremely hot or cold.
  • Page 68 Installation procedure User manual October 2019 P/N 3-9008-556 hydraulic bolt tensioning equipment will specify number of exposed threads outside the nut. • Do not use damaged or worn stud bolts or nuts. • Do not use nuts or stud bolts that do not fit together correctly. •...

  • Page 69: Testing The Product

    User manual Testing the product P/N 3-9008-556 October 2019 Testing the product Commission the control valve After installation, commission the control valve to ensure that the equipment is working properly. Procedure 1. Inspect all bolts used to secure the control valve in-line to ensure that proper mounting procedures have been followed and that flange connections are leak- free.
  • Page 70 Testing the product User manual October 2019 P/N 3-9008-556 Model 788DVC Digital Control Valve...

  • Page 71: Chapter 8 Operation Parameters

    User manual Operation parameters P/N 3-9008-556 October 2019 Operation parameters Control valve normal operation The most common application of the Daniel Model 788DVC Digital Control Valve is for truck loading of petroleum products. The valve may be used with a variety of flow meter types, including Daniel series 1200 Turbine Meters and Coriolis.
  • Page 72 Operation parameters User manual October 2019 P/N 3-9008-556 When pressure on both sides of the main valve piston are equal, a spring (located on the top of the piston) acts as a differential force and closed the main valve piston. As pressure against the bottom of the piston increases and exceeds the pressure exerted against the top of the piston, plus the force of the spring, spring tension is overcome and the valve opens.

  • Page 73: Chapter 9 Planned Maintenance

    User manual Planned maintenance P/N 3-9008-556 October 2019 Planned maintenance Maintenance considerations Read and understand all instructions and operating procedures before performing maintenance procedure, internal component inspection, or field requirement changes. To ensure safe and accurate performance, only informed and trained personnel should install, operate, repair and maintain this product.
  • Page 74 Planned maintenance User manual October 2019 P/N 3-9008-556 The control valve must be cleaned completely inside the housing components and stored/ shipped as it was received. Refer to Storage Preparations for cleaning instructions. After the meter is shut down, refer to Cylinder disassembly (NPS 2-8) for the detailed disassembly procedure.
  • Page 75 User manual Planned maintenance P/N 3-9008-556 October 2019 Figure 9-1: Using the piston to remove the seat ring from the 150/300 lb cylinder 9. Turn the cylinder over with the ports on top when removing the high pressure seat ring. Remove the set screw from the seat ring. Turn the seat ring counterclockwise to remove the seat ring and then remove the O-ring from the cylinder.

  • Page 76: Mechanical Assembly

    Planned maintenance User manual October 2019 P/N 3-9008-556 CAUTION EQUIPMENT HAZARD Observe all precautionary signs posted on the equipment. Failure to comply may result in injury to personnel or cause damage to the equipment. CAUTION BENT SHAFT HAZARD Be careful to avoid bending the shaft when using the punch. The shaft can be easily bent when using the punch incorrectly.
  • Page 77 User manual Planned maintenance P/N 3-9008-556 October 2019 Table 9-2: Valve cylinder head to cylinder (socket head screws) torque specifications (continued) Class Socket head screw Torque (ft-lb) size 1/4"-20 1/4"-20 1/4"-20 1/4"-20 5/16"-18 5/16"-18 9.4.2 Standard cylinder reassembly Reassembly of a control valve without a position indicator Procedure 1.
  • Page 78 Planned maintenance User manual October 2019 P/N 3-9008-556 CAUTION SPRING PRESSURE HAZARD Follow the instructions in Step Failure to comply may cause force to release the spring, resulting in serious injury or equipment damage. 13. Align the holes in the cylinder head with the mating holes in the cylinder and insert the screws into the holes in the cylinder head.
  • Page 79 User manual Planned maintenance P/N 3-9008-556 October 2019 3. Install the indicator guard on the indicator adaptor and secure it with the lockwashers and screws. Replace the two jack-out screws. 9.4.3 AP cylinder reassembly Procedure 1. Protect the cup-seals against damage or distortion of any kind. 2.

  • Page 80: Planned Maintenance Tasks

    Planned maintenance User manual October 2019 P/N 3-9008-556 5. Lower the "new" cylinder assembly and cylinder head into the valve body. Align the bolt holes in the cylinder head with the studs in the main valve body. 6. Fasten the cylinder head into position using retaining nuts. Tighten nuts, alternating to opposite sides, to assure a uniform seat.
  • Page 81 User manual Planned maintenance P/N 3-9008-556 October 2019 Table 9-3: Planned maintenance tasks (continued) Task Recommended action Part (seal) replacement Visual inspection of the O-rings is recommended once a year and replacement of the O-rings is recommended at least once every five years. Follow internal procedures for part replacement.
  • Page 82 Planned maintenance User manual October 2019 P/N 3-9008-556 Model 788DVC Digital Control Valve...

  • Page 83: Chapter 10 Corrective Maintenance

    User manual Corrective maintenance P/N 3-9008-556 October 2019 Corrective maintenance 10.1 Control valve troubleshooting Use the table below to troubleshoot the control valve. Contact the nearest Flow Lifecycle Services center for assistance with repairs of Daniel products. It is important that servicing be performed by trained and qualified service personnel.

  • Page 84: Verify The Return To Operational Condition

    Corrective maintenance User manual October 2019 P/N 3-9008-556 Table 10-1: Troubleshooting issues for 788 DVC Control Valves (continued) Condition Probable cause Correction Pilot malfunction Consult pilot manual (710-711 Control Valve pilot) Refer to Disassemble/Assemble the control valve. 10.2 Verify the return to operational condition Once corrective maintenance has taken place, verify that the control valve is working properly by following the steps below.

  • Page 85: Spare Parts

    User manual Spare parts P/N 3-9008-556 October 2019 Spare parts 11.1 Recommended spare parts Table 11-1: Recommended spare parts Description NPS Class Elastomer Without With With Visual Indicator Position Indicator Indicator Valve 150-300 Buna-N W520055-6 W520155-6 W520555-6 Assembly O-ring kit W520055-6 W520155-6 W520555-6...
  • Page 86 Spare parts User manual October 2019 P/N 3-9008-556 Table 11-1: Recommended spare parts (continued) Description NPS Class Elastomer Without With With Visual Indicator Position Indicator Indicator W540055-6 W540155-6 W540555-6 FFKM W540055-6 W540155-6 W540555-6 Aggressive W540055-6 W540155-6 W540555-6 Products W540055-6 W540155-6 W540555-6 W540055-6 W540155-6...
  • Page 87 User manual Spare parts P/N 3-9008-556 October 2019 Table 11-1: Recommended spare parts (continued) Description NPS Class Elastomer Without With With Visual Indicator Position Indicator Indicator W580055-6 W580055-6 FKM GFLT W580055-6 W580055-6 FKM V1289 W580055-6 W580055-6 Table 11-2: Spare parts for pilots Description 2 inch 3 inch...
  • Page 88 Spare parts User manual October 2019 P/N 3-9008-556 Model 788DVC Digital Control Valve...

  • Page 89: Chapter 12 Decommission

    User manual Decommission P/N 3-9008-556 October 2019 Decommission 12.1 Shut down the control valve Follow the steps below to shut down and disassemble the control valve for storage or shipment. WARNING PRESSURE HAZARD The control valve is subject to pressurized fluids. Isolate the control valve upstream and downstream.
  • Page 90 Decommission User manual October 2019 P/N 3-9008-556 Model 788DVC Digital Control Valve...

  • Page 91: Appendix A Needle Valve

    User manual Needle valve P/N 3-9008-556 October 2019 Needle valve Disassembly and assembly Figure A-1: Needle valve Procedure 1. Isolate and remove all pressure and drain before maintenance. 2. All parts associated with the adjustment stem are removable when the retainer is removed.

  • Page 92: Needle Valve

    Needle valve User manual October 2019 P/N 3-9008-556 Needle valve Figure A-2: Needle valve Table A-1: Part description for needle valve Item Description Part Number Quantity Number O-ring, NBR 152067 O-ring, EPR 152067-005 O-ring, FFKM 152067-075 O-ring, NBR (Low-swell) 152067-120 O-ring, CR 152067-116 O-ring, FKM...

  • Page 93: Order Spare Parts

    User manual Needle valve P/N 3-9008-556 October 2019 Table A-1: Part description for needle valve (continued) Item Description Part Number Quantity Number Retainer 460684M 460686 Order spare parts Provide the following information when ordering parts: • Daniel valve serial number •...
  • Page 94 Daniel Measurement and Control, Inc. ("Daniel") is an Emerson Process Management business unit. The Daniel name and logo are trademarks of Daniel Industries, Inc. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other trademarks are the property of their respective...

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