Troubleshooting
Source: DICE IOM Manual V12E, Page: 39Module Issues
Leaking from connector
Leaking from connector
| Possible Cause | Action |
|---|---|
| Insufficient pressure on connector from mushroom nut | Hand-tighten the mushroom nut (no tools) |
| O-ring failure | Replace the O-ring (30) |
Ball Valve Issues
Leaking fluid from connector area
Leaking fluid from connector area
| Possible Cause | Action |
|---|---|
| Carrier O-ring failure | Replace carrier O-ring (7) |
Ball valve leaks in closed position
Ball valve leaks in closed position
Fluid passes through the valve when handle is in closed position.
| Possible Cause | Action |
|---|---|
| Worn ball | Replace ball (4) |
| Worn ball valve seat | Replace both seats (6) and seat O-rings (8) |
| Loose carrier | Adjust carrier position per Maintenance procedure |
Valve difficult to operate
Valve difficult to operate
Ball valve does not fully open/close, or requires excessive torque.
| Possible Cause | Action |
|---|---|
| Excessive pressure between ball and seats | Adjust carrier position per Maintenance procedure |
| Excessive torque on stem nut | Loosen stem nut and retighten to 30 in-lb |
Handle does not operate valve
Handle does not operate valve
| Possible Cause | Action |
|---|---|
| Broken stem | Replace stem (3) |
| Broken stem/handle coupling | Replace stem (3) and handle (11) |
| Broken stem/ball coupling | Replace stem (3) and ball (4) |
Leakage near ball valve handle
Leakage near ball valve handle
| Possible Cause | Action |
|---|---|
| Stem O-ring failure | Replace stem O-ring (9) |
| Stem nut O-ring failure | Replace stem nut O-ring (10) |
Back Pressure and Pressure Relief Valve Issues
Leaking from adjustment screw
Leaking from adjustment screw
| Possible Cause | Action |
|---|---|
| Ruptured diaphragm | Replace diaphragm (16) |
Leaking from valve/block interface
Leaking from valve/block interface
| Possible Cause | Action |
|---|---|
| Ruptured diaphragm | Replace diaphragm (16) |
| Insufficient pressure between diaphragm and block | Tighten 4 mounting bolts (18) to 35 in-lb in star pattern |
Adjustment screw does not affect pressure
Adjustment screw does not affect pressure
| Possible Cause | Action |
|---|---|
| Spring failure | Replace spring (17) |
Pressure Indicator Issues
Leaking from pressure gauge NPT connection
Leaking from pressure gauge NPT connection
| Possible Cause | Action |
|---|---|
| Loose NPT connection | Tighten pressure gauge NPT connection on isolator |
| Ruptured isolator diaphragm | Ship isolator and gauge assembly to supplier for repair |
| Chemical attack on gauge connection | Ship isolator and gauge assembly to supplier for repair |
Leaking from bleeding screw
Leaking from bleeding screw
| Possible Cause | Action |
|---|---|
| Bleeding screw O-ring failure | Replace O-ring |
| Ruptured isolator diaphragm | Ship isolator and gauge assembly to supplier for repair |
Pressure reading incorrect
Pressure reading incorrect
| Symptom | Possible Cause | Action |
|---|---|---|
| Reading too high | Blocked injection path | Check for closed valves or blockage downstream |
| Reading too low | Pressure relief valve set too low | Readjust PRV per Startup procedure |
| Reading zero | System not pressurized | Verify pump is running and primed |
| Erratic reading | Air in system | Use bleed valve to purge air |
System Issues
Pump will not prime
Pump will not prime
| Possible Cause | Action |
|---|---|
| Trapped air in system | Slightly open bleed valve (32) while pump cycles until fluid flows |
| Check valve failure in pump | Inspect and replace pump check valves |
| Suction line air leak | Check suction line connections |
No flow to process
No flow to process
| Possible Cause | Action |
|---|---|
| Injection valve closed | Open injection valve (1) |
| Back pressure set too high | Readjust BPV to 20-30 psi above process pressure |
| Pump not running | Verify pump power and operation |
| Blocked injection line | Clear downstream blockage |
Chemical returns to tank
Chemical returns to tank
| Possible Cause | Action |
|---|---|
| Pressure relief valve set too low | Increase PRV set point |
| Back pressure too high relative to PRV | Verify PRV is set higher than BPV |
| BPV diaphragm failure | Replace BPV diaphragm (16) |
Calibration column does not fill
Calibration column does not fill
| Possible Cause | Action |
|---|---|
| Calibration column valve closed | Open calibration column valve (2) |
| Injection valve open | Close injection valve (1) during calibration |
| Separation valve closed (DM only) | Open separation valve (4) during calibration |
Calibration column does not drain
Calibration column does not drain
| Possible Cause | Action |
|---|---|
| Evacuation valve closed | Open evacuation valve (3) |
| Calibration column not vented | Vent top of calibration column to atmosphere |
| Blockage in evacuation line | Clear evacuation line |
Quick Reference
Common replacement parts
Common replacement parts
| Component | Part Numbers |
|---|---|
| Ball (4) | Contact supplier with serial number |
| Seats (6) | Contact supplier with serial number |
| O-ring — Carrier (7) | Contact supplier with serial number |
| O-ring — Seat (8) | Contact supplier with serial number |
| O-ring — Stem (9) | Contact supplier with serial number |
| O-ring — Stem nut (10) | Contact supplier with serial number |
| Diaphragm (16) | Contact supplier with serial number |
| Spring (17) | Contact supplier with serial number |
| O-ring — Connector (30) | Contact supplier with serial number |
When ordering parts, provide the module serial number engraved on the block.
Related Products
DICE DS — Suction Lift
1/2” module for suction lift applications
DICE DM — Flooded Suction
1/2” and 1” modules for flooded suction
Sources
DICE IOM Manual V12E
Page 39 • July 2022