USER INSTRUCTIONS - Flowserve Corporation
Contents
1. Should any problem arise call your Flowserve representa tive Installation DANGER Before installation check the purchase order num ber serial number and or the tag number to ensure that the valve and actuator being installed are correct for the intend ed application WARNING The maximum air supply for most Valtek cylin der actuators is 150 psi 10 3 bar In some cases the air p 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 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 pressure indicated on the sticker CAUTION Do not insulate extensions that are provided 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 responsi bility of the customer Typically the supplier does not know what the valve service conditions or environment may be Flowserve s standard body bolting 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 to2. 2014 Flowserve Corporation Irving Texas USA Flowserve is a registered trademark of Flowserve Corporation Sau di Arab ia Flowserve Abahsain Flow Control Co Ltd Makkah Road Phase 4 Plot 10 amp 12 2nd Industrial City Damman Kingdom of Saudi Arabia Phone 966 3 857 3150 ext 243 Fax 966 3 857 4243 flowserve com
3. Adjust handwheel until plug seats properly 8 Worn or damaged pressure bal anced Seals 8 Disassemble and replace pressure balanced seals 9 Check for leaks in air supply or instrument signal system tighten loose connections 9 Inadequate air supply pressure and replace leaky lines PRY 9 y 9 1 Improper plug adjustment limiting 1 Refer to steps 7 9 to 7 11 Assembly and Installation section for correct plug adjust stroke ment 2 Malfunctioning positioner 2 Refer to positioner maintenance instructions 3 Service conditions exceed trim l be Inadequate flow design capacity 3 Verify service conditions and consult factory 4 Incorrect actuator stroke 4 Verify actuator stroke 5 Check for leaks in air supply or instrument signal system tighten loose connections 5 Inadequate air supply pressure and replace leaky lines 1 Incorrect plug adjustment al lowing Stem motion impeded Excessive seat leakage improper cushion of air between 1 Refer to steps 7 9 to 7 11 Assembly and Installation section for correct plug adjust actuator piston and yoke 2 Inadequate air supply 2 Check air supply to actuator repair leaks and remove any restrictions in supply line ment Plug slams 3 Trim sized too large for flow rate 3 Verify the service conditions and actuator sizing install reduced trim Valve does not fail 1 Incorrect flow direction 1 Reconfirm direction and if necessary correct flow direction through va
4. Stem Stem Clamp Alignment 7 1 7 2 Remove the packing gland bolting yoke clamps and remove the actuator 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 CavControl and Chan nelStream valves the seat ring 33 degrees Lapping is not necessary if proper assembly procedures are followed CAUTION If re machining protect the stem while turning Ensure concentration of the seat surface with the plug stem or outside diameter of the seat ring if machining the seat To replace packing or change the packing box configuration 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 WARNING For valves equipped with separable end flang es do not machine body gasket surfaces Machining 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 appropriat
5. bolting has been tightened NOTE Step 7 10 applies only to valves with pneumatic actu ators If an electric or hydraulic actuator is used return the plug to the mid stroke position and proceed to tighten CAUTION Failure to return the plug to a mid stroke position 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 hy draulic actuators to accommodate the 1 16 inch 1 60 mm back drive during the tightening 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 impossible to move the flange If proper seating does not occur 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 actuator 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 bon net flange becomes tight against the finger tight body bolt ing the plug is properly 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
6. general corrosion As with any mechanical equipment periodic inspection and maintenance is required For more information about fas 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 welding 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 cryogenic applica tions to keep the packing isolated from the flowing medium permitting the packing temperature to remain close to am bient temperature Be sure to provide proper overhead clearance for the ac tuator to allow for disassembly of the plug from the valve body Refer to the appropriate actuator User Instructions for proper clearances Actuator User Instructions 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 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 3 9 4 1 Ca N FLOWSERVE N Valtek Mark One and Mark Two Cont
7. in unpack ing installing and performing maintenance as required on Flowserve products Product users and maintenance person nel should thoroughly review this bulletin prior to unpacking installing operating or performing any maintenance In most cases Flowserve valves actuators and accessories are designed 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 con tacting the manufacturer The product Installation Operation and Maintenance Instructions provides important additional safety information Applicability The following instructions are applicable to the maintenance and installation of Flowserve Valtek Mark One and Mark Two globe and angle body design control valves These instruc tions cannot claim to cover all details of all possible product variations nor can they provide information for every possi ble example of installation operation or maintenance This means that the instructions normally include only the direc tions to be followed by qualified personal using 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 appropri ate Flowserve sales office All Flowserve User Manuals are available at www flowserve com Terms Concerning Safety The safety terms DANGER WARNING CAUT
8. ION and NOTE are used in these instructions to highlight particular dangers and or to provide 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 precau tions are not taken CAUTION Indicates that minor personal injury and or proper ty damage can occur if proper precautions are not taken NOTE Indicates and provides additional technical informa tion which may not be obvious even to qualified personnel Compliance with other notes which may not be particularly emphasized with regard to transport assembly operation and maintenance and with regard to technical documentation 3 1 6 1 7 Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 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 problem atic applications e g under extremely high pressures with dangerous toxic or corrosive mediums When performing service inspection or repair operations always ensure that the valve and actuator are depressurized and that
9. Spacers Item 94 99 Lower Guide Item 83 m 2 Mg Bonnet Item 40 Plug Item 50 seat Ring Item 20 Body Item 1 Optional angle body Figure 3 Exploded View Mark One Body Assembly FLOWSERVE 5 12 5 13 5 14 6 1 6 2 6 3 6 3 1 6 3 2 6 3 3 N Spray a soap solution around the actuator cylinder retaining ring and actuator stem guide to check for air leaks through the O rings Clean any dirt and other foreign material from the plug stem If an air filter is supplied check and replace cartridge if nec essary Drain any moisture accumulated in the air filter 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 bon net and plug assembly called the top works should be low ered and blocked to prevent rolling 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 balanced sl
10. a N FLOWSERVE wee USER INSTRUCTIONS Valtek Control Products Installation Mark One and Mark Two Control Valves Operation Maintenance FCD VLENIM0001 01 AQ 08 14 y Jalted Ba Tl a i a m Experience In Motion a N FLOWSE RVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 Contents 1 General Information 3 2 Unpacking D 3 Installation D 4 Quick Check 6 5 Valve Maintenance 6 Disassembly and Inspection 9 7 Assembly and Installation 10 8 Sever Service Trim Options 12 8 1 CavControl 12 8 2 ChannelStream 12 8 3 MegaStream 13 8 4 Stealth 13 8 5 TigerTooth 14 Figures Figure 1 Mark One Control Valve Body Assembly optional angle body 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 I Common Lubricants Table II Suggested Bonnet Bolting Torque Values Table Ill Troubleshooting Chart FLOWSERVE ki 1 2 N General Information Using The following instructions are designed to assist
11. e actuator User Manual for detailed instructions on actuators Assembly and Installation NOTE Separate User Manuals with instructions on assem bling actuators positioners and other equipment can be found on www flowserve com Review any relevant User Manual before proceeding NOTE It is recommended that all soft goods are replaced 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 functioning 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 appropriate packing User Manual document number VLAIM040 and re install 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 spac FLOWSERVE 1 3 1 4 hao 7 6 gt gt Fola 7 8 N ers 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
12. e returned Contact your local Flowserve representative to obtain return authorization Storage In many cases Flowserve products are manufactured from stainless steel Products not manufactured from stainless steel are provided with an epoxy resin coating This means that Flowserve products are well protected from corrosion Nevertheless Flowserve products must be stored adequate ly in a clean dry environment Plastic caps or plywood pro tectors 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 accesso ries are included in each shipping container When lifting the valve from shipping container use straps through the yoke legs or the lifting lugs attached 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 acces sories or stroke plate WARNING When lifting a valve be aware that the centre of gravity may be above the lifting point Therefore 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 equipment Contact your shipper immediately if there is shipping dam age
13. eeve may stick to the plug and fall dur ing disassembly causing possible serious injury and dam age 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 allow ing 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 bottom 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 Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 6 3 4 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 retainer and pressure balancer sleeve are one and the same part In larg er valves there are separate pressu
14. hat the retainer is disassembled Plugs and retainer mating surfaces should a N FLOWSERVE N Figure 8 Mark One with MegaStream Trim Body Assembly Figure 9 Mark One with Stealth Trim Body Assembly 8 2 3 8 2 4 8 2 4 1 8 2 4 2 8 2 4 3 8 3 8 3 1 8 3 2 8 4 8 4 1 Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 be examined for damage Repair and replacement of dam aged parts is critical to maintaining cavitation resistance ChannelStream retainers should be cleaned of debris when ever the valve is opened Use the following steps if the retainer must be disassembled to clean or inspect for damage ChannelStream retainers in pressure classes 900 and higher cannot be disassembled in the field Contact your local 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 mak ing 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 Ex cessive heat from t
15. he bead welds that are too large can dis turb critical retainer tolerances Use an appropriate weld rod which is compatible with the retainer material If uncer tain contact the factory CAUTION To function properly ChannelStream is always installed flow over 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 As sembly and disassembly of the valve follows the standard procedures Megastream retainers plugs and seats should be exam ined for damage when disassembled Holes in the retainer Should be checked for worn or eroded surfaces Check for plugged holes in the retainer Multi stage MegaStream re tainers cannot be disassembled Repair and replacement of damaged parts is critical to maintaining noise control CAUTION To function properly MegaStream is always in Stalled 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 bonnet have dimen 13 14 a N FLOWSERVE Figure 10 Mark One with TigerTooth Trim Body Assembly Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 8 5 8 5 1 sional differences from the standard Mark One design As sembly and disassembly of the valve follows the standard procedures Stealth retainers plug
16. lve in correct position 2 Incorrect actuator fail direction 2 Consult actuator User Manual and change fail direction 15 Ca N FLOWSERVE N USA Flowserve Flow Control Division 1350 N Mt Springs Parkway Springville UT 84663 USA Phone 1 801 489 8611 Fax 1 801 489 3719 Austria Flowserve Control Valves GmbH Kasernengasse 6 9500 Villach Austria Phone 43 0 4242 41 181 0 Fax 43 0 4242 41181 50 France Flowserve France S A S BP 60 63307 Thiers Cedex France Phone 33 4738 04266 Fax 33 4738 01424 India Flowserve India Controls Pvt Ltd FCD VLENIM0001 01 AQ Printed in USA 08 14 Replaces VLAIM001 00 Plot 4 1A Road 8 EPIP Whitefield To find your local Flowserve representative eee Karnataka 960066 Phone 91 80 40146200 For more information about Flowserve Corporation visit Fax 91 80 28410286 www flowserve com or call USA 1 800 225 6989 China 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 Corporation has established industry 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 S numerous applicatio
17. moving parts To avoid in jury Flowserve provides pinch point protection in the form of cover plates especially where side mounted positioners are fitted If these plates are removed for inspection service Or repair special attention is required After completing work the cover plates must be refitted Apart from the operating instructions and the obligatory accident prevention direc tives valid in the country of use all recognized regulations for safety and good engineering practices must be followed Ca N FLOWSE RVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 Upper Guide Plug Item 87 Item 50 Upper Packing Item 88 Packing Spacers Body Bolting Item 94 99 Item 108 114 Lower Packing Bonnet Flange Item 83 Item 70 Ee Lower Guide Bonnet Item 83 Item 40 l Bonnet Gasket Item 58 Body Item 1 _ Seat Ring Seat F Item 20 Retainer Seat Gasket Item 30 Item 55 Optional angle body Figure 1 Mark One Control Valve Body Assembly FLOWSERVE 1 8 2 1 2 2 2 3 2 4 N WARNING Before products are returned to Flowserve for repair or service Flowserve must be provided with a cer tificate that confirms that the product has been decontami nated and is clean Flowserve will not accept deliveries if a cleaning certificate has not been provided Return authoriza tion is also required before parts ar
18. ns under a wide variety of industrial service conditions Although Flowserve can and often does provide general guidelines it cannot provide specific data Ingapore and warnings for all possible applications The purchaser user must therefore assume the ultimate responsibility for the proper sizing and selection installation operation and Flowserve Pte Ltd maintenance of Flowserve products The purchaser user should read and understand the Installation Operation Maintenance IOM instructions included with the product and i train its employees and contractors in the safe use of Flowserve products in connection with the specific application 12 Tuas Aven ue 20 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 Repu bl IC of Singapore 638824 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 Phone 65 6879 8900 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 change without notice Should any question arise concerning these provisions the purchaser user should contact Flowserve Corporation at any one of its Fax 65 6862 4940 worldwide operations or offices
19. plug open position Begin tightening the bonnet flange bolting in a manner that will keep the bon net 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 tight en all bolts evenly and completely to compress the bonnet gasket and to seat the bonnet Torque the bonnet bolts to the suggested torque values in Table II The bonnet will seat metal to metal with the body when the bonnet bolts are cor rectly torqued into place 11 12 Ca N FLOWSERVE N Figure 6 Mark One with CavControl Trim Body Assembly Hu m l Figure 7 Mark One with ChannelStream Trim Body Assembly Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 8 1 1 8 2 8 2 1 Apply air over the piston to seat the plug For all throttling valves adjust the stem clamp so that with full instrument signal to the positioner the full signal scribe line on the posi tioner cam points to the centre of the cam roller bearing CAUTION Make sure the slots of the stem clamp are perpen dicular 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 impor tant since this adjustment secures the actuator stem to the plug stem Adjust the stroke plate so the
20. priate instrument sig nal changes Check all air connections for leaks Check packing box bolting for the correct adjustment Re fer to the packing installation manual for specific details on maintaining the style of packing supplied FLOWSERVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 wee A CAUTION Do not overtighten packing This can cause exces 5 9 If the valve is supplied with a lubricator fitting check lubri Sive packing wear high stem friction that may impede plug cant supply and add lubricant if necessary See Table for movement and can damage the packing Over tightening common lubricants packing will not improve the stem seal unless the packing 5 6 If possible stroke the valve and check for smooth full has been previously damaged Damaged packing should be stroke operation Unsteady stem movement could indicate replaced an internal valve problem 7 NOTE Due to excessive friction a dry graphite packing can failure This is done by turning off the air supply and observ of graphite packing will provide smoother stroking Lubri ing the failure direction cation can be done by using a bonnet lubricator or by lib erally coating each packing ring by hand during installation D i Valve Mal ntenance Please refer to Table I for lists of common lubricants amp WARNING Keep hands hair and clothing away from all At least once every six months check for proper operation i l l moving part
21. re balancer sleeves and Seat retainers 6 4 Lift retainer seat ring and gaskets free of the body Care must be taken not to damage the gasket surfaces in the body when the gaskets are removed 6 9 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 assem bly Since the plug seating surface does not come in contact with the seat insert retainer it is not necessary to correct any minor 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 followed 6 6 Loosen the stem clamp and unscrew the plug from the actu ator stem W WARNING Danger exists when working with large valves and heavy parts Take care to properly support large parts to avoid damage to the parts of nearby equipment or personnel Table Il Suggested Bonnet Bolting Torque Values Bolt Size inches Bolt Stud Material inches Carbon Steel Stainless Steel 5 8 aa o e a0 ar Trae o 900 o a Trae soo a oso ase All values are 10 10 a N FLOWSERVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 6 7 6 8 Soft Seat Retainer Soft Seat _ A 69 Figure 4 Soft Seat Assembly A 6 10 H H Correct Figure 5 Actuator
22. retainers should turn easily CAUTION Installing seat retainers upside down can 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 cor rectly 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 care ger T9 19 2 7 10 Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 ful not to scratch or gall the plug as it enters the body To properly align the seat ring and plug first bring the bon net bolting to finger tightness With pneumatic actuators apply air pressure above the pis ton to seat the plug in the seat ring Proceed to step 7 10 With electric or hydraulic actuators move the actuator stem down until it is completely extended Next retract the actu ator 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 actuator limit switches will need to be readjust ed once the body
23. rol CAUTION With rare exception to function properly Tiger Tooth is always installed flow under FLOWSE RVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 Table Ill Troubleshooting Chart Problem Probable Cause Corrective Action 1 Over tightened packing 1 Adjust the packing box nuts to slightly over finger tight 2 Service temperature is beyond de operating limits of trim design 2 Reconfirm service conditions and contact factory 3 Check for leaks in air supply or instrument signal system tighten loose connections 3 Inadequate air supply and replace leaky lines 4 Malfunctioning positioner 4 Refer to positioner User Instructions 1 Improperly tightened bonnet 1 iti to step 7 11 Assembly and Installation section for correct tightening proce 2 Worn or damaged seat ring 2 2 Disassemble valve and replace or repair seat ring 00 valve and 2 Disassemble valve and replace or repair seat ring 00 Or repair seat ring 3 Worn or damaged seat or bonnet 3 Disassemble and replace gaskets gasket 4 Check for adequate air supply to actuator if air supply is adequate reconfirm 4 Inadequate actuator thrust Service conditions and contact factory 5 Incorrectly adjusted plug 5 ie to steps 7 9 to 7 11 Assembly and Installation section for correct plug adjust 6 Improper flow direction 6 Refer to original specifications or contact factory 7 Improper handwheel adjust ment acting as a limit stop 7
24. rol Valves FCD VLENIM001 01 AQ 8 14 Optional angle body Figure 2 Pressure Balanced Mark One Control Valve Body Assembly WARNING Failure to install half rings on the valve body can Cause serious personal injury Connect the air supply and instrument signal lines Throt tling control valves are equipped with a valve positioner Refer to the appropriate positioner bulletin for connections maximum air supplies and maintenance instructions An air filter should be installed before the positioner All connec tions 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 indicator on the stem clamp compared to the stroke indicator plate The plug should change position in a smooth linear fashion 4 2 4 3 4 4 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 Lubri cation can be done by using a bonnet lubricator or by lib erally coating each packing ring by hand during installation Please refer to Table I 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 appro
25. s and seats should be examined for damage when disassembled Holes in the retainer should be checked for worn or eroded surfaces Check for plugged holes in the retainer Stealth retainers cannot be disassem bled Repair and replacement of damaged parts is critical to maintaining noise control CAUTION With rare exception to function properly Stealth is always installed flow under When reinstalling Stealth retainers care must be given to orientating the retainer correctly Stealth retainers have an arrow that must be aligned with the valve outlet TigerTooth TigerTooth replaces the standard Mark One retainer with a welded or pinned stacked disk retainer see Figure 10 Sev eral of the parts including the plug seat ring and bonnet have dimensional differences from the standard Mark One design Assembly and disassembly of the valve follows the standard procedures TigerTooth retainers plugs and seats should be examined 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 re assembling to stack up the discs in the same order Each disc has been etched with a number for that purpose Weld ed TigerTooth retainers should not be disassembled outside a qualified service centre Repair and replacement of dam aged parts is critical to maintaining noise and or cavitation cont
26. s when operating the valve Failure to do so can by following the preventative maintenance steps outlined cae e oue nii below These steps can be performed while the valve is in jury line and in some cases without interrupting service If an 7 5 7 Make sure positioner linkage and stem clamp are securely internal problem is suspected refer to Section 6 Valve Dis l E E S fastened If the stem clamp is loose check plug thread en y p l gagement refer to the Reassembly and Installation sec 5 1 Look for signs of gasket leakage through the end flanges and tion for the correct procedure on aligning the plug with the bonnet Re torque flange and bonnet bolting if required seat Tighten stem clamp nut ing positioners and providing maintenance to actuators Oe Examine the valve for damage caused by corrosive fumes or Current User Manuals are available at www flowserve com process drippings C 9 8 Verify that the takeoff arm and follower arm are not binding 9 9 Clean valve and repaint areas of severe oxidation at either end of the stroke The follower arm attached to the positioner should be free to move slightly when the valve is 5 4 Check packing box bolting for proper tightness and packing at both ends of the stroke leakage If packing leakage is noticed packing maintenance is required Refer to the packing installation manual docu 5 9 Ensure all accessories brackets and bolting are securely ment number VLAIM040 for specific de
27. should be replaced each time the valve packing is replaced Do not rebuild the valve without the correct guide liners Re insert the plug stem into the packing box being careful not to score the plug stem or the guides Reinstall 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 actu ator stem threads The gland flange 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 correct installation For pressure balanced valves install the pressure balanced sleeve gasket Ensure that severe service retainers are correctly indexed by turning the retainer in the body Correctly aligned
28. 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 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 disassembly of the valve follows the standard procedures CavControl retainers plugs and seats should be examined for excessive cavitation damage when disassembled Holes in the retainer should be checked for worn or eroded surfac es Check for plugged holes in the retainer Plugs and retain er mating surfaces should be examined for damage Repair and replacement of damaged parts is critical to maintaining cavitation resistance CAUTION To function properly CavControl is always in stalled flow over ChannelStream ChannelStream replace the standard retainer with multiple sleeves pinned together see Figure 7 The plug seat ring and bonnet have dimensional differences from the standard Mark One design Assembly and disassembly of the valve follows the standard procedures ChannelStream retainers plugs and seats should be exam ined for excessive cavitation damage when disassembled The inner holes in the retainer should be checked for wear or erosion evidence of erosion should require t
29. tails on maintaining fastened the style of packing supplied 5 10 If possible remove air supply and observe actuator for cor AN CAUTION Do not overtighten packing This can cause exces rect fail safe action sive packing wear and high stem friction that may impede stem movement Packing that is tightened too tight will typ 5 11 Check rubber actuator bellows for splits cuts or wear ically not seal correctly Table I Common Packing Lubricants an E me a 7 Lubricant Manufacturer Application Description Fluorinated general purpose grease handles common liquids and gasses good lubricity in harsh mediums nonflammable chemically inert will not harm plastic or metal parts Acheson Colloids Graphite in petrolatum high pressure anti galling graphite remains Nickel Aluminum and graphite in oil suspension provides protection Om Chesterton 32 to 2600 Oto 1425 with an ultra thin coating of nickel particles Krytox E I DuPont 5 to 550 20 to 285 Ca N FLOWSERVE N Gland Flange Item 80 Bonnet Flange Item 70 Upper Packing Item 88 Lower Packing Item 88 Yoke Half Clamps amp Yoke Clamp Bolts Items 76 107 118 Bonnet Gasket Item 58 Seat Retainer Item 30 Seat Gasket Item 55 Valtek Mark One and Mark Two Control Valves FCD VLENIM001 01 AQ 8 14 Gland Bolting Items 109 117 Body Bolting Items 108 114 Upper Guide Item 87 Packing
30. the valve has been cleaned and is free from harmful substances In such cases pay particular attention to personal protection e g protective clothing gloves glasses etc Qualified Personnel Qualified personnel are people who on account of their training experience and instruction and their knowledge of relevant standards specifications accident prevention reg ulations 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 training schools Spare Parts Use only Flowserve original spare parts Flowserve cannot accept responsibility for any damages that occur 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 corro sion or deterioration before putting them into use service Repair To avoid possible injury to personnel or damage to prod ucts safety terms must be strictly adhered to Modifying this product substituting non factory parts or using main tenance procedures other than those outlined in these Instal lation Operation and Maintenance Instructions could dras tically affect performance be hazardous to personnel and equipment and may void existing warranties Between the actuator and the valve there are
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