Valtek Mark One
Contents
1. that will keep the bonnet flange square parallel with the body Tighten the first bolt 1 6 turn or one nut flat then tighten the bolt directly opposite 1 6 turn and so on around the flange Firmly tighten all bolts evenly and completely to compress the bonnet gasket and to seat the bonnet Torque the bonnet bolts to the sug gested torque values in Table Il The bonnet will seat metal to metal with the body when the bonnet bolts are correctly torqued into place Apply air over the piston to seat the plug For all throt tling valves adjust the stem clamp so that with full in strument signal to the positioner the full signal scribe line on the positioner cam points to the centre of the cam roller bearing CAUTION Make sure the slots of the stem clamp are perpendicular to the bolting See Figure 5 NOTE For on off valves the bottom of the stem clamp should simply be lined up with the bottom of actuator stem 1 16 inch 1 6 mm Tighten the stem clamp bolting Proper tightness is important since this adjustment secures the actuator Stem to the plug stem Adjust the stroke plate so the stem clamp points to the closed position If the valve has been taken out of the line make sure the flow arrow indicates proper flow direction upon reinstallation Adjust and test all accessories rr FLOWSERVE Ne Figure 6 Mark One with CavControl Trim Body Assembly Figure 7 Mark One with ChannelStream Trim Body Assembly 82. Mark One VLENIM0001 01 07 07 Nm Gland Bolting Items 109 117 Gland Flange A Item 80 Body Bolting Items 108 114 Bonnet Flange Item 70 Upper Guide Upper Packing Item 87 Item 88 Packing Spacers Item 94 99 Lower Packing Item 88 Lower Guide Item 83 Yoke Half Clamps mr amp Yoke Clamp Bolts Items 76 107 118 Bonnet Item 40 Bonnet Gasket Item 58 Plug Item 50 Seat Retainer Item 30 seat Ring Item 20 Seat Gasket Item 55 Body Item 1 Figure 3 Exploded View Mark One Body Assembly FLOWSERVE 6 2 6 3 6 3 3 6 4 6 5 N p Valve Disassembly To disassemble the valve body refer to Figures 1 2 and 3 then proceed as follows WARNING Depressurize line to atmospheric pressure and drain all fluids before working on the valve Failure to do so can cause serious injury If valve is air to open apply air under the piston to lift the plug off the seat before taking the valve apart If valve is air to close proceed to step 6 3 Remove the bonnet flange bolting and lift actuator bonnet and plug out of the valve Once removed the actuator bonnet and plug assembly called the top works should be lowered and blocked to prevent roll ing during the disassembly of the top works WARNING Danger exists in removing the actuator bonnet and plug especially if a pressure balanced plug is used The pressure balanc
3. change without notice Should any question arise concerning these provisions the purchaser user should contact Flowserve Corporation at any one of its worldwide operations or offices 2007 Flowserve Corporation Irving Texas USA Flowserve is a registered trademark of Flowserve Corporation flowserve com Flowserve Worldwide Flowserve Flow Control Division 1350 N Mt Springs Parkway Springville UT 84663 USA Phone 801 489 8611 Fax 801 489 3719 Flowserve Australia Pty Ltd 14 Dalmore Drive Scoresby Victoria 3179 Australia Phone 61 3 9759 3300 Fax 61 3 9759 3301 Flowserve Austria GmbH Control Valves Villach Operation Kasernengasse 6 9500 Villach Osterreich Phone 43 0 4242 41 181 0 Fax 43 0 4242 41181 50 Flowserve India Controls Pvt Ltd Plot 4 1A Road 8 EPIP Whitefield Bangalore Karnataka 560066 India Phone 91 80 40146200 Fax 91 80 28410286 Flowserve Fluid Motion and Control Suzhou Co Ltd No 35 Baiyu Road Suzhou Industrial Park Suzhou Jiangsu Province P R 215021 China Phone 86 512 6288 8790 Fax 86 512 6288 8736 Flowserve Regional Flowserve Canada Corp 9044 18th Street Edmonton Alberta T6P 1K6 Canada Phone 780 449 4850 Fax 780 449 4851 Flowserve Flow Control Quick Response Center 104 Chelsea Parkway Boothwyn Pennsylvania USA Phone 610 497 8600 Fax 610 497 6680 User instructions Mark One VLENIM0001 01 07 07 Flowserve Pte Ltd 12 T
4. cover plates especially where side mounted posi FLOWSERVE User instructions Mark One VLENIM0001 01 07 07 Ne Upper Guide Item 87 Upper Packing Item 88 Packing Spacers Item 94 99 Lower Packing Plug Item 50 Body Bolting Item 108 114 Bonnet Flange Item 83 10 mn Lower Guide Bonnet Item 83 Item 40 Bonnet Gasket Item 58 Body Item 1 Seat Ring Seat Item 20 Retainer Seat Gasket Item 30 Item 55 Figure 1 Mark One Control Valve Body Assembly FLOWSERVE 1 8 2 2 2 3 2 4 Nes tioners are fitted If these plates are removed for in spection service or repair special attention is required After completing work the cover plates must be re fitted Apart from the operating instructions and the obligatory accident prevention directives valid in the country of use all recognized regulations for safety and good engineering practices must be followed WARNING Before products are returned to Flowserve for repair or service Flowserve must be provided with a certificate that confirms that the product has been decontaminated and is clean Flowserve will not ac cept deliveries if a cleaning certificate has not been provided Return authorization is also required before parts are returned Contact your local Flowserve rep resentative to obtain return authorization Storage In many
5. damage the control valve parts CAUTION Seat rings retainers and pressure balanced Sleeves must be installed squarely into the body to function correctly To check to make sure the parts are installed correctly rotate these parts a little by hand The parts should rotate freely without binding NOTE When the seat retainer has only two ports one of the two ports should be aligned with the upper port of the body Place air under the actuator piston on air to open valves to retract the plug Lower the plug and bonnet squarely into the body Be careful not to scratch or gall the plug as it enters the body To properly align the seat ring and plug first bring the bonnet bolting to finger tightness With pneumatic actuators apply air pressure above the piston to seat the plug in the seat ring Proceed to Step 7 10 With electric or hydraulic actuators move the actua tor stem down until it is completely extended Next retract the actuator stem 1 8 inch 3 2 mm Install the stem clamp onto the plug stem and actuator stem and tighten the associated bolting Move the actuator stem completely down Adjust actuator limit switches according to the actuator s operating manual The ac tuator limit switches will need to be readjusted once the body bolting has been tightened NOTE Step 7 10 applies only to valves with pneumatic actuators If an electric or hydraulic actuator is used return the plug to the mid stroke position and proceed
6. the plug stem into the packing box being careful not to score the plug stem or the guides Rein Stall pressure balanced seals if required Turn actuator back onto the plug without turning the plug inside the bonnet Make sure the gland flange and bonnet flange are in place before engaging the plug stem and actuator stem threads The gland flange FLOWSERVE 7 9 7 6 Nes chamfer must be face down towards the valve body Leave approximately three to four plug stem threads exposed Attach yoke clamp and gland flange bolting For valves with a 2 inch spud be sure the half rings are in place between the yoke and bonnet Firmly tighten yoke clamp bolting The packing box nuts should be just over finger tight NOTE Do not allow the gland flange to contact and gall the polished plug stem Install new bonnet and seat gaskets with the bevelled edge up for Teflon gaskets Insert the seat ring into the body with the step side down When the seat ring is properly in place it will turn easily in the body Place the seat retainer into the body with the thin end of the cathedral window down Most retainers have an arrow pointing up to verify cor rect installation For pressure balanced valves install the pressure balanced sleeve gasket Ensure that se vere service retainers are correctly indexed by turning the retainer in the body Correctly aligned retainers should turn easily CAUTION Installing seat retainers upside down can
7. 2 8 2 1 8 2 2 8 2 4 1 8 2 4 2 8 2 4 3 User instructions Mark One VLENIM0001 01 07 07 Severe Service Trim Options CavControl CavControl replaces the standard Mark One retainer with a drilled stepped hole retainer see Figure 6 The plug and bonnet have dimensional differences from the standard Mark One design Assembly and disas sembly of the valve follows the standard procedures CavControl retainers plugs and seats should be ex amined for excessive cavitation damage when disas Sembled Holes in the retainer should be checked for worn or eroded surfaces Check for plugged holes in the retainer Plugs and retainer mating surfaces Should be examined for damage Repair and replace ment of damaged parts is critical to maintaining cavi tation resistance CAUTION To function properly CavControl is always installed flow over ChannelStream ChannelStream replace the standard retainer with multiple sleeves pinned together see Figure 7 The plug seat ring and bonnet have dimensional differ ences from the standard Mark One design Assembly and disassembly of the valve follows the standard procedures ChannelStream retainers plugs and seats should be examined for excessive cavitation damage when disassembled The inner holes in the retainer should be checked for wear or erosion evidence of ero sion should require that the retainer is disassembled Plugs and retainer mating surfaces should be exam ined for d
8. 3 9 3 6 3 2 User instructions Mark One VLENIM0001 01 07 07 Installation DANGER Before installation check the purchase or der number serial number and or the tag number to ensure that the valve and actuator being installed are correct for the intended application WARNING The maximum air supply for most Valtek cylinder actuators is 150 psi 10 3 bar In some cas es the air supply must be limited to less than 150 psi 10 3 bar This is indicated on a sticker found near the upper air port on the actuator cylinder An air regulator should be installed to ensure the supply pressure does not exceed the actuator design pres Sure indicated on the sticker CAUTION Do not insulate extensions that are pro vided for hot or cold services CAUTION On valves equipped with air filters the air filter must point down to perform properly NOTE Selecting the proper fastener material is the responsibility of the customer Typically the supplier does not know what the valve service conditions or environment may be Flowserve s standard body bolt ing material is B7 2H B8 8 stainless steel is optional for applications more than 800 F 425 C and with stainless steel or alloy body valves The customer therefore must consider the material s resistance to stress corrosion cracking in addition to general cor rosion As with any mechanical equipment periodic inspection and maintenance is required For more information about fas
9. FLOWSERVE USER INSTRUCTIONS Valtek Mark One and Installation Mark Two Control Valves Operation Maintenance O GA 3 T 2 w 3 h A EN n mo Ju 9 E 5 Experience In Motion i N FLOWSERVE User instructions Mark One VLENIM0001 01 07 07 Nes Contents 1 General Information 2 Unpacking 3 Installation 4 Quick Check g Valve Maintenance 6 Disassembly and Inspection 7 Assembly and Installation 8 severe Service Trim Options 8 1 CavControl 8 2 ChannelStream 8 3 MegaStream 8 4 Stealth 8 0 TigerTooth Figures Figure 1 Mark One Control Valve Body Assembly Figure 2 Pressure Balanced Mark One Control Valve Body Assembly Figure 3 Exploded View Mark One Body Assembly Figure 4 Soft Seat Assembly Figure 5 Actuator Stem Stem Clamp Alignment Figure 6 Mark One with CavControl Trim Body Assembly Figure 7 Mark One with ChannelStream Trim Body Assembly Figure 8 Mark One with MegaStream Trim Body Assembly Figure 9 Mark One with Stealth Trim Body Assembly Figure 10 Mark One with TigerTooth Trim Body Assembly Tables Table Common Lubricants Table Il Suggested Bonnet Bolting Torque Values Table III Troubleshooting Chart FLOWSERVE 1 1 1 2 a gt EF Nes General Information Using The following instructions are designed to assist in unpacking installing and performing maintenance as requir
10. Figure 9 Mark One with Stealth Trim Body Assembly MegaStream MegaStream replaces the standard Mark One retainer with a drilled hole retainer see Figure 8 The plug and bonnet are typically identical to the standard Mark One design Assembly and disassembly of the valve follows the standard procedures MegaStream retainers plugs and seats should be ex amined for damage when disassembled Holes in the retainer should be checked for worn or eroded sur faces Check for plugged holes in the retainer Multi stage MegaStream retainers cannot be disassembled Repair and replacement of damaged parts is critical to maintaining noise control CAUTION To function properly MegaStream is al ways installed flow under Stealth Stealth replaces the standard Mark One retainer with a braised stacked disk retainer see Figure 9 Several of the parts including the plug seat ring and bon net have dimensional differences from the standard Mark One design Assembly and disassembly of the valve follows the standard procedures Stealth retainers plugs and seats should be exam ined for damage when disassembled Holes in the retainer should be checked for worn or eroded sur faces Check for plugged holes in the retainer Stealth retainers cannot be disassembled Repair and re placement of damaged parts is critical to maintaining noise control CAUTION With rare exception to function properly Stealth is always installed flow under When rei
11. amage Repair and replacement of damaged parts is critical to maintaining cavitation resistance ChannelStream retainers should be cleaned of debris whenever the valve is opened Use the following steps if the retainer must be dis assembled to clean or inspect for damage Channel stream retainers in pressure classes 900 and higher cannot be disassembled in the field Contact your lo cal Flowserve representative for service options Carefully grind away the small bead welds located on the assembly pins near the top of the retainer This will loosen the pins which hold the retainer together Using a punch locate the hole in the retainer opposite the pin and drive each pin out of the retainer The retainer can now be inspected for damage or cleaned Reassemble the retainer sleeves and reinstall the pins making sure to leave an open hole opposite each pin so that the pin can be driven out in the future Apply a small 1 8 inch bead of weld to each pin to hold it in place NOTE Do not weld more than the approved 1 8 inch Excessive heat from the bead welds that are too large can disturb critical retainer tolerances Use an appro priate weld rod which is compatible with the retainer material If uncertain contact the factory CAUTION To function properly ChannelStream is al ways installed flow over FLOWSERVE User instructions Mark One VLENIM0001 01 07 07 Ne Figure 8 Mark One with MegaStream Trim Body Assembly
12. ameter of the seat ring if machining the seat 6 9 To replace packing or change the packing box con figuration push out packing spacer and guides from underneath the bonnet with a dowel around 0 13 inch 3 3 mm larger in diameter than the plug stem Table Il Suggested Bonnet Bolting Torque Values tibs Nm fllbs Nm sa 80 108 50 6 34 140 190 90 12 114 730 990 460 64 188 990 194 630 84 All values are 10 rr FLOWSERVE Ne Soft Seat Retainer Soft Seat nn Seat Ring Figure 4 Soft Seat Assembly Correct Figure 5 Actuator Stem Stem Clamp Alignment User instructions Mark One VLENIM0001 01 07 07 6 10 7 1 1 2 7 3 7 4 WARNING For valves equipped with separable end flanges do not machine body gasket surfaces Ma chining could cause failure of the separable flange lip causing end gasket leakage and valve failure CAUTION When using separable end flanges and spiral wound gaskets use gaskets with outer backup rings Failure to do so could result in excess stress in some applications Check to see the seating surfaces on both the seat ring and plug are free of damage to ensure tight shutoff Make sure the gasket surfaces on the seat ring bonnet and body are clean and undamaged Examine the plug stem and bonnet bore for scoring scratches pitting or other damage Refer to the appropriate actuator User Manual for de tailed instru
13. cases Flowserve products are manufactured from stainless steel Products not manufactured from Stainless steel are provided with an epoxy resin coat ing This means that Flowserve products are well protected from corrosion Nevertheless Flowserve products must be stored adequately in a clean dry environment Plastic caps or plywood protectors are fitted to help protect the flange faces and prevent the ingress of foreign materials These caps should not be removed until the valve is actually mounted into the system Unpacking While unpacking the valve check the packing list against the materials received Lists describing the valve and accessories are included in each shipping container When lifting the valve from shipping container use Straps through the yoke legs or the lifting lugs at tached to the body bolting for valves over four inch or the adjusting screw for valves four inch and under Take care to position lifting straps to avoid damage to the tubing mounted accessories or stroke plate WARNING When lifting a valve be aware that the cen tre of gravity may be above the lifting point There fore Support must be given to prevent the valve from rotating Failure to do so can cause serious injury to personnel and damage to the valve and nearby equip ment Contact your shipper immediately if there is shipping damage Should any problem arise call your Flowserve repre sentative pPb 3 1 3 2 3 3 3 4
14. cedure on align the valve is in line and in some cases without inter ing the plug with the seat Tighten stem clamp nut rupting service If an internal problem is suspected Y NOTE Refer to the appropriate User Manuals when refer to Section 6 Valve Disassembly and Inspection i adjusting positioners and providing maintenance to 9 1 Look for signs of gasket leakage through the end flang actuators es and bonnet Re torque flange and bonnet bolting if Current User Manuals are available at www flowserve com required Refer to Table Il for bonnet bolt torque val 5 8 Verify that the takeoff arm and follower arm are not UES binding at either end of the stroke The follower arm 5 2 Examine the valve for damage caused by corrosive attached to the positioner should be free to move fumes or process drippings a slightly when the valve is at both ends of the stroke 9 3 Clean valve and repaint areas of severe oxidation 5 9 Ensure all accessories brackets and bolting are se 5 4 Check packing box bolting for proper tightness and curely fastened packing leakage If packing leakage is noticed packing 5 10 If possible remove air supply and observe actuator for maintenance is required Refer to the packing installa correct fail safe action tion manual document number VLAIMO040 for specif 5 11 Check rubber actuator bellows for splits cuts or wear ic details ue maintaining the style of packing supplied 512 Spray a soap solution a
15. ctions on actuators Assembly and Installation NOTE Separate User Manuals with instructions on as sembling actuators positioners and other equipment can be found on www flowserve com Review any rel evant User Manual before proceeding NOTE It is recommended that all soft goods are re placed when rebuilding Mark One and Two control valves Soft goods include gaskets pressure balanced Seals soft seat inserts guide liners and packing seats Replacing these parts helps to ensure proper function ing of the control valve To reassemble the valve body refer to figures 1 2 and 6 thru 9 and proceed as follows If the packing has been removed refer to the ap propriate packing User Manual document number VLAIM040 and reinstall the packing and lower guide exactly as shown Make sure at least 1 8 inch is left at the top of the packing box for the top guide to sit into the bonnet Different packing spacers permit a wide variety of packing configurations such as twin Seal and vacuum pressure packing CAUTION Valves with extended bonnets or metal bellows seals must not have lower packing installed Instead lower packing rings should be installed with the upper set Lower packing installed in extended bonnets or metal bellows seal valves will diminish the integrity of the packing assembly NOTE Guide liners should be replaced each time the valve packing is replaced Do not rebuild the valve without the correct guide liners Re insert
16. e of the body Care must be taken not to damage the gasket surfaces in the body when the gaskets are removed Valves with soft seats see figure 4 require the seat ring to be inspected and possibly disassembled Check to see that seating surfaces on the plug and Seat assemblies are free of damage If the seat insert is worn remove it from the assembly Since the plug User instructions Mark One VLENIM0001 01 07 07 Seating surface does not come in contact with the seat insert retainer it is not necessary to correct any mi nor damage to that part The plug seating surface can be re machined to a 30 degree angle Lapping is not required when proper reassembly procedures are fol lowed 6 6 Loosen the stem clamp and unscrew the plug from the actuator stem fl WARNING Danger exists when working with large valves and heavy parts Take care to properly sup port large parts to avoid damage to the parts of nearby equipment or personnel 6 7 Remove the packing gland bolting yoke clamps and remove the actuator 6 8 If the seat surfaces need re machining both surfaces on plug and seat ring must be reworked The seat angle on the plug is 30 degrees 36 degrees for Cav Control and ChannelStream valves the seat ring 33 degrees Lapping is not necessary if proper assembly procedures are followed AN CAUTION If re machining protect the stem while turning Ensure concentration of the seat surface with the plug stem or outside di
17. ed on Flowserve products Product users and maintenance personnel should thoroughly review this bulletin prior to unpacking installing operat ing or performing any maintenance In most cases Flowserve valves actuators and accessories are de signed for specific applications e g with regard to medium pressure and temperature For this reason they should not be used in other applications without first contacting the manufacturer The product Instal lation Operation and Maintenance Instructions pro vides important additional safety information Applicability The following instructions are applicable to the main tenance and installation of Flowserve Valtek Mark One and Two control valves These instructions cannot claim to cover all details of all possible product varia tions nor can they provide information for every pos sible example of installation operation or maintenance This means that the instructions normally include only the directions to be followed by qualified personal us ing the product for its defined purpose If there are any uncertainties in this respect particularly in the event of missing product related information clarification must be obtained via the appropriate Flowserve sales office All Flowserve User Manuals are available at www flowserve com Terms Concerning Safety The safety terms DANGER WARNING CAUTION and NOTE are used in these instructions to highlight par ticular dangers and or to prov
18. ed sleeve may stick to the plug and fall during disassembly causing pos sible serious injury and damage to the valve or nearby equipment If sleeve is observed sticking to the plug steps 6 3 1 to 6 3 4 should be consulted CAUTION Heavy actuators may require a hoist Lift the valve with the yoke legs using a lifting strap and a hoist Great care should be taken to lift the actuator and plug straight out of the body to avoid damage to the plug and seat If the sleeve is observed sticking to the plug during removal fully extend the plug by applying air above the piston allowing the sleeve to remain in the body and the bonnet to rise above the body In the gap between the top of the sleeve and the bot tom of the bonnet place wooden blocking of equal thickness in at least three places The wooden blocks must not extend in far enough that they interfere with plug movement The plug must be allowed to stroke up to the bonnet By applying air below the piston retract the plug until the plug head is freed from the sleeve Once the plug is free from the sleeve remove the plug and bonnet assembly from the body Lift the pressure balanced sleeve out of the valve body using lifting points on the top of the sleeve NOTE In many small Mark One valves the seat re tainer and pressure balancer sleeve are one and the Same part In larger valves there are separate pres Sure balancer sleeves and seat retainers Lift retainer seat ring and gaskets fre
19. ide additional information on aspects that may not be readily apparent DANGER Indicates that death severe personal injury and or substantial property damage will occur if proper precautions are not taken WARNING Indicates that death severe personal injury and or substantial property damage can occur if proper precautions are not taken CAUTION Indicates that minor personal injury and or property damage can occur if proper precautions are not taken NOTE Indicates and provides additional technical in formation which may not be obvious even to qualified personnel User instructions Mark One VLENIM0001 01 07 07 1 3 2 b 1 5 1 6 1 7 Compliance with other notes which may not be partic ularly emphasized with regard to transport assembly operation and maintenance and with regard to techni cal documentation e g in the operating instructions product documentation or on the product itself is essential in order to avoid faults which can directly or indirectly cause severe personal injury or property damage Protective Clothing DANGER Flowserve products are often used in prob lematic applications e g under extremely high pres sures with dangerous toxic or corrosive mediums When performing service inspection or repair opera tions always ensure that the valve and actuator are depressurized and that the valve has been cleaned and is free from harmful substances In such cases pay particula
20. nstalling Stealth retainers care must be given to orientating the retainer correctly Stealth re tainers have an arrow that must be aligned with the valve outlet in N FLOWSERVE User instructions Mark One VLENIM0001 01 07 07 Nes Figure 10 Mark One with TigerTooth Trim Body Assembly TigerTooth TigerTooth replaces the standard Mark One retainer with a welded or pinned stacked disk retainer see Figure 10 Several of the parts including the plug seat ring and bonnet have dimensional differences from the standard Mark One design Assembly and disas sembly of the valve follows the standard procedures TigerTooth retainers plugs and seats should be ex amined for damage when disassembled The retainer should be checked for worn or eroded surfaces Check for debris lodged in the retainer Pinned TigerTooth retainers can be disassembled and cleaned Care Should be taken when reassembling to stack up the discs in the same order Each disc has been etched with a number for that purpose Welded TigerTooth retainers should not be disassembled outside a quali fied service centre Repair and replacement of dam aged parts is critical to maintaining noise and or cavi tation control CAUTION With rare exception to function properly TigerTooth is always installed flow under i N FLOWSERVE User instructions Mark One VLENIM0001 01 07 07 Ne Table Ill Troubleshooting Chart Probable Cause Corrective Action Stem mo
21. r attention to personal protection e g protec tive clothing gloves glasses etc Qualified Personnel Qualified personnel are people who on account of their training experience and instruction and their knowl edge of relevant standards specifications accident prevention regulations and operating conditions have been authorized by those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible dangers Contact your local Flowserve representation for a schedule of train ing schools Spare Parts Use only Flowserve original spare parts Flowserve cannot accept responsibility for any damages that oc cur from using spare parts or fastening materials from other manufactures If Flowserve products especially Sealing materials have been on store for long periods of time check them for corrosion or deterioration be fore putting them into use service Repair To avoid possible injury to personnel or damage to products safety terms must be strictly adhered to Modifying this product substituting non factory parts or using maintenance procedures other than those Outlined in these Installation Operation and Mainte nance Instructions could drastically affect perform ance be hazardous to personnel and equipment and may void existing warranties Between the actuator and the valve there are moving parts To avoid injury Flowserve provides pinch point protection in the form of
22. roper plug adjustment 1 Refer to steps 7 9 to 7 11 Assembly and Installation section for correct limiting stroke plug adjustment 2 Malfunctioning positioner 2 Refer to positioner maintenance instructions 3 Service conditions exceed trim 3 Verify service conditions and consult factory design capacity 4 Incorrect actuator stroke 4 Verify actuator stroke 5 Inadequate air supply pressure 5 Check for leaks in air supply or instrument signal system tighten loose connections and replace leaky lines Plug slams 1 Incorrect plug adjustment al 1 Refer to steps 7 9 to 7 11 Assembly and Installation section for correct lowing improper cushion of air plug adjustment between actuator piston and yoke 2 Inadequate air supply 2 Check air supply to actuator repair leaks and remove any restrictions in supply line 3 Trim sized too large for flow 3 Verify the service conditions and actuator sizing install reduced trim rate Valve does not 1 Incorrect flow direction 1 Reconfirm direction and if necessary correct flow direction through valve GOE nee 2 Incorrect actuator fail direction 2 Consult actuator User Manual and change fail direction rer FLOWSERVE Ne FCD VLENIM0001 01 07 07 Replaces VLAIMO01 00 To find your local Flowserve representative please use the Sales Support Locator System found at www flowserve com contact htm or call USA 801 489 8611 Flowserve Corporation has established indust
23. round the actuator cylinder re AN CAUTION Do not overtighten packing This can cause taining ring and actuator stem guide to check for air excessive packing wear and high stem friction that leaks through the O rings may impede stem movement Packing that is tight 5 13 Clean any dirt and other foreign material from the plug ened too tight will typically not seal correctly stem 9 9 If the valve is supplied with a lubricator fitting check 5 14 Ifan air filter is supplied check and replace cartridge if lubricant supply and add lubricant if necessary See necessary Drain any moisture accumulated in the air Table for common lubricants filter 5 6 If possible stroke the valve and check for smooth full Stroke operation Unsteady stem movement could in dicate an internal valve problem Table I Common Packing Lubricants il kuorcont Manfacurer Temperate Temperature e Application Description Krytox E l DuPont 5 to 550 to 285 Fluorinated general purpose grease handles common liquids and gasses good lubricity in harsh mediums nonflammable chemically inert will not harm plastic or metal parts GP 460 Acheson Colloids 32 to 1000 0to 540 Graphite in petrolatum high pressure anti galling graphite Company remains above 600 F 316 C 125 Chesterton 32 to 2600 Oto 1425 Nickel Aluminum and graphite in oil suspension provides protection with an ultra thin coating of nickel particles FLOWSERVE User instructions
24. ry leadership in the design and manufacture of its products When properly selected this Flowserve product is designed to perform its intended function safely during its useful life However the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service conditions Although Flowserve can and often does provide general guidelines it cannot provide specific data and warnings for all possible applications The purchaser user must therefore assume the ultimate responsibility for the proper sizing and selection installation operation and maintenance of Flowserve products The purchaser user should read and understand the Installation Operation Maintenance IOM instructions included with the product and train its employees and contractors in the safe use of Flowserve products in connection with the specific application While the information and specifications contained in this literature are believed to be accurate they are supplied for informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon Nothing contained herein is to be construed as a warranty or guarantee express or implied regarding any matter with respect to this product Because Flowserve is continually improving and upgrading its product design the specifications dimensions and information contained herein are subject to
25. tails on maintaining the style of packing supplied FLOWSERVE Nes CAUTION Do not overtighten packing This can cause excessive packing wear high stem friction that may impede plug movement and can damage the packing Over tightening packing will not improve the stem Seal unless the packing has been previously damaged Damaged packing should be replaced User instructions Mark One VLENIM0001 01 07 07 NOTE Due to excessive friction a dry graphite packing can cause the plug stem to move in a jerky fashion Lubrication of graphite packing will provide smoother stroking Lubrication can be done by using a bonnet lubricator or by liberally coating each packing ring by hand during installation Please refer to Table for lists 4 5 Make sure the valve fails in the correct direction in of common lubricants case of air failure This is done by turning off the air WARNING Keep hands hair and clothing away from supply and observing the failure direction all moving parts when operating the valve Failure to do so can cause serious injury D Valve Maintenance 5 7 Make sure positioner linkage and stem clamp are se At least once every six months check for proper oper curely fastened If the stem clamp is loose check plug ation by following the preventative maintenance steps thread engagement refer to the Reassembly and In outlined below These steps can be performed while stallation section for the correct pro
26. tener materials contact your Flowserve representative Pipelines must be correctly aligned to ensure that the valve is not fitted under tension Fire protection must be provided by the user Before installing the valve clean the line of dirt weld ing chips scale and other foreign material Whenever possible the valve should be installed in an upright position Vertical installation permits easier valve maintenance This is also important for cryo genic applications to keep the packing isolated from the flowing medium permitting the packing tempera ture to remain close to ambient temperature Be sure to provide proper overhead clearance for the actuator to allow for disassembly of the plug from the valve body Refer to the appropriate actuator User Instructions for proper clearances Actuator User In structions are available at www flowserve com Double check flow direction to be sure the valve is installed correctly Flow direction is indicated by the arrow attached to the body If welding the valve into the line use extreme care to avoid excess heat buildup in the valve FLOWSERVE Nes User instructions Mark One VLENIM0001 01 07 07 3 8 3 9 4 1 Figure 2 Pressure Balanced Mark One Control Valve Body Assembly If the valve has separable end flanges verify that the half rings are installed on the valve body before bolting the valve into the line WARNING Failure to install half rings on the val
27. tion 1 Over tightened packing 1 Adjust the packing box nuts to slightly over finger tight impeded 2 Service temperature is beyond 2 Reconfirm service conditions and contact factory Operating limits of trim design 3 Inadequate air supply 3 Check for leaks in air supply or instrument signal system tighten loose connections and replace leaky lines 4 Malfunctioning positioner 4 Refer to positioner User Instructions Excessive seat 1 Improperly tightened bonnet 1 Refer to step 7 11 Assembly and Installation section for correct tightening leakage procedure 2 Worn or damaged seat ring 2 Disassemble valve and replace or repair seat ring 3 Worn or damaged seat or bon 3 Disassemble and replace gaskets net gasket 4 Inadequate actuator thrust 4 Check for adequate air supply to actuator if air supply is adequate recon firm service conditions and contact factory 5 Incorrectly adjusted plug 5 Refer to steps 7 9 to 7 11 Assembly and Installation section for correct plug adjustment 6 Improper flow direction 6 Refer to original specifications or contact factory 7 Improper handwheel adjust 7 Adjust handwheel until plug seats properly ment acting as a limit stop 8 Worn or damaged pressure 8 Disassemble and replace pressure balanced seals balanced seals 9 Inadequate air supply pressure 9 Check for leaks in air Supply or instrument signal system tighten loose connections and replace leaky lines Inadequate flow 1 Imp
28. to tighten 7 10 7 11 7 12 7 13 7 14 7 15 User instructions Mark One VLENIM0001 01 07 07 CAUTION Failure to return the plug to a mid stroke po sition electric or hydraulic operators only will cause damage to the actuator and or the valve during the bonnet tightening sequence This is due to the inability of most electric hydraulic actuators to accommodate the 1 16 inch 1 60 mm back drive during the tighten ing sequence For air to close valves skip this step and go to step 7 11 For air to open valves check for proper plug Seating as follows When proper seating occurs the bonnet flange will be forced up against the finger tight body bolting with such force that it will be impossi ble to move the flange If proper seating does not oc cur the bonnet flange can be wiggled with light hand force for small valves and light wrench force for larger valves Should this occur place air under the actua tor piston and retract the actuator to approximate mid stroke position Turn the plug out of the actuator plug Stem one additional thread and repeat above seating procedure When the bonnet flange becomes tight against the finger tight body bolting the plug is prop erly seated If necessary repeat above procedure until proper seating occurs stroke the valve open and closed several times to center the seat ring Retract the plug open position Begin tightening the bonnet flange bolting in a manner
29. uas Avenue 20 Singapore 638824 Singapore Phone 65 6879 8900 Fax 65 6862 4940 Flowserve de Venezuela Zona Industrial Av 68 No 149B 155 Zona Industrial Maracaibo Zulia 1042 Venezuela Phone 582 61 736 1771 Fax 582 61 736 1912 Flowserve Corporation PO Box 209 Al Khobar 31952 Saudi Arabia Phone 9663 857 3146 Fax 9665 4915276 Flowserve Unit 1 12 Director Road Spartan Exit 2 Kempton Park Gauteng 1613 South Africa Phone 27 0 11 923 7300 Fax 27 0 11 974 6420 Flowserve Flow Control Quick Response Center 5114 Railroad Street Deer Park Texas 77536 USA Phone 281 479 9500 Fax 281 479 8511 Flowserve Flow Control Quick Response Center 2920 W Cardinal Drive Beaumont Texas 77705 USA Phone 409 842 6600 Fax 409 840 5213
30. ve body can cause serious personal injury Connect the air supply and instrument signal lines Throttling control valves are equipped with a valve po sitioner Refer to the appropriate positioner bulletin for connections maximum air supplies and maintenance instructions An air filter should be installed before the positioner All connections must be free of leaks CAUTION On valves equipped with air filters the air filter must point down to perform properly Quick check Prior to start up check the control valve by following these steps stroke the valve and observe the plug position indica tor on the stem clamp compared to the stroke indica 4 2 4 3 4 4 tor plate The plug should change position in a smooth linear fashion NOTE Due to excessive friction a dry graphite packing can cause the plug stem to move in a jerky fashion Lubrication of graphite packing will provide smoother stroking Lubrication can be done by using a bonnet lubricator or by liberally coating each packing ring by hand during installation Please refer to Table for lists of common lubricants WARNING Keep hands hair and clothing away from all moving parts when operating the valve Failure to do so can cause serious injury Check for full stroke by making appropriate instrument Signal changes Check all air connections for leaks Check packing box bolting for the correct adjustment Refer to the packing installation manual for specific de
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