Emerson Ace95 Vapor Saver Tank Blanketing Valve Instruction Manual
2015-03-30
: Emerson Emerson-Ace95-Vapor-Saver-Tank-Blanketing-Valve-Instruction-Manual-681074 emerson-ace95-vapor-saver-tank-blanketing-valve-instruction-manual-681074 emerson pdf
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ACE95 Series Instruction Manual Form 5667 May 2010 Type ACE95 and Type ACE95Sr Tank Blanketing Valves W9133 W8155 Figure 1. Type ACE95 Tank Blanketing Valve Figure 2. Type ACE95Sr Tank Blanketing Valve Introduction Scope of the Manual maintain a positive pressure and thereby reduce the possibility of tank wall collapse during pump out operations, in addition to preventing liquid from vaporizing into the atmosphere. Product Description Specifications ACE95 Series tank blanketing valves are self-contained, balanced, pilot operated, and used for accurate pressure control on gas blanketing systems. These valves help control emissions and provide protection against atmospheric contamination. ACE95 Series valves The following page lists specifications and ratings for ACE95 Series tank blanketing valves. Factory specifications are stamped on a nameplate fastened to the upper actuator case of the valve. D102775X012 This instruction manual provides installation, startup, and maintenance procedures for the ACE95 Series (Type ACE95 and Type ACE95Sr) tank blanketing valves. See Figures 1 and 2. www.fisherregulators.com ACE95 Series Specifications Body Sizes and End Connection Styles Type ACE95 Angled Body*: 3/4 NPT 1 NPT NPS 1 (DN 25), CL150RF NPS 1 (DN 25), CL300RF NPS 1 (DN 25), PN16/25/40RF NPS 1 (DN 25) Sanitary Flange In-Line Body: 3/4 NPT 1 NPT NPS 1 (DN 25), CL150RF NPS 1 (DN 25), CL300RF NPS 1 (DN 25), PN16/25/40RF NPS 1 x 2 (DN 25 x 50), CL150RF NPS 1 x 2 (DN 25 x 50), PN16/25/40RF NPS 1 (DN 25), Sanitary Flange Type ACE95Sr Angled Body*: 2 NPT NPS 2 (DN 50), CL150RF NPS 2 (DN 50), CL300RF Maximum Operating Inlet Pressure 200 psig (13,8 bar) Pressure Registration External Accuracy Typically within 0.5-inches w.c. (1 mbar) when flowing 5 to 70 percent of advertised capacities. Main Valve Flow Characteristic Linear Flow Coefficients for Relief Valve Sizing Type ACE95: Type ACE95Sr: Cv 1 use Cv 1.1 Cv 20 use Cv 22 Cv 2 use Cv 2.2 Cv 45 use Cv 50 Cv 4 use Cv 4.4 Cv 60 use Cv 66 Cv 7.5 use Cv 9.25 Cv 10 use Cv 11 Material Temperature Capabilities Nitrile (NBR): –20° to 180°F (–29° to 82°C) Fluorocarbon (FKM): 0° to 212°F (–18° to 100°C) Ethylenepropylene (EPDM/FDA): –20° to 212°F (–29° to 100°C) Maximum Outlet (casing) Pressure 20 psig (1,4 bar) Perfluoroelastomer (FFKM): –20° to 212°F (–29° to 100°C) Maximum Operating Outlet Pressure 1.5 psig (0,10 bar) Approximate Weights Control Pressure Ranges -5.0-inches w.c. to 1.5 psig (-12 mbar to 0,10 bar) see Table 1 With all accessories: Type ACE95: 40 pounds (18 kg) Type ACE95Sr: 60 pounds (27 kg) *Various Single Array Manifold (SAM) tank connections are also available. Contact your local Sales Office for more information. Table 1. Control Pressure Ranges SPRING MATERIAL SPRING FREE LENGTH, INCH (mm) -5 to -0.5-inches w.c. (-12 to -1 mbar) Stainless Steel 2.75 (69,9) 0.88 (22,4)(1) 0.080 (2,03) 0.085 (2,16)(1) -1 to 1-inches w.c. (-2 to 2 mbar) Stainless Steel 2.75 (69,9) 1.60 (40,6)(1) 0.080 (2,03) 0.065 (1,65)(1) Stainless Steel Stainless Steel Stainless Steel Stainless Steel 2.75 2.00 2.00 2.75 0.080 0.112 0.125 0.225 CONTROL PRESSURE RANGE 0.5 to 5-inches w.c. 4 to 10-inches w.c. 8 to 15-inches w.c. 0.5 to 1.5 psig (1 to 12 mbar) (10 to 25 mbar) (20 to 37 mbar) (0,03 to 0,10 bar) (69,9) (50,8) (50,8) (69,9) SPRING WIRE DIAMETER, INCH (mm) (2,03) (2,84) (3,18) (5,72) 1. The second spring is located under the diaphragm assembly. Principle of Operation ACE95 Series tank blanketing valves are pilot operated, activated by the diaphragm, and control the vapor space pressure over a stored liquid. The unit is controlled by a very large diaphragm actuator. The oversized actuator offers high sensitivity to changes in tank pressure. When a storage tank cools and 2 tank vapors condense, ACE95 Series valves replace the condensing vapors with an inert gas to prevent internal tank pressure from decreasing. Positive tank pressure prevents outside air from contaminating the product and reduces the possibility of atmospheric pressure collapsing the tank. As demand is satisfied, the valve closes. ACE95 Series pilot valve (open) orifice rolling diaphragm Pilot Spring range Spring diagnostic port sensing line INLET PRESSURE TANK PRESSURE INLET BLEED PRESSURE ATMOSPHERIC PRESSURE inlet pressure INLET PRESSURE Tank pressure TANK PRESSURE inlet bleedBLEED pressurePRESSURE INLET atmospheric pressurePRESSURE ATMOSPHERIC Figure 3. ACE95 Series Operational Schematic (valve open) ACE95 Series valves respond to slight decreases in internal tank pressure by opening and increasing the flow rate of inert gas into the tank. When the tank’s liquid level has been lowered to the desired point and the vapor pressure setpoint is re-established, the valve closes. Installation and Startup ! Warning Personal injury, equipment damage, or leakage due to escaping accumulated gas or bursting of pressure-containing parts may result if this gas blanketing system is overpressured or installed where service conditions could exceed the limits given in the Specifications section and on the appropriate nameplate, or where conditions exceed any ratings of the adjacent piping or piping connections. To avoid such injury or damage, provide pressure-relieving or pressure-limiting devices (as required by Title 49, Part 192, of the U.S. Code of Federal Regulations, by the National Fuel Gas Code Title 54 of the National Fire Codes of the National Fire Protection Agency, or by other applicable codes) to prevent service conditions from exceeding those limits. Additionally, physical damage to the tank blanketing system could result in personal injury and property damage due to escaping accumulated gas. To avoid such injury and damage, install the tank blanketing valve in a safe location. 3 ACE95 Series Blanketing Gas Supply line shutoff valve Line strainer sensing line shutoff valve ShutOff Valve emergency Tank vent Tank vent Blanketing gas to tank gas tank liquid E0623 Figure 4. ACE95 Series Tank Blanketing Valve Installation This ACE95 Series valve was assembled and preset to the customer specified pressure and setpoint. The control pressure range of the valve is stamped on the nameplate fastened to the upper actuator case. The gas blanketing setpoint is the only adjustable feature on this unit. 1. Use qualified personnel when installing, operating, and maintaining valves. Before installing, inspect the valve and tubing for any shipment damage or foreign material that may have collected. Make certain the body interior is clean and the pipelines are free of foreign material. Apply pipe compound only to the male pipe threads with a threaded body, or use suitable line gaskets and good bolting practices with a flanged body. the tank. Three connections are required: a) blanketing gas supply to valve, b) valve outlet to tank, and c) sensing line to tank. Piping Considerations caution Undersized piping may inadequately deliver blanketing gas at the specified inlet pressure under full flow conditions. This may result in unacceptable performance under high demand conditions. Unnecessarily long or restricted outlet piping may result in poor setpoint control. 2. Inspect the nameplate on the upper actuator case. It displays the model number, serial number, a blanketing gas supply pressure range, and the maximum inlet pressure and set pressure. These must agree with the system that you are blanketing. The serial number will be needed in any communication with your local Sales Office. Inlet Piping 3. Clean the gas blanketing supply lines of all dirt and foreign material before connecting them to the ACE95 Series tank blanketing valve. Outlet Piping 4. The valve must be mounted so the actuator case is horizontal. The valve should be mounted above 4 The blanketing gas supply line should be equipped with a Number 100 mesh strainer to remove dirt and pipe scale. Inlet piping must be sized to adequately deliver blanketing gas at the specified inlet pressure under full flow conditions. Type ACE95 or Type ACE95Sr valve outlet is piped into the tank vapor space. Outlet piping must be full size and self-draining to the tank. The valve should be situated above and as close as possible to the tank vapor space for best performance. ACE95 Series Sensing Line adjusting screw (key 2) The sensing line should be 1/2-inch (13 mm) tubing or pipe, must slope down toward the tank, and should not contain low points (or traps) that could catch liquid. The sensing line must enter the tank above the liquid level at a point that senses the vapor space pressure and is free from turbulence associated with tank nozzles or vents. actuator cap (Key 1) lock Nut (key 3) vent (key 6) Note Best control is obtained when both connections to the tank are separate. If the tank has only one available nozzle, contact Emerson® for alternate methods of installation. A single array manifold is available for such situations. spring case (key 7) Gauges and Shutoff Valves Inlet gas shutoff valves are desirable for servicing. If this ACE95 Series tank blanketing valve was not ordered with an inlet pressure gauge, it is advisable to install a gauge between the inlet shutoff valve and the blanketing valve. Note Safety considerations may dictate full port shutoff valves between the tank and blanketing valve, and at the valve inlet. Startup, Adjustment, and Shutdown Note Tank vents and safety relief valves must be in place and operating. caution Always open the outlet valve before the inlet valve. Operation in the reverse order could result in inlet pressure being applied to the actuator casing, potentially damaging it. Startup 1. Open shutoff valves between the blanketing valve and the tank (both sensing and outlet). See Figure 4. 2. Slowly open the supply line shutoff valve (to the blanketing valve) and leave it fully open. 3. Monitor the tank vapor space pressure. W8160 Figure 5. Spring Case, Adjusting Screw, and Actuator Cap Adjustment The setpoint of this unit is factory set. If an adjustment is to be made, it should be done so in small increments while the unit is supplying gas to the tank. To change the setpoint: 1. Unscrew and remove the actuator cap (key 1) from the top of the spring case (key 7). See Figure 5. 2. Loosen the lock nut (key 3) and turn the adjusting screw (key 2) clockwise to raise the setpoint. (Turning the screw counter-clockwise lowers the setpoint.) 3. Observe the effects of the change. 4. When the adjustment is complete, tighten the lock nut (key 3) and replace the actuator cap (key 1). Shutdown Installation arrangements vary, but in any installation it is important to open and close valves slowly and to close the upstream shutoff valve first when shutting down the system. Diagnostics Note If a diagnostics pressure gauge was not ordered with the unit, a pressure gauge must be installed in the diagnostic port to perform diagnostic analysis. 5 ACE95 Series Diagnostics are an optional feature of the ACE95 Series Tank Blanketing valves that aid in evaluating valve operation. The diagnostic analysis relies on the relationship of pilot pressure and pressure in the main valve chambers (see Figure 3). The basic relationships are as follows: In order to evaluate a valve, examine the valve nameplate to determine the Cv and inlet pressure range main valve spring. The inlet pressure gauge indicates actual pressure supplied to the valve. Follow these steps and refer to the diagnostics tables on the following pages to evaluate a valve under actual operating conditions: 1. Select the Table (Tables 3 through 8) that corresponds to the Cv and inlet pressure range of your valve. 2. Determine the actual valve operating inlet pressure in the first column of the diagnostics table. Table 2. Diagnostic Analysis Pressure Ranges DIAGNOSTIC (PRESSURE CHAMBER) STATUS Equal to inlet supply pressure Pilot and main valves are closed. Tank at or above set pressure. Slightly below inlet supply pressure Pilot valve supplies gas to tank. Tank pressure is just below set pressure. Well below inlet supply pressure Pilot and main valves are both supplying gas to the tank. Tank pressure is below setpoint. 3. In the second column of the table, determine the pressure of the pilot as it opens. Pressure to Start Opening Main Valve: The diagnostic pressure drops to this level as the tank pressure decreases and reaches the valve setpoint. The pilot is fully open at this pressure. Pressure to Fully Open Main Valve: At this point, both the main valve and pilot valve are fully open and supplying gas to the tank. Maintenance Valve parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and replacement of parts depends on the severity of service conditions and the requirements of local, state, and federal regulations. Due to the care Emerson® takes in meeting all manufacturing requirements, use only replacement parts manufactured or furnished by Emerson. All O-rings, gaskets, and seals should be lubricated with a good grade of general purpose lubricant and installed gently rather than forced into position. Suggested lubricant, sealant, and adhesive are as follows: Lubricant: Dow Corning® 111 or equivalent Sealant: Loctite® PST #592, Polytetrafluoroethylene (PTFE) Tape or equivalent Adhesive: Loctite #222 or equivalent Be certain that nameplates are updated to accurately indicate any field changes in equipment, materials, service conditions, or pressure settings. Monthly Maintenance 4. Determine the diagnostic pressure for the start to open pressure of the main valve in the third column. 1. Visually inspect the unit to ensure tight connections, tight seals, and safe operation. 5. The fourth column displays the diagnostic pressure for the full open pressure of the main valve. 2. Observe the blanketing pressure. There are four pressures involved in evaluating a valve: actual inlet pressure, pressure to start opening pilot valve, pressure to start opening main valve, and pressure to fully open main valve. Actual Inlet Pressure: The gas pressure supplied to the inlet of the valve. This is the maximum diagnostic pressure. Pressure to Start Opening Pilot Valve: The diagnostic pressure drops to this value as the valve senses decreasing tank pressure. The main valve remains closed at this pressure. 6 3. Inspect the inlet pressure for the proper pressure range (stamped on the valve nameplate). Annual Maintenance 1. Visually inspect the unit to ensure tight connections, tight seals, and safe operation. 2. Observe the blanketing pressure. 3. Inspect the inlet pressure for the proper pressure range (stamped on the valve nameplate). 4. Visually inspect valve for any external wear. 5. If there is evidence of leakage or unstable internal motion, a rebuild with seal replacement and relubrication may be in order. ACE95 Series Table 3. Type ACE95 Diagnostics Table: Cv 1 through 4, Inlet Pressure Range Spring 25 to 50 psig (1,7 to 3,4 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) 25 (1,7) 30 (2,1) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) 24 (1,7) 9 (0,62) 2 (0,14) 29 (2,0) 13 (0,90) 6 (0,41) 35 (2,4) 34 (2,3) 16 (1,1) 9 (0,62) 40 (2,8) 39 (2,7) 20 (1,4) 13 (0,90) 45 (3,1) 44 (3,0) 24 (1,7) 17 (1,2) 50 (3,4) 49 (3,4) 28 (1,9) 21 (1,4) Table 4. Type ACE95 Diagnostics Table: Cv 1 through 4, Inlet Pressure Range Spring 51 to 120 psig (3,5 to 8,3 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) When Main Valve Starts to Open, Psig (bar) 51 (3,5) 50 (3,4) 29 (2,0) 5 (0,35) 60 (4,1) 59 (4,1) 36 (2,5) 12 (0,83) 70 (4,8) 69 (4,8) 43 (3,0) 19 (1,3) 80 (5,5) 79 (5,4) 51 (3,5) 27 (1,9) 90 (6,2) 89 (6,1) 59 (4,1) 34 (2,3) 100 (6,9) 99 (6,8) 66 (4,6) 42 (2,9) 110 (7,6) 109 (7,5) 74 (5,1) 50 (3,4) 120 (8,3) 119 (8,2) 81 (5,6) 57 (3,9) Disassembly and Assembly caution Before removing the valve from the line, ensure that it is isolated from the gas supply pressure and that all pressure has been released from the valve. (The drain on the inlet filter is convenient to bleed off gas.) All tank connections must be closed or sealed in accordance with your plant’s operating and safety procedures. If installed, electrical connections to the explosion proof switch must be deactivated before opening the enclosure or disconnecting the wiring (in accordance with codes and safety practices). It is recommended that all seals and diaphragms be replaced as a matter of good practice whenever a valve is disassembled and re-assembled. Parts kits are available through your local Sales Office. If you are performing disassembly or assembly operations on a Type ACE95Sr valve, refer to the Parts List and see Figure 9. If you are working on a Type ACE95 valve, refer to the Parts List and see Figure 8. When Main Valve is Fully Open, Psig (bar) Note Have your model number, serial number, inlet pressure and set pressure range, Cv value, and tank vent/relief setting available when ordering parts. Valve information is on the nameplate (on the upper actuator case). Disassembly ! Warning To avoid personal injury resulting from sudden release of pressure, isolate the valve from all pressure and cautiously release trapped pressure from the pilot or valve before attempting disassembly. Spring Case Disassembly 1. Remove the actuator cap (key 1) and the spring load by unthreading the adjusting screw (key 2). See Figure 5. 2. Unthread the hex-head screws, lock washers, and nuts (keys 32, 28, and 31) from the upper and lower actuator cases (keys 33 and 30). Lift the upper actuator case from the lower actuator case. 3. Remove the spring seat and range spring (keys 5 and 8). 7 ACE95 Series Table 5. Type ACE95 Diagnostics Table: Cv 1 through 4, Inlet Pressure Range Spring 121 to 200 psig (8,3 to 13,8 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) 121 (8,3) 120 (8,3) 74 (5,1) 30 (2,1) 130 (9,0) 129 (8,9) 81 (5,6) 37 (2,6) 140 (9,7) 139 (9,6) 88 (6,1) 45 (3,1) 150 (10,3) 149 (10,3) 96 (6,6) 53 (3,7) 160 (11,0) 159 (11,0) 104 (7,2) 60 (4,1) 170 (11,7) 169 (11,7) 111 (7,7) 68 (4,7) 180 (12,4) 179 (12,3) 119 (8,2) 75 (5,2) 190 (13,1) 189 (13,0) 127 (8,8) 83 (5,7) 200 (13,8) 199 (13,7) 134 (9,2) 91 (6,3) Table 6. Type ACE95 Diagnostics Table: Cv 7.5 and 10, Inlet Pressure Range Spring 25 to 50 psig (1,7 to 3,4 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) 25 (1,7) 24 (1,7) 11 (0,76) 0 (0,0) 30 (2,1) 29 (2,0) 14 (0,97) 3 (0,21) 35 (2,4) 34 (2,3) 17 (1,2) 6 (0,41) 40 (2,8) 39 (2,7) 21 (1,4) 9 (0,62) 45 (3,1) 44 (3,0) 24 (1,7) 13 (0,90) 50 (3,4) 49 (3,4) 27 (1,9) 16 (1,1) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) Actuator/Diaphragm Disassembly Main Valve Disassembly 1. Disassemble the diaphragm by unthreading the diaphragm retaining nut (key 13) from the diaphragm bolt (key 15). 1. Remove the main valve (key 25) along with the main valve spring (key 26), spring shim [key 34, 25 to 50 psig (1,7 to 3,4 bar), Type ACE95 only], and spring guide (key 49, Type ACE95Sr only) from the bonnet (key 17). 2. Remove the upper and lower diaphragm plates (keys 10 and 48) and the diaphragm (key 11). [The actuator gasket (key 12) sits on top of the diaphragm.] In cases where the pressure range is positive, the upper diaphragm plate is larger than the lower diaphragm plate. 3. Remove the internal bonnet screws and lock washers (keys 28 and 29) that attach the lower actuator case (key 30) to the bonnet. Remove the lower actuator case and the actuator O-ring (key 53, Type ACE95) or gasket (key 27, Type ACE95Sr). 4. Remove the cap screws and lock washers (keys 28 and 29, Type ACE95 or keys 50 and 51, Type ACE95Sr) that attach the bonnet (key 17) to the body (key 18). 5. Lift the bonnet (key 17) from the body (key 18). Note Slightly rotating the bonnet may help loosen the O-ring (key 19). 8 2. Unthread the screw (key 20) from the main valve. 3. Remove the plug (key 22) from the main valve (key 25). See Figure 7. 4. Insert wooden dowel rod (or similar blunt tool) through the bottom of the bonnet bore to remove the cage (keys 35 and 40) sub-assembly. Pilot/Cage Disassembly caution Do not wrench or bend the stem of the poppet (key 42). Use soft-jawed pliers to hold the piston without damaging it. 1. The upper cage (key 40) will readily separate from the lower cage (key 35). See Figure 6. 2. Gently press the poppet stem (key 42) to remove the pilot from the upper cage (key 40). 3. Insert a small drill bit into the cross-drilled hole on the poppet (key 42) to turn and loosen. Unthread the poppet from the piston (key 37). Remove the rolling diaphragm (key 38). ACE95 Series Table 7. Type ACE95 Diagnostics Table: Cv 7.5 and 10, Inlet Pressure Range Spring 51 to 120 psig (3,5 to 8,3 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) 51 (3,5) 50 (3,4) 24 (1,7) 3 (0,21) 60 (4,1) 59 (4,1) 30 (2,1) 9 (0,62) 70 (4,8) 69 (4,8) 36 (2,5) 15 (1,0) 80 (5,5) 79 (5,4) 42 (2,9) 22 (1,5) 90 (6,2) 89 (6,1) 49 (3,4) 28 (1,9) 100 (6,9) 99 (6,8) 55 (3,8) 34 (2,3) 110 (7,6) 109 (7,5) 61 (4,2) 41 (2,8) 120 (8,3) 119 (8,2) 68 (4,7) 47 (3,2) Table 8. Type ACE95 Diagnostics Table: Cv 7.5 and 10, Inlet Pressure Range Spring 121 to 200 psig (8,3 to 13,8 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) 121 (8,3) 120 (8,3) 63 (4,3) 31 (2,1) 130 (9,0) 129 (8,9) 69 (4,8) 37 (2,6) 140 (9,7) 139 (9,6) 75 (5,2) 43 (3,0) 150 (10,3) 149 (10,3) 82 (5,7) 49 (3,4) 160 (11,0) 159 (11,0) 88 (6,1) 56 (3,9) 170 (11,7) 169 (11,7) 94 (6,5) 62 (4,3) 180 (12,4) 179 (12,3) 101 (7,0) 68 (4,7) 190 (13,1) 189 (13,0) 107 (7,4) 75 (5,2) 200 (13,8) 199 (13,7) 113 (7,8) 81 (5,6) Assembly When assembling the Type ACE95 or Type ACE95Sr tank blanketing valve, clean all parts, inspect for unusual wear, and lightly lubricate all O-rings and the groove that locates the rolling diaphragm bead. See Figures 8 and 9. Bonnet Sub-Assembly Prepare the bonnet (key 17) by installing two (2) internal O-rings (key 16). Pilot/Cage Sub-Assembly Refer to Figures 6, 8, and 9 when performing pilot/cage sub-assembly operations. 1. Apply Loctite® #222 or equivalent to the piston threads. Place the rolling diaphragm (key 38) over the threaded portion of the piston (key 37). Position the bead as shown in Figure 6. 2. Thread the poppet (key 42) onto the piston (key 37). Use soft-jawed pliers to restrain the piston so it is not damaged. Do not hold the poppet by the poppet stem. Insert a small drill bit into the cross-drilled hole on the poppet stem (key 42) to turn and tighten. 3. Slide the O-ring (key 39) onto the poppet (key 42). 4. Place the pilot sub-assembly into the upper cage (key 40). 5. Press the lower cage (key 35) and upper cage (key 40) together to ensure the groove in the lower cage engages the bead on the rolling diaphragm (key 38). Note Ensure that the rolling diaphragm bead is positioned so that it sits in the groove of the lower cage (see Figures 8 and 9). If it does not, the rolling diaphragm was installed upside-down in Cage Sub-Assembly step 2. 6. Remove the lower cage (key 35). 7. Lubricate the piston (key 37) and lower cage (key 35) groove. 8. Install the pilot spring (key 36) into the piston (key 37) and re-install the lower cage (key 35). 9. Hold the pilot sub-assembly together and insert it into the bonnet (key 17). Press firmly (the bonnet O-rings will offer resistance). 10. Press the poppet stem. It should freely move up and down. If it does not, repeat the procedure to this point to determine the cause. 9 ACE95 Series Table 9. Type ACE95Sr Diagnostics Table: Cv 20 through 60, Inlet Pressure Range Spring 25 to 50 psig (1,7 to 3,4 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) 25 (1,7) 24 (1,7) 16 (1,1) 5 (0,35) 30 (2,1) 29 (2,0) 20 (1,4) 9 (0,62) 35 (2,4) 34 (2,3) 24 (1,7) 14 (0,97) 40 (2,8) 39 (2,7) 29 (2,0) 18 (1,2) 45 (3,1) 44 (3,0) 33 (2,3) 23 (1,6) 50 (3,4) 49 (3,4) 38 (2,6) 27 (1,9) Table 10. Type ACE95Sr Diagnostics Table: Cv 20 through 60, Inlet Pressure Range Spring 51 to 120 psig (3,5 to 8,3 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) 51 (3,5) 50 (3,4) 39 (2,7) 11 (0,76) 60 (4,1) 59 (4,1) 48 (3,3) 19 (1,3) 70 (4,8) 69 (4,8) 57 (3,9) 28 (1,9) 80 (5,5) 79 (5,4) 66 (4,6) 37 (2,6) 90 (6,2) 89 (6,1) 75 (5,2) 46 (3,2) 100 (6,9) 99 (6,8) 84 (5,8) 55 (3,8) 110 (7,6) 109 (7,5) 93 (6,4) 64 (4,4) 120 (8,3) 119 (8,2) 102 (7,0) 73 (5,0) Note Use soft-jawed pliers to restrain the main valve (key 25) while applying Loctite® #222 or equivalent to the threads of the screw (key 20). Main Valve Sub-Assembly 1. Prepare the main piston (key 25) by installing the plug and O-ring (keys 22 and 23) with the screw (key 20) and lock washer (key 21). Apply Loctite #222 or equivalent to the screw threads. 2. Install the main valve spring (key 26), spring shim [key 34, 25-50 psig (1,7-3,4 bar), Type ACE95 only], and spring guide valve [key 49, 25-50 psig (1,7-3,4 bar)/51-120 psig (3,5-8,3 bar), Type ACE95Sr only] into the piston (key 25). 3. Place the main valve sub-assembly [piston, spring, and plug (keys 25, 26, and 22)] into the body (key 18). 4. Place an O-ring (key 19) into the body (key 18). Body Sub-Assembly 1. Place the bonnet (key 17) onto the body (key 18) and main valve (key 25). 2. Press firmly to seat the bonnet O-ring joint. Attach the bonnet (key 17) to the body (key 18) with four cap screws and lock washers (keys 28 and 29, Type ACE95 or keys 50 and 51, Type ACESr). 3. Place the actuator O-ring (key 53, Type ACE95) or gasket (key 27, Type ACE95Sr) and the lower actuator case (key 30) onto the bonnet (key 17). 10 4. Install lock washers (key 28), and hex-head screws (key 29). 5. Tighten all hex-head screws (key 29) uniformly. Diaphragm Sub-Assembly 1. Place an O-ring (key 14) into the groove of the diaphragm bolt (key 15). 2. Build the diaphragm sub-assembly with the lower diaphragm plate (key 48), diaphragm (key 11), and upper diaphragm plate (key 10). Fasten the plates together with the diaphragm bolt (key 15) and the diaphragm retaining nut (key 13). The diaphragm retaining nut sits on the upper diaphragm plate. Apply Loctite #222 or equivalent to the diaphragm bolt. Note Two different diaphragm plates are used when the pressure range is positive. In cases where the pressure range is positive, the upper diaphragm plate (key 10) is larger than the lower diaphragm plate (key 48). 3. If you are using a negative spring range, install the lower range spring (key 162) into the lower actuator case (key 30). 4. Place the diaphragm sub-assembly into the lower actuator case (key 30) with the diaphragm retaining nut (key 13) on top. Place the actuator gasket (key 12) on top of the diaphragm ACE95 Series Table 11. Type ACE95Sr Diagnostics Table: Cv 20 through 60, Inlet Pressure Range Spring 121 to 200 psig (8,3 to 13,8 bar) DIAGNOSTIC PORT PRESSURE ACTUAL INLET SUPPLY PRESSURE TO VALVE, PSIG (bar) When Pilot Starts to Open, Psig (bar) When Main Valve Starts to Open, Psig (bar) When Main Valve is Fully Open, Psig (bar) 121 (8,3) 120 (8,3) 103 (7,1) 60 (4,1) 130 (9,0) 129 (8,9) 111 (7,7) 68 (4,7) 140 (9,7) 139 (9,6) 120 (8,3) 77 (5,3) 150 (10,3) 149 (10,3) 129 (8,9) 86 (5,9) 160 (11,0) 159 (11,0) 138 (9,5) 95 (6,6) 170 (11,7) 169 (11,7) 147 (10,1) 104 (7,2) 180 (12,4) 179 (12,3) 156 (10,8) 113 (7,8) 190 (13,1) 189 (13,0) 165 (11,4) 122 (8,4) 200 (13,8) 199 (13,7) 174 (12,0) 134 (9,2) rolling diaphragm (key 38) poppet (stem) (key 42) W8162 cross-drilled hole o-ring (key 39) piston (key 37) Upper Cage (key 40) Lower cage (key 35) W8161 Figure 6. Cage Sub-Assembly (key 11) and align the holes with those on the lower actuator case (key 30). 5. If it was removed, place the spring case gasket (key 9) between the spring case (key 7) and upper actuator case (key 33) before attaching the spring case to the upper actuator case. Attach the spring case to the upper actuator case with hex-head screws (key 32). 6. Place the range spring (key 8) and spring seat (key 5) onto the diaphragm sub-assembly over the diaphragm retaining nut (key 13). 7. Place the upper actuator case (key 33) over the range spring (key 8), spring seat (key 5), and the lower actuator case (key 30). 8. Build the actuator case by installing hex-head screws, lock washers, and nuts (keys 32, 28, and 31) into the upper and lower actuator cases (keys 33 and 30). Use a washer (key 47) on steel cases. 9. Thread the range spring adjusting screw (key 2) in about halfway. 10. Tighten all nuts (key 31) uniformly. 11. Reinstall the valve according to the instructions in the Installation section of this manual. 12. Adjust the setpoint according to the instructions in the Adjustment section. 13. Replace the actuator cap (key 1). 11 ACE95 Series Parts Ordering Each ACE95 Series valve is assigned a serial number printed on the nameplate on the main valve actuator. Refer to this number when contacting your local Sales Office for assistance, or when ordering replacement parts. When ordering a replacement part, be sure to reference the key number for each needed part and include the complete 11-character part number from the following parts list. Key Description Parts Kits Actuator Diaphragm and Gasket Kit (includes keys 9, 11 and 12) Types ACE95 and ACE95Sr Rolling Diaphragm and Seal Kits (includes keys 4, 14, 16, 19, 23, 24, 27, 38, 39, 41) Type ACE95, Cv 1 through 4 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Type ACE95, Cv 7.5 and 10 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Type ACE95Sr Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) 1 2 3 4* 5 6 7 8 9* 10 11 12* 13 Cap Stainless Steel Steel Adjusting Screw 0.5 to 5-inches w.c. (1 to 12 mbar) 4 to 10-inches w.c. (10 to 25 mbar) 8 to 15-inches w.c. (20 to 37 mbar) 0.5 to 1.5 psi (0,03 to 0,10 bar) -1.0 to 1.0-inches w.c. (-2 to 2 mbar) -5 to -0.5-inches w.c. (vac) (-12 to -1 mbar) Lock Nut O-Ring Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Spring Seat Vent (Type Y602-A12) Spring Case Stainless Steel Steel Range Spring 0.5 to 5-inches w.c. (1,2 to 12,4 mbar) 4 to 10-inches w.c. (10 to 25 mbar) 8 to 15-inches w.c. (20 to 37 mbar) 0.5 to 1.5 psi (0,03 to 0,10 bar) -1.0 to 1.0-inches w.c. (-2 to 2 mbar) -5 to -0.5-inches w.c. (VAC) (-12 to -1 mbar) Gasket (spring tower) Diaphragm Plate (upper) Diaphragm (main) - FEP Gasket (actuator) Diaphragm Retaining Nut * Recommended Spare Part 12 screw (key 20) Lock Washer (key 21) plug (key 22) spring (main VALVE) (key 26) O-ring (key 23) piston (main) (key 25) Part Number O-ring (key 24) 10C1273X012 19B9098X012 19B9098X032 19B9098X022 19B9098X042 19B9099X012 19B9099X032 19B9099X022 19B9099X042 19B6038X012 19B6038X032 19B6038X022 19B6038X042 GC053301X02 GC053301X32 GC060216X12 GC060216X12 GC060216X12 GC060221X12 GC060216X12 GC060216X12 GC060313X02 1F463606992 1F4636X0082 1N571406382 1F4636X0052 GC050502X02 27A5516X012 GC053101X02 GC053101X32 GC220701X22 GC220702X22 GC220703X22 GC220708X22 GC220701X22 GC220701X22 GC070428X02 GC260104X02 GC070234X72 GC070427X02 GC053215X02 W8160 Figure 7. Typical Main Valve and Spring (Type ACE95Sr shown) Key Description 14* O-Ring Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) 15 Diaphragm Bolt 16* O-Ring (2 required) Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) 17 Bonnet Cv 1 through 4 Cv 7.5 and 10 Cv 20 through 60 18 Body Cv 1 through 4 3/4 NPT 1 NPT Cv 7.5 and 10 1 NPT Cv 20 through 60 2 NPT 19* O-Ring Type ACE95 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Type ACE95Sr Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) 20 Round-Head Machine Screw Type ACE95 Type ACE95Sr 21 Lock Washer Type ACE95 Type ACE95Sr Part Number GC070173X02 GC070173X52 GC070173X12 GC070173X62 GC053210X02 1F115306992 1F1153X0062 1F1153X0022 1F1153X0032 GC050929X12 GC050929X02 GC050919X62 GE02625X012 GE02623X012 GE02627X012 GC050927X62 1C415706992 1C4157X0092 1C4157X0032 1C4157X0082 1F3581X0082 1F3581X0102 1F3581X0022 1F3581X0092 1A3776X0012 GC060225X02 GC060903X02 GC060906X02 ACE95 Series Key Description 22 Plug Type ACE95 Cv 1 Cv 2 Cv 4 Cv 7.5 Cv 10 Type ACE95Sr Cv 20 Cv 45 Cv 60 23* O-Ring Type ACE95, Cv 1 through 4 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Type ACE95, Cv 7.5 and 10 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Type ACE95Sr Cv 20 through 60 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) 24* O-Ring Type ACE95 Cv 1 through 4 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Type ACE95 Cv 7.5 and 10 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) Type ACE95Sr Cv 20 through 60 Nitrile (NBR) Ethylenepropylene (EPDM/FDA) Fluorocarbon (FKM) Perfluoroelastomer (FFKM) 25 Piston (main valve) Type ACE95: Cv 1 through 4 Type ACE95: Cv 7.5 and 10 Type ACE95Sr: Cv 20 through 60 26 Spring (main valve) Type ACE95 Cv 1 through 4, 25 to 50 psig (1,7 to 3,4 bar) Cv 1 through 4, 51 to 120 psig (3,5 to 8,3 bar) Cv 1 through 4, 121 to 200 psig (8,3 to 13,8 bar) Cv 7.5 and 10, 25 to 50 psig (1,7 to 3,4 bar) Cv 7.5 and 10, 51 to 120 psig (3,5 to 8,3 bar) Cv 7.5 and 10, 121 to 200 psig (8,3 to 13,8 bar) Type ACE95Sr Cv 20 through 60, 25 to 50 psig (1,7 to 3,4 bar) Cv 20 through 60, 51 to 120 psig (3,5 to 8,3 bar) Cv 20 through 60, 121 to 200 psig (8,3 to 13,8 bar) Part Number GC053206X02 GC053205X02 GC053204X02 GC053213X02 GC053212X02 GC053220X02 GC053221X02 GC053218X02 1D2888X0032 1D2888X0042 1D2888X0052 1D2888X0022 18A1088X022 18A1088X042 18A1088X052 18A1088X032 1C628006992 1C6280X0102 1C6280X0012 1C6280X0092 1C782206992 1C7822X0122 1C7822X0132 1C7822X0112 1D2375X0062 1D2375X0082 1D237506382 1D2375X0072 1D785306992 1D7853X0032 1D7853X0042 1D7853X0012 GC053203X02 GC053211X02 GC053219X02 GC220704X22 GC220705X22 GC220706X22 GC220705X22 GC220706X22 GC220709X22 GC220714X22 GC220712X22 GC220713X22 Key Description Part Number 27* Gasket (bonnet/actuator) (Type ACE95Sr Only) GC070429X32 28 Lock Washer Type ACE95 (28 required) GC060906X02 Type ACE95Sr Actuator Flange (20 required) GC060906X02 Actuator to Bonnet (4 required) GC060905X02 29 Hex-Head Machine Screw Type ACE95 (8 required) 1A3917X0062 Type ACE95Sr (4 required) GC060224X12 30 Actuator Case (lower) Stainless Steel GC260105X02 Steel GC260105X32 31 Hex Nut (20 required) 1A3457K0012 32 Hex-Head Machine Screw (24 required) GC060220X02 33 Actuator Case (upper) Stainless Steel GC260102X02 Steel GC260102X12 34 Spring Shim (Type ACE95 only) 25 to 50 psig (1,7 to 3,4 bar) GC053209X02 35 Lower Cage GC053002X02 36 Spring (cage) GC220707X22 37 Piston (pilot) GC053202X02 38* Rolling Diaphragm Nitrile (NBR) GC071101X02 Ethylenepropylene (EPDM/FDA) GC071101X22 Fluorocarbon (FKM) GC071101X12 Perfluoroelastomer (FFKM) GC071101X32 39* O-ring Nitrile (NBR) 1D2888X0032 Ethylenepropylene (EPDM/FDA) 1D2888X0042 Fluorocarbon (FKM) 1D2888X0052 Perfluoroelastomer (FFKM) 1D2888X0022 40 Cage (upper) GC053001X02 41* O-Ring Nitrile (NBR) 10A0042X052 Ethylenepropylene (EPDM/FDA) 10A0042X072 Fluorocarbon (FKM) 10A0042X012 Perfluoroelastomer (FFKM) 10A0042X062 42 Pilot (poppet) GC053201X02 43 Pilot Filter (optional, not shown) Aluminum 10C1269X022 Stainless Steel 10C1269X012 48 Diaphragm Plate (lower) Positive Spring Range [3-inch (76 mm) - diameter] GC260113X02 Negative Spring Range [9-inch (229 mm) - diameter] GC260104X02 49 Spring Guide (Type ACE95Sr only) 25 to 50 psig (1,7 to 3,4 bar)/ 51 to 120 psig (3,5 to 8,3 bar) GC050505X22 50 Hex Head Cap Screw (4 required) GC060224X12 51 Lock Washer (4 required) GC060905X02 53* O-ring (Type ACE95 Only) Nitrile (NBR) 1H991206992 Ethylenepropylene (EPDM/FDA) 1R3971X0012 Fluorocarbon (FKM) 1R397106382 Perfluoroelastomer (FFKM) 1R3971X0022 138 Hex-Head Pipe Plug (Type ACE95 Only) NPS 3/4 body 1A771535072 NPS 1 (DN 25) body 1A7947X0022 139 Hex-Head Pipe Plug 1A767535072 162 Lower Range Spring [neg. pressure range only, used with upper spring (key 8)] -1.0 to 1.0-inches w.c. (-2 to 2 mbar) GC220717X22 -5 to -0.5-inches w.c. (vac) (-12 to -1 mbar) GC220710X22 168 Sealant ----------169 Lubricant ----------- * Recommended Spare Part 13 ACE95 Series 42 41 locate groove in lower cage for rolling diaphragm bead 40 1 39 2 168 3 38 36 35 4 37 5 6 162 7 32 33 8 32 29 28 9 10 13 12 11 28 31 30 48 53 15 14 16 29 28 17 26 18 25 24 23 22 20 21 19 34 NOT REQUIRED IN ALL ASSEMBLIES GE03297 APPLY LUB/SEALANT Figure 8. Type ACE95 Tank Blanketing Valve 14 ACE95 Series 42 41 1 2 40 locate groove in lower cage for rolling diaphragm bead 3 39 4 38 5 37 6 32 36 7 162 E0626 12 8 33 35 10 11 9 47 32 13 48 28 31 30 14 28 29 15 27 16 locate groove in lower cage for rolling diaphragm bead 17 26 49 50 51 19 18 25 24 23 22 20 21 E0625 Figure 9. Type ACE95Sr Tank Blanketing Valve 15 ACE95 Series Industrial Regulators Natural Gas Technologies TESCOM Emerson Process Management Regulator Technologies, Inc. Emerson Process Management Regulator Technologies, Inc. Emerson Process Management Tescom Corporation USA - Headquarters McKinney, Texas 75069-1872 USA Tel: 1-800-558-5853 Outside U.S. 1-972-548-3574 USA - Headquarters McKinney, Texas 75069-1872 USA Tel: 1-800-558-5853 Outside U.S. 1-972-548-3574 USA - Headquarters Elk River, Minnesota 55330-2445 USA Tel: 1-763-241-3238 Asia-Pacific Shanghai, China 201206 Tel: +86 21 2892 9000 Asia-Pacific Singapore, Singapore 128461 Tel: +65 6777 8211 Europe Bologna, Italy 40013 Tel: +39 051 4190611 Europe Bologna, Italy 40013 Tel: +39 051 4190611 Gallardon, France 28320 Tel: +33 (0)2 37 33 47 00 Middle East and Africa Dubai, United Arab Emirates Tel: +971 4811 8100 Europe Selmsdorf, Germany 23923 Tel: +49 (0) 38823 31 0 For further information visit www.fisherregulators.com The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners. Fisher is a mark owned by Fisher Controls, Inc., a business of Emerson Process Management. 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, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Process Management does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Process Management product remains solely with the purchaser. ©Emerson Process Management Regulator Technologies, Inc., 2001, 2010; All Rights Reserved
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