How to Install a FlowCon Removable PICV Insert- A Short Tutorial

9 May

This tutorial covers an insert installation in a valve housing within a live system after flushing with a blank cap OR replacing an already installed PICV insert. Please be aware that this quick installation guide is only applicable to FlowCon Pressure Independent Control Valves!

Installing a FlowCon PICV Valve Insert:

STEP 1:Identify the insert size required

The housing that covers ½”, ¾” and 1” connection sizes requires a 20mm insert and the housing for 1 ¼” and 1 ½” connection sizes requires a 40mm insert.

STEP 2: Identify the insert

There are 5 20mm options available and 2 40mm options, each with 41 stepless set points.

STEP 3: Isolate the flow and return

Before any work can be undertaken, the PICV must be isolated. This is done by isolating the flow and then the return of the two flushing bypass valves.

STEP 4: Confirm PICV is isolated- Loosen the cap

As a precaution, check the PICV is isolated by loosening the cap or insert by slightly turning in an anti-clockwise direction, without removing the blank cap or insert.

STEP 5: Remove blank cap or old insert

After confirming the PICV is isolated, the cap or insert can be fully removed.

STEP 6: Install new insert

Gently fit the insert into the body and screw into place by turning clockwise by hand to avoid cross threading. Then use a socket or spanner to tighten. Once the insert flange comes into contact with the PICV body, the process is complete and will seal perfectly. Make sure not to overtighten the insert.

Confirm the system operating pressure does not exceed the rating of the valve.

STEP 7: Equalise pressure

To avoid damage to the insert diaphragm, it is important to equalise the pressure across the PICV, by slowly cracking the return isolating valve. After 2-3 seconds the return isolating valve, followed by the flow isolating valve can be fully opened.

The PICV insert is now safely installed and the flow and return valves can be opened and closed without risk of damage.

Check out our YouTube channel for more “How To” videos and videos specific to FlowCon Pressure Independent Control Valves in typical UK applications. For specific support please contact us directly.