Installation and Maintenance Manual

Forbes Marshall Pilot Operated Pressure

Reducing Valve
FMPRV41

Energy Conservation | Environment | Process Efficiency [Link]

Table of Contents

1. Preface .................................................................................1

2. Important Safety Notes ........................................................1

3. Brief Product Information .....................................................3

4. Product Working Principle .....................................................9

5. Installation Guidelines ........................................................10

6. Startup and Commissioning .................................................15

7. Maintenance Guidelines ....................................................16

8. Troubleshooting ..................................................................28

9. Available Spares ................................................................31

10. Warranty Period .................................................................33

PLEASE NOTE - Throughout this manual this cautionary symbol is used to

describe a potential damage or injury that might occur if the safety
considerations are overlooked. This symbol denotes CAUTION, WARNING or
DANGER.

Forbes Marshall Pilot Operated Pressure Reducing Valve

1. Preface:
This manual is intended for anyone using, commissioning, servicing, or disposing the below
mentioned productssafely and efficiently.
Forbes Marshall Pilot Operated Pressure Reducing Valve [FMPRV41]
Sizes: DN15 (1/2“), DN 20 (3/4”), DN 25 (1”), DN 40 (1 ¾”) and DN 50 (2”)
PLEASE NOTE:
Throughout this manual the following cautionary symbol is used to describe a potential damage
or injury that might occur if the safety considerations are overlooked.
2. Important Safety Notes:
Read this section carefully before installing/operating/maintaining the product. The
precautions listed in this manual are provided for personnel and equipment safety.
Furthermore, Forbes Marshall accepts no responsibility for accidents or damage
occurring as a result of failure to observe these precautions. Note that the product is
designed to perform for non-contaminated fluids only. A contamination in the form of
chemical, foreign particle etc. can lead to problem with product performance and life of
the product.
If these products in compliance with the operating instructions are, properly installed,
commissioned, maintained and installed by qualified personnel (refer Section 2.7) the safety
operations of these products can be guaranteed. General instructions for proper use of tools and
safety of equipments, pipeline and plant construction must also be complied with.
2.1 Intended use:
Check if the product is suitable for intended use/ application by referring to the installation
and maintenance instructions, name plates and technical information sheets.
i) The product is suitable for use as defined in the technical information sheet. In case the
need arises to use the product on any other fluid please contact Forbes Marshall for
assistance.
ii) Check for the suitability in conformance to the limiting conditions specified in technical
information sheet of the product.
iii) The correct installation and direction of fluid flow has to be determined.
iv) Forbes Marshall products are not intended to resist external stresses, hence necessary
precautions to be taken to minimize the same.
2.2 Accessibility and Lighting :
Safe accessibility and working conditions are to be ensured prior to working on the product.

FMPRV41 1
 2.3 Hazardous environment and media:
The product has to be protected from hazardous environment and check to ensure that no
hazardous liquids or gases pass through the product.
2.4 Depressurizing of systems and normalizing of temperature:
Ensure isolation and safety venting of any pressure to the atmospheric pressure. Even if the
pressure gauge indicates zero, do not make an assumption that the system has been
depressurized.
To avoid danger of burns allow temperature to normalize after isolation.
2.5 Tools and consumables:
Ensure you have appropriate tools and / or consumables available before starting the work.
Use of original Forbes Marshall replacement parts is recommended.
2.6 Protective clothing:
Consider for the requirement of any protective clothing for you/ or others in the vicinity for
protection against hazards of temperature (high or low), chemicals, radiation, dangers to
eyes and face, noise and falling objects.
2.7 Permits to work:
All work to be carried out under supervision of a competent person. Training should be
imparted to operating personnel on correct usage of product as per Installation and
Maintenance instruction. “Permit to work” to be complied with (wherever applicable), in
case of absence of this system a responsible person should have complete information and
knowledge on what work is going on and where required, arrange to have an assistant with
his primary goal and responsibility being safety. “Warning Notices” should be posted
wherever necessary.
2.8 Handling:
There is a risk of injury if heavy products are handled manually. Analyze the risk and use
appropriate handling method by taking into consideration the task, individual, the working
environment and the load.
2.9 Freezing:
Provision should be made to protect systems which are not self-draining, against frost
damage (in environment where they may be exposed to temperatures below freezing point)
to be made.
2.10 Returning products:
Customers and Stockist are reminded that, when returning products to Forbes Marshall they
must provide information on any hazards and the precautions to be taken due to
contamination residues or mechanical damage which may present a health, safety or
environmental risk.
This information must be provided in writing including Health and Safety data sheets
relating to any substances identified as hazardous or potentially hazardous.

2 Forbes Marshall Pilot Operated Pressure Reducing Valve

3. Brief Product Information:
3.1 Description:
The Forbes Marshall Pilot Operated Forbes Marshall Pilot Operated Pressure Reducing Valve,
FMPRV41 is a SG iron pilot operated Forbes Marshall Pilot Operated Pressure Reducing Valve
suitable for steam or compressed air.
3.2 Sizes and End Connections:
DN 15, 20, 25, 40 and 50
Screwed: BSPT / NPT for DN 15, 20, 25
Flanged: BS 10 table “F/H” for DN 40 and 50
DN15 FMPRV41 LC versions available
3.3 Limiting Conditions:

PMO-Maximum allowable pressure 17 bar g

TMO-Maximum allowable temperature 232°C
Cold hydraulic test pressure 34 bar g
Spring range 0.3 to 17 bar g
3.4 Pressure Sensing Pipe:
The FMPRV41 controls the pressure by sensing the downstream pressure through a
pressure sending pipe taken to the union (item L ) or through the internal sensing pipe
(item M). Fitting of the external pressure sensing pipe is described in the user manual
supplied with the [Link]: Capacity is reduced and there is a possibility of hunting if
an external pressure sensing pipe is not fitted.
3.5 Operating Range:
232 D
A B
Temperature °C

200
150
Steam F
100 saturation
curve
50
G C E
0 5 10 15 17 20
Pressure bar g
The product must not be used in this region.

KV Values
The Kv values are full capacities and should be used for safety valve sizing purpose
only
SIZE DN15 DN20 DN25 DN40 DN50
KV 2.8 5.5 8.1 17 28
For conversion Cv (UK)=Kv x 0.963
Cv (US)=Kv x 1.156

FMPRV41 3
 Figure 1: Forbes Marshall Pilot Oprated Presure Reducing valve - FMPRV41 steam.

4 Forbes Marshall Pilot Operated Pressure Reducing Valve

 Materials:
No Part Material Standard
1 Adjustments screw Carbon Steel IS1367Gr14
2 Adjustment lock nut SS Type 304
3 Spring housing SG iron EN-JS1025 DIN EN 1563
4 Top spring pad C-20 IS2062
5 Pressure adjustment Spring SS Type 302 IS4454 Part IV Gr.1
6 Bottom spring pad SS Type 304 ASTM A276
7 Spring housing
Securing nut Carbon Steel HT IS 1367
Securing studs Carbon Steel HT IS 1367
DN 15-32 M10x95mm
DN 40, 50 M12x95mm
8 Pilot diaphragms SS Type 304 ASTM A240
9 Pilot valve chamber SG iron EN-JS1025 DIN EN1563
10 Pilot valve plunger SS Type 304
11 Pilot valve seat with SS BS 970 431 S29
integral seal +PTFE
12 Pilot valve ball SS AISI 420
13 Pilot valve Spring SS BS 2057 302 S26
14 Pilot Valve clip SS ASTM A240 Type 301
15 Pilot filter cap gasket SS BS 1449-304-S16
16 Pilot filter cap SS ASTM A743Gr. CA 40
17 Pilot filter element Bronze
18 Internal strainer SS ASTM A240 Type 304
19 Body gasket SS forced
exfoliated graphite
20 Main valve return spring Stainless Steel BS 2056 302 S26
21 Main valve Stainless Steel ASTM A276 Type 420
22 Main valve seat Stainless Steel ASTM A276 Type 420
23 Balance pipe assembly Stainless Steel ASTM A213 Type 304
24 Main Valve body SG iron EN JS1025 DIN EN 1563
25 Lower diaphragm chamber SG iron EN-JS1025 DIN EN 163
26 Lower diaphragm chamber
Securing nuts Carbon steel S1367
Securing Bolts Carbon steel S 1367
DN 15 - 25 M12x50mm
DN 40, 50 M12x50mm
27 Main diaphragm pad SS Type 304 ASTM A240
28 Lower diaphragm pad SS Type 304 ASTM A276
29 Pushrod SS Type 431
30 Lock nut SS Type 316
31 Control pipe assembly SS Type 304 ASTM A213
32 Name plate SS

FMPRV41 5
 3.6 Product Dimension and Drawing:

Dimensions (approx.) in mm
FMPRV41 (Steam)
Size Screwed A Flanged A1 B D E
M
DN15 160 ..... 181 410 130
DN15 LC 160 ..... 181 410 130
DN20 160 ..... 181 410 130
DN25 180 ..... 203 430 144
DN40 ..... 212 251 450 149
DN50 ..... 232 251 480 174

FMPRV41 STEAM

Figure 2: Dimensional drawing of FMPRV41-STEAM

FMPRV41 (Air)
Size Screwed A Flanged A1 B D E
DN15 160 ..... 181 360 130
DN15 LC 160 ..... 181 360 130
DN20 160 ..... 181 360 130
DN25 180 ..... 203 383 144
DN40 ..... 212 251 415 149
DN50 ..... 232 251 415 174

FMPRV41 AIR

Figure 3: Dimensional drawing of FMPRV41-Air

6 Forbes Marshall Pilot Operated Pressure Reducing Valve

3.6 Steam Capacity Chart:
Note
The capacities quoted below are based on valves fitted with an external pressure
sensing pipe. Reliance on the internal pressure sensing pipe will mean that
capacities may be reduced. In the case of low downstream pressure this reduction
could be up to 30% of the valve capacity.
3.6.1 How to Use the Chart (for steam application):
Saturated Steam
A valve is required to pass 600kg/h reducing from 6 bar g to 4 bar g. Find the point
at which the curved 6 bar g upstream pressure line crosses the horizontal 4 bar g
downstream pressure line. A perpendicular dropped from this point gives the
capacities of all FMPRV41 sizes under these conditions.
Superheated steam
Because of the higher specific volume of superheated steam a correction factor
must be applied to the figure obtained from the chart above. For 55°C of
superheat the factor is 0.95 and for 100°C of superheat the factor is 0.9.
Using the example given for saturated steam, the DN40 valve would pass
1150X0.95=1092kg/hr. if the steam had 55°C superheat. It is still big enough to
pass the required load of 600kg/hr.

Upstream pressure bar g

Figure 4: FMPRV 41 Sizing (Steam application)

FMPRV41 7
 3.6.2. How to Use the Chart: (for air application)
Capacities are given in cubic decimeters of free air per second (dm3/s). The use of
the capacity chart can be best explained by an example.
Required, a valve to pass 100dm3/s of free air reducing from 12 bar g to 8 bar g.
Find the point at which the curved 12 bar g upstream pressure line crosses the
horizontal 8 bar g downstream pressure line. A perpendicular dropped
from this point shows that, a DN15 valve will pass approximately 120 dm3/s under these
conditions and is the correct valve size to choose.
KV Values
The Kv values are full capacities and should be used for safety valve
sizing purpose only.
SIZE DN15 DN20 DN25 DN40 DN50
KV 2.8 5.5 8.1 17 28
For conversion Cv (UK)=Kv x 0.963
Cv (US)=Kv x 1.156
Compressed Air Capacity Chart
Downstream pressure bar g

Upstream pressure bar g

Figure 5: FMPRV 41 Sizing (air application)

8 Forbes Marshall Pilot Operated Pressure Reducing Valve

4. Product Working Principle: [Refer to Figure 1]
A Forbes Marshall Pilot Operated Pressure Reducing Valve balances the downstream pressure
through the pressure sensing pipe (23) against the pressure adjustment control spring (5). This in
turn moves the pilot valve plunger (10) in the pilot valve assembly (10, 11, 12, 13 and 14), to
modulate a control pressure which is directly proportional to the pilot valve opening. This control
pressure is transmitted to the underside of the main diaphragm (27) through the control pipe
(31). This movement in the diaphragm (27) pushes the pushrod (29) up and the main valve (21)
opens in proportion to the pilot valve opening.
Under stable load conditions, the pressure underneath the pilot diaphragm (8) balances the force
which is set on the adjustment spring (5). This settles the pilot valve, allowing a constant pressure
working under the main diaphragm (27). This makes sure that the main valve (21) is also settled,
hence giving a stable downstream pressure.
When downstream pressure rises, the pressure under the pilot diaphragm (8) becomes greater
than the force created by the pressure adjustment spring (5) and this makes pilot diaphragm (8) to
move upwards. This closes the pilot valve seat (11) and will interrupt the transmission of steam
pressure underneath the main diaphragm (27). The top of the main diaphragm (27) is always
subjected to downstream pressure at all the times and, as there is more pressure above the main
diaphragm (27) than below, the main diaphragm (27) moves down pushing the steam
underneath it into the downstream outlet through the control pipe (31) and surplus pressure
orifice. The pressure on either side of the main diaphragm (27) is balanced, and a small excess
force created by the main valve return spring (20) closes the main valve seat (22).
Any variation in load or pressure will immediately be sensed on the pilot diaphragm (8), which will
act to adjust the position of the main valve accordingly, ensuring a constant downstream pressure.

FMPRV41 9
5. Installation Guidelines:
Note: Before implementing any installations observe the 'Important Safety notes” in
section 2. Referring to the Installation and Maintenance Instructions, name-plate and
Technical Information Sheet, check that the product is suitable for the intended
installation.
5.1 Fitting:
The valve should always be fitted in a horizontal pipeline with the main diaphragm chamber
below the line (figure 7). To meet the high capacities or widely varying loads or where stand-
by facility is required, two or more valves may be used in parallel (figure 6). For pressure turn
down in excess of 10 to 1 consideration should be given to using the two valves in series. To
avoid turbulence between the two pressure reducing valves, the distance must be
equivalent to atleast 50 pipe diameters. To ensure adequate drainage of the space between
the two pressure reducing valves a trap set should be fitted as shown in figure 8.

Figure 6: Recommended installation of FMPRV41

*This is a typical representation of Forbes Marshall Pilot Operated Pressure Reducing Valve

10 Forbes Marshall Pilot Operated Pressure Reducing Valve

 Fig. 7: Installation of Two FMPRV41 in parallel
*This is a typical representation of Forbes Marshall Pilot Operated Pressure Reducing Valve

Figure 8: Installation of Two FMPRV41 in series

*This is a typical representation of Forbes Marshall Pilot Operated Pressure Reducing Valve

FMPRV41 11
 Sr. No. DESCRIPTION
1 Interconnecting Pipework for Pressure Reducing Station
2 Stop Valve (Inlet)
3 Stop Valve (Bypass)
4 Strainer
5 Forbes Marshall Pilot Operated Pressure Reducing Valve, FMPRV41
6 Stop Valve (Outlet)
7 Safety Valve
8 Stop Valve ( Pressure Balancing Line)
9 Moisture Separator
10 Drain Trap Assembly
11 Dial Pressure Gauge (Inlet)
12 Dial Pressure Gauge (Outlet)
13 Stop Valve (Dial Pressure Gauge)
5.2 Pipeline sizing:
The piping on both sides of the valve must be sized so that velocities do not exceed 30 m/s.
normally, a correctly sized FMPRV41 will be smaller than the connecting pipe work.
5.3 Pipeline stresses:
Line stresses caused by expansion or inadequate support should not be imposed on the
valve body.
5.4 Isolating Valves:
These should preferably be of the full bore type.
5.5 Removal of condensate:
Ensure that the pipework is supplied with dry steam. The ideal arrangement is to fit a
separator in the steam supply. If the steam is known to be dry then a drain pocket may be
adequate. If there is a rise in the low pressure line after the valve then a further drain point
should be provided to keep the valve drained after shutdown.
5.6 Preventing Dirt:
The valve should be protected from dirt / foreign particles using pipeline strainer. The
strainer should be fitted on its side to prevent the accumulation of water.
5.7 Pressure Control Pipe:
For applications that require closer control, improved stability or maximum capacity
condition the internal balance pipe should be replaced by an external pressure sensing pipe
(supplied by others) as follows:

12 Forbes Marshall Pilot Operated Pressure Reducing Valve

 Remove the internal balance pipe assembly. The resulting 1/8'' BSP tapping in the side of the
body should be blanked using a plug provided in the bag attached to the valve. The other
1/4'' BSP tapping in the side of the pilot valve chamber should be used to fit the external
pressure sensing pipe. This is suitable for the fitting of 13.7mm O/D pipe. If suitable pipe is
not available the compression fitting can be removed and 1/4'' nominal bore steel pipe
screwed directly to the pilot valve chamber. The pressure control pipe should be connected
in to the top of the reduced pressure main at a point where in either direction there is a
length of straight pipe uninterrupted by fittings for at least 1mor 15 pipe diameters
whichever is the greater. It should be arranged with a positive fall so that any condensate
can drain away from the [Link] the size of the reduced pressure main makes it
difficult to maintain a fall when entering the top of the main, the pressure control pipe may
be connected in the side of the main.
5.8 Pressure gauges:
It is essential to fit a pressure gauge on the downstream side so that the valve can be properly
set. A pressure gauge on the upstream side can also be useful.
5.9 Continuous Duty:
For continuous duty applications where a constant steam supply is essential then a parallel
stand- by pressure reducing valve station is recommended to allow for planned
maintenance see fig 6. Alternatively a by-pass line can be used (see fig 7). It is important that
the by-pass should have a similar capacity to the Forbes Marshall Pilot Operated Pressure
Reducing Valve which is achieved by choosing an appropriately sized valve or by using a
reduced orifice in the line.
The hand wheel should be pad locked to prevent unauthorised use, and when in use should
be under constant manual supervision.
The by-pass may be arranged above or to the side of the main assembly but never below it.
5.10 Safety valve:
A safety valve should be fitted to protect the down steam equipment from excessive
pressure. It should be set to lift below the safe working pressure of the downstream
equipment and will normally be sized to pass the full capacity of the pressure reducing valve.
The safety valve set pressure should take account of its re seat characteristics and the 'No-
load' pressure setting of the pressure reducing valve. For example, the typical blowdown
value (re seat differential) for a DIN type safety valve is 10% of the set pressure. The
minimum possible safety valve set pressure must there for equal the no-load set pressure of
the reducing valve plus the blowdown value of the safety valve plus a small margin of atleast
0.1bar. If the safety valve lifts and the working pressure is too close then it will not be able to
close properly and will simmer, create a leak which is often wrongly diagnosed as a result of a
leaking reducing valve.
Discharge pipe work should be taken to a safe place.

FMPRV41 13
 5.11 Position in relation to other control valves

Figure 9: FMPRV41 position in relation to other control equipment

*This is a typical representation of FMPRV41 position in relation to other control
equipment.

Line or system stop valves, either remotely actuated or manually, should be installed on the
upstream side of the Forbes Marshall Pilot Operated Pressure Reducing Valve FMPRV41.
Where there is downstream control equipment, particularly temperature control valve,
ensure the control equipment is atleast 50 pipe diameters away from the FMPRV41 to
prevent pressure pulses being transmitted back causing unstable operation and premature
wear or if this is impractical an intermediate vessel can provide a similar benefit.
Where a safety valve is required to protect the process system downstream of a FMPRV41
and where a temperature control valve is also being used downstream of the FMPRV41, it is
recommended that the safety valve is fitted downstream of the temperature control valve
rather than in between the FMPRV41 and the temperature control valve. If any slight
leakage occurs this will avoid any pressure build-up causing nuisance operation of the
safety valve but provide complete protection for the downstream system.
Where valves are installed downstream of the FMPRV41 the intermediate downstream
pipework must be properly trapped to ensure no condensate can build up on the
downstream side of the FMPRV41.

14 Forbes Marshall Pilot Operated Pressure Reducing Valve

6. Startup and Commissioning : (Refer figure 7)

1. Ensure that all connections are properly made and that all stop valves (2, 3 and 6) are
closed.
2. Close all stop valve (2, 3 and 6) at reducing valve station, including valves on bypass line
if fitted.
3. Check that adjustment screw of the Forbes Marshall Pilot Operated Pressure Reducing
Valve, FMPRV41 (5) is turned fully anti-close wise until spring is slack.
4. Check that the pressure gauge isolating valve (13) are open.
5. For correct operation of the FMPRV41 (5) it is important that the pilot and main valves
are not subjected to dirt or other hard particles .Therefore, prior to bringing the
FMPRV41 (5) into operation ensure that the upstream pipework has been cleared of all
the loose dirt and hard particles and that the main strainer screen (4) is examined and
cleaned if necessary.
6. Slowly open the upstream stop valve (2) until it is fully open.
7 Using a suitable sized spanner slowly turn adjustment screw of FMPRV41 (5) in a
clockwise direction until desired downstream pressure reading is obtained.
8. Holding the adjustment screw of FMPRV41 (5) in position with the spanner tighten
down the lock-nut to secure the setting of the adjustment spring.
9. Slowly open the downstream stop valve (6) until it is fully open.
Note: After installation or maintenance ensure that the system is fully functional. Carry
out tests on any alarms or protective devices. It is recommended that after
commissioning the pilot filter is changed and the spare one (supplied with the valve) is
fitted.

FMPRV41 15
7. Maintenance Guidelines:
Before undertaking any maintenance on the product it must be isolated from both
supply line and return line and any pressure should be allowed to safely normalize to
atmosphere. The body gasket (all FMPRV41derivatives) and actuating chamber gasket
contains a thin stainless steel support ring which may cause physical injury if not
handled and disposed of correctly.
7.1 Routine and Preventive Maintenance:
Please refer to the maintenance schedule mentioned in the table below to undertake
routine maintenance of the FMPRV41.

SR. PARAMETERS TO BE CHECKED FREQUENCY FOR CHECKING VARIOUS PARAMETERS

Forbes Marshall Pilot Operated

A Daily Weekly Monthly Quarterly Half Yearly Annually.
Pressure Reducing Valve

1 Clean Main valve strainer Y

2 Clean Pilot valve chamber assembly kit Y

3 Check & clean Main / Pilot diaphragm Y

4 Clean SS tube & stud coupling with split pin Y

5 Main valve cleaning Y

FMPRV41 overhauling and push rod

6 Y
checking

7 Pilot Valve chamber Strainer Y

16 Forbes Marshall Pilot Operated Pressure Reducing Valve

 7.2 Tool Kit:
To carry out maintenance of the Forbes Marshall Pilot Operated Pressure Reducing Valve
FMPRV41 refer the tools mentioned in the table below.
Size Component Tool used and Size
DN 15 / Main valve seat assembly Ring spanner 36 mm (A/F)
Veriner to measure depth & lift of the push rod (main valve head &
DN 15 1.8 mm lift
seat assembly)
Veriner to measure depth and lift of the push rod (main valve head
DN 20 2.3 mm lift
and seat assembly)
Main valve seat assembly Ring spanner 41 mm (A/F)
DN 25 Veriner to measure depth and lift of the push rod (main valve head
2.8 mm lift
and seat assembly)
Push rod lock nut Open spanner 13 mm (A/F)
Lower stud coupling Box spanner 13 mm (A/F)
Pilot valve assembly Ring spanner 19 mm (A/F)
M12 bolt and nut for bottom plate assembly Box spanner 19 mm (A/F)
Pilot Valve Chamber Assembly
DN 15 / M10 studs Stud Runner M10 X 1.5
20 /25 Nut Ring spannar 17mm (A/F)
Split Pin Nose Plier
M10 bolt for housing and spring assembly Box Spanner 17 mm (A/F)
4 No control pipe (Elbow fitting ) Open Spanner 13mm (A/F)
Lower drain Open Spanner 10mm (A/F)
Strainer cap Box Spanner 19 mm (A/F)
Main valve assembly (31mm slot and OD 37mm) Customer made tool has to be designed.
DN 40 Veriner to measure depth and lift of the push rod (main valve head
4.5 mm lift
and seat assembly)
Main valve assembly (42mm slot and OD 49 mm) Customer made tool has to be designed.
DN 50 Veriner to measure depth and lift of the push rod (main valve head
4.8 mm lift
and seat assembly)
Push rod lock nut Open spanner 17mm (A/F)
Stud coupling and long nut on lower plate Box spanner 13 mm (A/F)
M12 bolt and nut for bottom plate assembly Box spanner 19 mm (A/F)
Split Nut Nose Plier
Pilot Valve Chamber Assembly
DN 40 / M12 stud Stud Runner M12 X 1.75
50 Nut Ring spanner 24mm (A/F)
Strainer cap Box spanner 19 mm (A/F)
Pilot valve seat Open spanner 19mm (A/F)
M12 bolt for housing and spring Box spanner 19 mm (A/F)
4 No. control pipe (elbow fitting ) Open spanner 13 mm (A/F)
Low drain Open spanner 11mm (A/F)

FMPRV41 17
 7.3 Procedure to renew the pilot filter element: (Refer to Figure 10)
1. Isolate the reducing valve and depressurize the system completely.
2. Unscrew the filter cap (1) and carefully withdraw the filter element (2).
3. Replace the element and tighten the filter cap.
Note: The gasket is re-usable.
Filter
element
2

Filter cap
1
Figure 10: Filter element
7.4 Procedure to renew or change the pressure adjustment spring: (Refer to Figure 11)
Isolate the reducing valve and completely depressurize the system in order to change the
pressure adjustment spring.
1. Release the adjustment lock-nut (2) by turning in the anticlockwise direction.
2. Turn the adjustment screw (1) anticlockwise. Ensure there is no compression on the
pressure adjustment spring (4).
3. Undo the 4 off spring housing securing nuts and bolts (3) and remove the spring
housing.
4. Remove and replace the pressure adjustment spring (4) and the top spring plate (5).
Reassemble in reverse order.
Adjustment
Screw (1)

1 Adjustment
Locknut (2)

Spring Housing securing

Nuts and Bolts (3)

Top Spring Plate

(5)

Adjustment
Spring (4)

Figure 11: Pressure adjustment spring

18 Forbes Marshall Pilot Operated Pressure Reducing Valve

 7.5 Procedure to renew the pilot valve assembly FMPRV41steam: (Refer to Figure12)
1. Unscrew the unions of balancing pipe and controlling pipe (1) and release the pipe work.
2. Unscrew spring housing securing nuts and bolts (2), thereby releasing the spring housing,
spring (3), top spring plate (4), bottom spring plate (5) and pilot diaphragm (6)
3. Unscrew and remove the pilot valve assembly (7) (19 mm A/F). The pilot assembly hasan
integral PTFE seal.
The following handling precautions should be observed.
Handling precautions for PTFE
Within its working temperature range PTFE is a completely inert material, but
when heated to its sintering temperature it gives rise to gaseous decomposition
products or fumes which can produce unpleasant effects if inhaled. Fumes can be
produced during processing: for example, when the material is heated to sinter
it, or when brazed connections are being made to cable insulated PTFE. The
inhalation of these fumes is easily prevented by applying local exhaust
ventilation to atmosphere as near to their source as possible.
Smoking should be prohibited in workshops where PTFE is handled because
tobacco contaminated with PTFE will during burning give rise to polymer fumes.
It is therefore important to avoid contamination of clothing, especially the
pockets, with PTFE and to maintain a reasonable standard or personal cleanliness
by washing hands and removing any PTFE particles lodged under the fingernails.
4. Screw the new pilot valve into the housing and tighten the nuts to the recommended
torque (Refer Table1).
5. Check that there is a very slight clearance between the top of the plunger and a
straightedge placed across the diaphragm location recess.

Top spring plate (4)

Straight edge
Spring (3) Spring [Link] nuts and
bolts (2)

Bottom Spring Plate (5)

Pilot Diaphragms (6)
Plunger (8)

Pilot Valve
Assembly (7)

Unions of Unions of balancing

balancing pipe (1) pipe (1)

Figure 12: Pilot valve assembly FMPRV41 steam

FMPRV41 19
 6. Refit the two pilot diaphragms (6) and ensure that all contact faces are clean.
Diaphragms showing signs of wear or damage should be replaced.
7. Replace the bottom spring plate (5).
8. Assemble the spring housing and tighten the nuts to the recommended torques.

SIZE OF VALVE NUT SIZE TIGHTENINGA TORQUES

Dn15, DN20, DN25 M10 40-50 Nm
DN40 AND DN50 M12 45-55 Nm
Table 1 : Recommended tightening torques for spring housing nuts

7.6 Procedure to renew the pilot valve assembly for FMPRV41 air: ( Refer to fig.13 & 14)
Isolate the reducing valve and zero the pressure.
1. Unscrew the unions of balancing pipe and controlling pipe (1) and release the pipe work.
2. Unscrew spring housing securing nuts and bolts (2), thereby releasing the spring
housing, spring (3), top spring plate (4), bottom spring plate (5) and pilot diaphragm (6).

Top spring plate (4)

Spring (3)
Spring [Link] nuts
and bolts (2)

Bottom Spring Plate (5)

Pilot Diaphragms (6)

Unions of balancing Unions of control pipe (1)

pipe (1)

Figure 13: FMPRV41 air

3. Remove pilot valve housing (7).
4. Ensure main return spring (8) is still in position.
5. Unscrew and remove pilot valve assembly (9) (22 mm A/F)
6. Screw new pilot valve into housing and tighten the nuts to the recommended torques
(Refer Table1)

20 Forbes Marshall Pilot Operated Pressure Reducing Valve

 Pilot Valve
Housing (7)

Pilot Valve
Assembly (9)

Main Valve
Return Spring (8)

Figure 14: Dismantling Pilot Valve housing

7. Check that there is a very slight clearance between the top of the plunger and a straight
edge placed across the diaphragm location recess.
Note: The plunger is usually longer than what is required owing to production
tolerances. In order to achieve the correct length, it is generally necessary to grind or
machine material of the top end. Ensure the sharp edges formed as a result of
machining are removed, as these can damage the diaphragm.
7.7 Procedure to clean or replace the internal strainer screen: (FMPRV41 Steam / Air)
(Refer to Figure 15)
Isolate the reducing valve and zero the pressure.
1. Unscrew the unions (1) and release the pipework.
2. Unscrew the spring housing securing nuts and bolts (2).
3. Remove the pilot valve housing (3).
4. Remove the internal strainer screen (4) and clean or replace.
5. Ensure the gasket (5) faces are clean.
6. Check that the main valve return spring (6) is in position.
7. Fit a new gasket.
8. Replace the internal strainer screen.
9. Assembled the pilot valve housing (3) complete with spring housing assembly and
tighten the nuts to the recommended torques as shown in table 1.
10. Refit the pipe work and retighten unions to ensure a tight seal. Bring the valve in to
commission, following as many steps as necessary in section 6.

FMPRV41 21
 Spring Hsg. securing nuts
and bolts (2)
Pilot Valve Hsg. (3)

Gasket Faces (5)

Internal Strainer screen (4)

Unions (1)
Gasket Faces (5)

Main Valve return

spring (6)

Figure 15: Procedure to clean or replace the internal strainer screen

7.8 Procedure to renew the pilot valve diaphragms: (FMPRV41 Steam/Air) (Refer to
Figure 16)
Isolate the reducing valve and zero the pressure.
1. Unscrew the unions of balancing pipe and controlling pipe (1) and release the pipe work
2. Unscrew spring housing securing nuts and bolts (2), thereby releasing the spring
housing, spring (3), top spring plate (4), bottom spring plate (5) and pilot diaphragm (6)
3. Ensure the bottom spring plate (5) and pilot valve assembly is clean.
4. Replace the pilot valve diaphragms (6).
5. Assemble the spring housing and tighten the nuts to the recommended torque as
shown in Table 1. Bring the valve back into commission, following as many steps as
necessary in section 6.
Top spring plate (4)

Spring (3)
Spring [Link] nuts and
bolts (2)

Bottom Spring Plate (5)

Pilot Diaphragms (6)

Unions of
control pipe (1)
Unions of balancing
pipe (1)

Figure 16: Replacing/ Maintaining Pilot valve diaphragm

22 Forbes Marshall Pilot Operated Pressure Reducing Valve

 7.9 Procedure to renew or clean main diaphragms: (Refer to Figure 17)
Isolate the reducing valve and zero the pressure.
1. Undo the long union nut (1) and pull away.
2. Undo the M12 nuts and bolts (2).
3. Drop away the lower diaphragm chamber (3), the two main diaphragms (4),
diaphragm plate (5) and the pushrod assembly(6).
4. Thoroughly clean the lower diaphragm chamber (3) making sure contact faces are
clean.
5. Replace the diaphragm plate (5) and pushrod assembly (6) and loosely fit the lower
diaphragm chamber (3) on two bolts either side of the union connection .
6. Bring the two new diaphragms together and slide into position .
If the diaphragms are not renewed, but cleaned only, care must be taken to replace the
diaphragms in their original order.
7. Push the lower chamber (3) and tighten the M12 nuts and bolts (2). Progressively and
evenly tighten to a torque of 80 - 100 N m .
8. Retighten the long union nut to ensure a steam tight seal .
9. Bring the valve back into commission, following as many steps as necessary in section 6

M12 nuts
and bolts (2)

Push Rod
assembly (6) 17 (a)

Diaphragm Plate (5)

Main Diaphragms (4)

Union nut (1)

Lower Diaphragm
Chamber (3)

17 (c)
17 (a)

Figure 17: Main Diaphragms

FMPRV41 23
 7.10 Procedure to service or renew the main valve and seat (FMPRV41 Steam/Air):
(Refer to Figure 18, 19 and 20)
Isolate the reducing valve and zero the pressure.
For this section refer to figure 18
1. Unscrew the unions of balancing pipe and controlling pipe (1) and release the pipe
work
2. Unscrew spring housing securing nuts and bolts (2), thereby releasing the pilot valve
housing (3), complete with spring housing assembly (4).

Spring Housing
Assembly (4)

Spring Housing
securing nuts and bolts
(2)

Pilot Valve
Housing (3)

Unions of control pipe

(1)
Unions of balancing pipe (1)

Figure 18: (FMPRV41 Steam/Air)

For this section refer to figure 19
3. Remove the strainer screen (1) and gasket (2) and clean.
4. Remove the main valve spring (3) and the main valve head (4). Clean to remove dirt or
scaleas necessary.
5. Remove the main valve seat (5). Clean and remove dirt and scale as necessary.
6. Examine the faces of the main valve head (4) and seat (5). If they are only slightly
wornthey may be lapped on a flat plate using a fine grinding paste. If either is badly
worn orunfit for further use they must be replaced.
7. Refit the valve seat (5) applying jointing compound to the seating faces and tighten to
therecommended torque as shown in Table 2.

24 Forbes Marshall Pilot Operated Pressure Reducing Valve

 Strainer
screen (1)

Gasket (2)

Main valve spring (3)

Main valve head (4)

Main valve seat

(5)

Figure 19: Cleaning the main valve head and seat

Where a new part has been fitted it will be necessary to reset the main valve pushrod to
give the correct valve lift: (Refer to Figure 20)
To do this it is necessary to expose the main diaphragm plate (2) and pushrod assembly(5).
1. Undo the long nuts and pull away.
2. Undo the M12 nuts and bolts (1).
3. Drop away the lower diaphragm chamber (4), the two diaphragms (3), and diaphragm
plate (2) and pushrod assembly (5).

M12 nuts
and bolts (1)

Push Rod
assembly (5)

Diaphragm Plate (2)

Main Diaphragms (3)

Lower Diaphragm
Chamber (4)

Figure 20: Resetting the main valve pushrod

Table 2: TORQUE FOR MAIN VALVE SEAT FMPRV41 STEAM/AIR

FMPRV41 25
 4. Refit the pushrod assembly.
5. Refit the main valve head, make sure valve locates on seat.
6. Check the valve lift shown in Table 3 using a depth gauge and adjust if necessary
byscrewing the pushrod in or out of the diaphragm plate.
Table 3 : VALVE LIFT FMPRV41 STEAM/AIR

Size of Valve Valve Lift

DN15 1.8
DN20 2.3
DN25 2.8
DN40 4.3
DN50 4.8

For this section refer to figure 21

7. Thoroughly clean the lower diaphragm chamber (4) making sure contact faces are
clean.
8. Replace the diaphragm plate (2) and pushrod assembly (1) and loosely fit the lower
diaphragm chamber on two bolts (5) either side of the union connection to locate the
spigot in the recess.
9. Refit the diaphragms (3) in exactly the same way as when they were dismantled.
10. Push the lower diaphragm chamber (4) home to locate in the recess and refit the M12
nuts and bolts. Progressively and evenly tighten to a torque of 80 - 100 N m.
11. Retighten the long union nut to ensure a steam tight seal.

M12 bolts (5) Push rod

assembly (1)

Diaphragm plate (2)

Main Diaphragms (3)

Lower diaphragm
chamber (4)

Figure 21: Resetting the main valve pushrod

26 Forbes Marshall Pilot Operated Pressure Reducing Valve

 7.11. Procedure to reassemble the valve: (Refer to Figure 22)

Gasket (1)

Main Valve
spring (2)
Unions (4)

Main Valve
Head (3) Unions (4)
Internal Strainer
Screen (5)

Figure 22: Reassembling

1. Refit the main valve head (3).
2. Replace the main valve return spring (2).
3. Fit a new gasket (1).
4. Replace the internal strainer screen (5).
5. FMPRV41 - Steam
Assemble the pilot valve housing complete with spring housing assembly and tighten
the nuts to the recommended torques.
FMPRV41 - AIR
Assemble the pilot valve housing and tighten the nuts to the recommended torques
6. Refit the pipework and retighten the unions (4) to ensure a tight seal. Bring the valve
back into commission, following as many Steps as necessary in Section 6.

FMPRV41 27
8. Troubleshooting:
Before undertaking the following fault finding procedure, ensure the valve has been isolated and
that upstream & downstream pressures are zero. Possible fault checks are given in a logical order
below. A pressure reducing valve typically has the following failure modes:
1) Downstream pressure zero or too low:
If downstream pressure of Forbes Marshall Pilot Operated Pressure Reducing Valve is zero,
please check following before dismantling the Forbes Marshall Pilot Operated Pressure
Reducing Valve.
1. Downstream pressure gauge: - Please ensure that it should be in working condition.
2. Upstream pressure: - It Should be as per the pressure reducing valve upstream design
pressure.
3. Isolation valve not fully Open - Ensure Upstream & Downstream Isolation valves are in
full open condition
4. Upstream Strainer Clogged – Ensure upstream Strainer is in clean condition: Clean it if it
is found as clogged.

Failure Mode Possible Cause Remedy

Please ensure that pressure adjustment bolt is not in

Pressure adjustment bolt loose condition. If so, rotate it clockwise slowly to set the
desired downstream pressure.

Ensure Pilot valve strainer, Control pipe assembly &SS hex

Clogging in pressure coupling fixed to bottom diaphragm chamberare clean. If
reducing valve found clogged clean it properly. Check the internal
balancing line for blockage.

Downstream
If main diaphragms are permanently deformed or
pressure zero Main Diaphragms
punctured - replace the same.
or too low

Please check if Push rod is jammed in liner bush at lower

Jamming of push rod
position. Open & clean it.

Check that pushrod lock nut is intact & it is in full

tightens condition. If it is loose there is a chance that the
Main valve lift disturbed:
main valve lift may be reduced. To re adjust the main
valve lift, Please refer the main valve lift setting video clip.

28 Forbes Marshall Pilot Operated Pressure Reducing Valve

 2) Downstream pressure is equal to upstream pressure:
If downstream pressure of Forbes Marshall Pilot Operated Pressure Reducing Valve is equal
to upstream pressure, please check following before dismantling the Forbes Marshall Pilot
Operated Pressure Reducing Valve.
1. By Pass isolation valve: - Please ensure that it should not be leaking & should be in full
closed condition.
2. Feedback line: - Isolation valve installed in the feedback line should be fully open and
the line should not be clogged, clean it if necessary.

Failure Mode Possible Cause Remedy

1. Please ensure that pressure adjustment bolt is not in

full tight condition. Release it fully, ensure that the
downstream pressure is zero and re adjust the
required downstream pressure by slowly rotating it
clockwise.
2. If downstream pressure does not respond to the
adjustment bolt rotation, check the pilot valve or
main valve leakage by following the next step.
A) Close the upstream isolation valve
B) Loosen the pressure adjustment bolt and Make the
downstream pressure zero
Pressure adjustment bolt C) Remove the SS tubing from Pilot valve chamber &
center T Joints
Downstream D) Open the upstream isolation valve slowly & check for
pressure is steam leakage
equal to E) If steam coming from Pilot valve chamber – it means
upstream Pilot valve is leaking.
pressure F) Clean the Pilot valve or replace it, if required.
G) If steam coming from “T” joint – It means either
Main valve is leaking or Main valve return Spring is
broken - Clean & lap the main valve head or replace
the MV return spring if found broken. If the problem
still persists then follow the next step.

Check the control orifice Clean it if found clogged.

Check pilot diaphragm Replace if found deformed or damaged.

Check that pushrod lock nut is intact & it is in full

tighten condition. If it is loose there is a chance that the
Pushrod locknut
main valve lift may be disturbed. To re adjust the main
valve lift.

FMPRV41 29
 3) Hunting:
Hunting or Pressure Fluctuations may coincide with variations in steam load. In such case,
check following before dismantling the Forbes Marshall Pilot Operated Pressure Reducing
Valve.
1. WET Steam- Ensure steam is not wet and Moisture separator is installed before the
pressure reducing valve & the steam trap below it, is operational.
2. Up Stream Pressure – It is recommended to have stable upstream pressure however the
Forbes Marshall Pilot Operated Pressure Reducing Valve will give constant downstream
pressure with + or - 20% variation in designed Upstream pressure.
3. Partial Blockage in Upstream - If the pressure drops during full-load conditions, it is
possible that there is a partial blockage in the upstream line or that the upstream pipe
work is undersized. Steam Line should be sized properly to carry the required steam
flow rate at given pressure considering steam velocity of 25 M/S. Please refer steam line
sizing chart for correct steam line size.
4. Isolation valves - Ensure Upstream & Downstream Isolation valves are in full open
condition. By pass valve should be in full closed condition and it should not be leaking.
5. Upstream Strainer Clogged – Ensure upstream Strainer is in clean condition: Clean it if it
is found as clogged.
6. Bypass valve – Check whether the bypass valve is leaking. Replace if found so.

Failure Mode Possible Cause Remedy

Sticking of push rod Check that the Main valve pushrod is not sticking. Open & clean
in the Main Valve it. Also check whether the push rod outer surface is not
Chamber deformed. Replace the push rod if it is found deformed.

Diaphragms Over
Stretched / If Pilot diaphragms or main diaphragms overstretched or
permanently deformed -replace the same.
deformed

Set the pressure reducing valve in no flow condition i.e. all

Hunting process valves are closed. Now Apply full- load to the pressure
reducing valve by opening all the process valves. If the
downstream pressure drops excessively during full-load
pressure reducing condition but it is maintaining by opening of by-pass valve, it is
valve sizing. likely that the valve is undersized; in which case it should be
replaced. Please refer the pressure reducing valve sizing chart
given in Technical information sheet to know the correct
pressure reducing valve size. Consult Forbes Marshall for correct
sizing of the valve.

Check Split pin port Check the port is clean and the split pin is free to move

30 Forbes Marshall Pilot Operated Pressure Reducing Valve

9. Available Spares:

STEAM

U
R L

A,B
A

Q
Pilot valveassembly

M B S

AIR

Pilot valveassembly
O
T STEAM

C
H
D
I
E J P
F
Push rodassembly
K
G

STEAM AIR

Figure 23: Parts Available as spares (Heavy outline ) for FMPRV41

FMPRV41 31
No. Description Version Symbol Spare Code

Spring Hsg stud & Nut kit DN 15/20/25 S2055878

STEAM A
Spring Hsg stud & Nut kit DN 40 / 50 S2055879
1
Spring Hsg stud & Nut kit DN 15/20/25 S2031934
AIR B
Spring Hsg stud & Nut kit DN 40 / 50 S2031935
Body lower Bolt & Nut kit DN 15/20/25 S2031993
2 STEAM/ AIR C
Body lower Bolt & Nut kit DN 15/20/25 S2031993
Main valve kit Assembly with Spring DN 15 S2055880
Main valve kit Assembly with Spring DN 15 (long neck) S2055948
Main valve kit Assembly with Spring DN 15 (low capacity) S2055946
Main valve kit Assembly with Spring DN 20 S2055881
STEAM D,E,F,G
Main Valve kit Assembly with Spring DN 20 (long neck) S2055947
Main Valve kit Assembly with Spring DN 25 S2055882
Main Valve kit Assembly with Spring DN 40 S2055883
Main valve kit Assembly with Spring DN 50 S2055884
3
Main valve kit Assembly with Spring DN 15 S2019705
Main valve kit Assembly with Spring DN 15 (long neck) S2055950
Main valve kit Assembly with Spring DN 15 (low capacity) S2055949
Main valve kit Assembly with Spring DN 20 S2019706
AIR H,I,J,K
Main Valve kit Assembly with Spring DN 20 (long neck) S2055951
Main Valve kit Assembly with Spring DN 25 S2019707
Main Valve kit Assembly with Spring DN 40 S2019708
Main valve kit Assembly with Spring DN 50 S2019709
Control Pipe Assembly Kit DN 15/20 S2055885
Control Pipe Assembly Kit DN 20 S2055886
Control Pipe Assembly Kit DN 25 STEAM L S2055886
Control Pipe Assembly Kit DN 40 S2055887
4 Control Pipe Assembly Kit DN 50 S2055888
Control Pipe Assembly Kit DN 15/20 S2019606
Control Pipe Assembly Kit DN 25 S2019607
AIR M
Control Pipe Assembly Kit DN 40 S2019608
Control Pipe Assembly Kit DN 50 S2019609

32 Forbes Marshall Pilot Operated Pressure Reducing Valve

 No. Description Version Symbol Spare Code
Pipe Assembly Kit DN 15 / 20 S2055889
Pipe Assembly Kit DN 25 S2055890
STEAM N
Pipe Assembly Kit DN 40 S2055891
Pipe Assembly Kit DN 50 S2055892
5
Pipe Assembly Kit DN 15 / 20 S2019710
Pipe Assembly Kit DN 25 S2019711
AIR O
Pipe Assembly Kit DN 40 S2019712
Pipe Assembly Kit DN 50 S2019713
Main Diaphragm Kit DN 15 /20 S2019636
6 Main Diaphragm Kit DN 25 STEAM / AIR P S2019692
Main Diaphragm Kit DN 40 / 50 S2019693
7 Pilot Diaphragm Kit DN 15/20/25/40/45 STEAM/AIR Q S2019680
P.V. Chamber Assembly Kit DN 15/25/25 S2055893
STEAM R
P.V. Chamber Assembly Kit DN 40 / 50 S2055894
8
P.V. Chamber Assembly Kit DN 15/20/25 S2019549
AIR S
P.V. Chamber Assembly Kit DN 40/50 S2019559
Gasket Kit DN 15/20/ 25 S2019642
9 STEAM/AIR T
Gasket Kit DN 40/50 S019527
10 Pressure Adjustment Conical Spring STEAM/AIR U S2038888
Main Valve Return Spring kit DN 15/20 S2019701
11 Main Valve Return Spring kit DN 25 STEAM/AIR H S2019702
Main valve return spring kit DN 40/50 S2019703
Repair kit for DN 15 S2055895
Repair kit for DN20 S2055896
A,B,L,S,Q,M,
12 Repair kit for DN25 STEAM S2055897
R,I,O,V
Repair kit for DN40 S2055898
Repair kit for DN 50 S2055899
Push Rod Assembly kit for DN 15/20 S2055936
Push Rod Assembly kit for DN 25 S2055937
13 STEAM/ AIR V
Push Rod Assembly kit for DN 40 S2055938
Push Rod Assembly kit for DN 50 S2055939

How to Order:
1 no. Forbes Marshall Pilot Operated Forbes Marshall Pilot Operated Pressure Reducing
Valve, DN 40 FMPRV41 having a 0.2-17 bar g spring and flanged BS10 table “F/H”
connections.

10. Warranty Period:

As per the ordering information and agreement in the contract.

FMPRV41 33
Disclaimer:
This information is strictly proprietary and legally privileged. All contents herein shall be the property of Forbes
Marshall Pvt Ltd and having protection under the intellectual property rights. No part of this information or data may
be distributed or disclosed in any form to any third party. Any dissemination, use, review, distribution, printing or
copying is strictly prohibited, if you are not the intended recipient or user of this information.

Forbes Marshall Pvt Ltd

Manufacturing: B-85, Phase II Chakan Indl Area, Sawardari, Chakan
Tal. Khed, Dist, Pune 410 501. Tel: +91(0)2135 393400
Sales: Opp 106th Milestone, Bombay Pune Road, Kasarwadi,
Pune 411034 Tel.: +91 (0)20 39858555
CIN No: U28996PN1985PTC037806

Email : seg@[Link] [Link]

Doc# FMSS/0415/UM-FMPRV41/V2.R0