USER INSTRUCTIONS - Flowserve Corporation
Contents
1. 8 EPIP Whitefield Bangalore Karnataka 560066 India Phone 91 80 40146200 Fax 91 80 28410286 FCD VLENIM0001 02 AQ Printed in USA 08 15 Replaces VLAIM001 00 China Flowserve Fluid Motion and Control Suzhou Co Ltd No 35 Baiyu Road Suzhou Industrial Park Suzhou For more information about Flowserve Corporation visit Jiangsu Province P R 215021 China www flowserve com or call USA 1 800 225 6989 Phone 86 512 6288 8790 Fax 86 512 6288 8736 To find your local Flowserve representative Singapore Flowserve Pte Ltd 12 Tuas Avenue 20 Republic of Singapore 638824 Phone 65 6879 8900 Fax 65 6862 4940 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 Sau di Arab ia 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 Flowserve Abahsain Flow Control maintenance of Flowserve products The purchaser user should read and understand the Ins2. call your Flowserve representative Ca N FLOWSERVE N 3 Installation 3 1 3 2 3 3 3 4 3 5 3 6 x gt gt DANGER Before installation check the purchase order 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 cases 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 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 responsibility 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 to general corrosion As with any mechanical equipment periodic inspection and maintenance is requ
3. anti galling graphite remains above 600 F 316 C Nickel Aluminum and graphite in oil suspension provides protection with an ultra thin coating of nickel particles flowserve com Ca N FLOWSERVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 we Gland Bolting Items 109 117 Gland Flange Item 80 Body Bolting Items 108 114 Bonnet Flange Item 70 Upper Guide Upper Packing emi 2g Item 88 Packing Spacers Item 94 99 Lower Packing Item 88 Lower Guide Item 83 Yoke Half Clamps wz EE 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 Optional angle body Figure 3 Exploded View Mark One Body Assembly Ca N FLOWSERVE N Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 6 3 2 In the gap between the top of the sleeve and the bottom of 6 9 To replace packing or change the packing box configuration the bonnet place wooden blocking of equal thickness in at push out packing spacer and guides from underneath the least three places The wooden blocks must not extend in bonnet with a dowel around 0 13 inch 3 3 mm larger in far enough that they interfere with plug movement The plug diameter than the plug stem must be allowed to stroke up to the bonnet A WARNING For val
4. 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 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 actuator 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 Ca N FLOWSERVE N 7 6 Vf 7 8 7 9 7 9 1 19 2 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 corre
5. supplied CAUTION Do not overtighten packing This can cause exces Sive packing wear high stem friction that may impede plug movement and can damage the packing Over tightening pack ing will not improve the stem seal unless the packing has been previously damaged Damaged packing should be replaced Make sure the valve fails in the correct direction in case of air failure This is done by turning off the air supply and observing the failure direction flowserve com a N FLOWSERVE Valtek Mark One and Mark Two Control Valves FCD VLENIMO01 02 AQ 8 15 ail E i Optional angle body D Figure 2 Pressure Balanced Mark One Control Valve Body Assembly 5 Valve Maintenance At least once every six months check for proper operation by following the preventative maintenance steps outlined below These steps can be performed while the valve is in line and in some cases without interrupting service If an internal problem is suspected refer to Section CAUTION Do not overtighten packing This can cause excessive packing wear and high stem friction that may impede stem movement Packing that is tightened too tight will typically not seal correctly 9 9 lf the valve is supplied with a lubricator fitting check lubricant 6 Valve Disassembly and Inspection supply and add lubricant if necessary See Table for 5 1 Look for signs of gasket leakage through the end flanges and common lubricants bonnet Re torque flange an
6. ER WARNING CAUTION 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 xa A WARNING Indicates that death severe personal injury and or Substantial property damage can occur if proper precautions are not taken A CAUTION Indicates that minor personal injury and or property damage can occur if proper precautions are not taken NOTE Indicates and provides additional technical information which may not be obvious even to qualified personnel Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 1 3 2 Compliance with other notes which may not be particularly emphasized with regard to transport assembly operation and maintenance and with regard to technical 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 1 4 Protective Clothing DANGER Flowserve products are often used in problematic 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 a
7. Or FLOWSERVE wee USER INSTRUCTIONS Flowserve Valtek Control Products Installation Mark One and Mark Two Control Valves Operation Maintenance FCD VLENIM0001 02 AQ 08 15 y Jalted Ba Tl r i a m Experience In Motion rr FLOWSERVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 wee Contents 1 General Information 3 2 Unpacking 4 3 Installation D 4 Quick Check 5 5 Valve Maintenance 6 6 Disassembly and Inspection T 7 Assembly and Installation 9 8 Severe Service Trim Options 12 8 1 CavControl 12 8 2 ChannelStream 12 8 3 Diamondback 13 8 4 MegaStream 14 8 5 Stealth 14 8 6 TigerTooth 14 Figure 1 Mark One Control Valve Body Assembly optional angle body 4 Figure 2 Pressure Balanced Mark One Control Valve Body Assembly 6 Figure 3 Exploded View Mark One Body Assembly 8 Figure 4 Soft Seat Assembly 10 Figure 5 Actuator Stem Stem Clamp Alignment 10 Figure 6 Mark One with CavControl Trim Body Assembly 12 Figure 7 Mark One with ChannelStream Trim Body Assembly 12 Figure 8 Diamondback Trim Body Assembly 12 Figure 9 Mark One with MegaStream Trim Body Assembly 13 Figure 10 Mark One with Stealth Trim Body Assembly 13 Tables Table Common Lubricants 7 Table II Suggested Bonnet Bolting Torque Values 9 Table III Troubleshooting Chart 15 Ca N FLOWSERVE N 1 General Information 1 1 Using The following instructions are de
8. VLENIM001 02 AQ 8 15 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 Excessive heat from the bead welds that are too large can disturb critical retainer tolerances Use an appropriate weld rod which is compatible with the retainer material If uncertain contact the factory CAUTION To function properly ChannelStream is always installed flow over 8 3 DiamondBack 8 3 1 8 3 2 8 3 3 8 3 4 8 3 5 DiamondBack replaces the standard Mark One retainer with a stacked disk retainer that is either welded or bolted and pinned see Figure 8 Several of the parts including the plug Seat ring and bonnet may have dimensional differences from the standard Mark One design Assembly and disassembly of the valve follows the standard procedures DiamondBack 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 erosion should require that the retainer is disassembled or replaced Plugs and retainer mating Surfaces should be examined for damage Repair and replacement of damaged parts is critical to maintaining cavitation resistance DiamondBack retainers should be cleaned of debris wh
9. bly of the valve follows the standard procedures 8 2 2 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 erosion should require that the retainer is disassembled Plugs and retainer mating surfaces should be examined for damage Repair and replacement of damaged parts is critical to maintaining cavitation resistance Figure 7 Mark One with ChannelStream Trim Body Assembly 8 2 3 ChannelStream retainers should be cleaned of debris whenever the valve is opened 8 2 4 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 8 2 4 1 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 Figure 8 Diamondback Trim Body Assembly 8 2 4 2 The retainer can now be inspected for damage or cleaned N FLOWSERVE wee Figure 9 Mark One with MegaStream Trim Body Assembly Figure 11 Mark One with TigerTooth Trim Body Assembly 8 2 4 3 A Valtek Mark One and Mark Two Control Valves FCD
10. ct 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 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 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 actuator 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 actuato
11. d bonnet bolting if required 5 6 If possible stroke the valve and check for smooth full stroke Refer to Table II for bonnet bolt torque values operation Unsteady stem movement could indicate an 5 2 Examine the valve for damage caused by corrosive fumes or internal valve problem process drippings NOTE Due to excessive friction a dry graphite packing can ins cause the plug stem to move in a jerky fashion Lubrication 5 3 Clean valve and repaint areas of severe oxidation l l l l of graphite packing will provide smoother stroking 5 4 Check packing box bolting for proper tightness and packing Lubrication can be done by using a bonnet lubricator or by leakage If packing leakage is noticed packing maintenance is required Refer to the packing installation manual document number VLAIM040 for specific details on maintaining the style of packing supplied liberally coating each packing ring by hand during installation Please refer to Table for lists of common lubricants Ca N FLOWSERVE N 5 7 9 8 5 9 5 10 5 11 9 12 9 13 5 14 WARNING Keep hands hair and clothing away from all moving parts when operating the valve Failure to do so can cause serious injury Make sure positioner linkage and stem clamp are securely fastened If the stem clamp is loose check plug thread engagement refer to the Reassembly and Installation section for the correct procedure on aligning the plug with the seat Tighte
12. e valve and accesso been provided Return authorization is also required before parts ries are included in each shipping container are returned Contact your local Flowserve representative to obtain an return authorization 2 2 When lifting the valve from shipping container use straps through the yoke legs or the lifting lugs attached to the 1 8 Storage body bolting for valves over four inch or the adjusting screw for valves four inch and under Take care to position lifting In many cases Flowserve products are manufactured from stainless straps to avoid damage to the tubing mounted accessories Steel Products not manufactured from stainless steel are provided with or stroke plate an epoxy resin coating 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 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 2 3 Contact your shipper immediately if there is shipping damage 2 4 should any problem arise
13. enever the valve is opened It is rare that DiamondBack stacks require disassembly to clean The passages of the DiamondBack can be cleaned by pushing a wire through the passages from the inside of the stack by air or by water rinsing When required pinned and bolted DiamondBack retainers can be disassembled and cleaned in the field Welded DiamondBack retainers should not be disassembled outside a qualified service center Disassembly of Bolted DiamondBack Retainers Remove the nuts from the bolts studs Place the retainer with the crown disk facing down and remove the bolts studs from the stack Remove the bottom indexed disk Press the pins out away from the crown disk Take the discs apart maintain ing the order of assembly Replace damaged discs alignment pins bolts or nuts Inspect and clean out disc passages flowserve com rr FLOWSERVE wee Reassembly Care should be taken when reassembling to stack up the discs in the same order and the same rotation Start by driving the pins into the crown disk Then place each disk in descending order until all disks except the bottom indexed disc are in place Drive the pins until they are bottomed out Place the bottom disk on and replace the bolts studs Bolts must be torqued torque values are available from your local Flowserve contact A CAUTION To function properly DiamondBack is always installed flow under 8 4 Megastream 8 4 1 8 4 2 A Megastream replace
14. ent A 2 Malfunetioning positioner Refer to positioner maintenance instructions E service conditions exceed trim design Verify service conditions and consult factory Capacity 4 Incorrect actuator stroke Verify actuator stroke Check for leaks in air Supply or instrument signal system r Inadequate air supply pressure tighten loose connections and replace leaky lines 1 Incorrect plug adjustment allowing improper cushion of air between actuator piston and Refer to steps 7 9 to 7 11 Assembly and Installation section for correct plug adjustment yoke Check air supply to actuator repair leaks and remove any mecati ak SLES restrictions in supply line ER Verify the service conditions and actuator sizing install Trim sized too large for flow rate duced trii R Reconfirm direction and if necessary correct flow direction Incorrect flow direction through valve Incorrect actuator fail direction Consult actuator User Manual and change fail direction flowserve com ra N FLOWSERVE Nu 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 Plot 4 1A Road
15. he finger tight body bolting 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 plug open position Begin tightening the bonnet flange bolting in a manner 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 Suggested 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 throttling valves with analog positioners when the valve is in its fail Safe position adjust the stem clamp slightly so that the full open or full closed scribe line on the positioner cam points to the center of the cam roller bearing Adjustment can be made by sliding the stem clamp on the actuator stem CAUTION Make sure the slots of the stem clamp are perpendicular to the bolting See Figure 5 NOTE For on off valves and valves with digital positioners 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 adjustme
16. he retainer correctly Stealth retainers have an arrow that must be aligned with the valve outlet Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 8 6 TigerTooth TigerTooth replaces the standard Mark One retainer with a welded or pinned stacked disk retainer see Figure 11 several 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 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 qualified service centre Repair and replacement of damaged parts Is critical to maintaining noise and or cavitation control CAUTION With rare exception to function properly TigerTooth is always installed flow under Se FLOWSERVE N Problem Stem motion impeded Excessive seat leakage Inadequate flow Plug slams Valve does not fail in correct position Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 Table IlI Troubleshooting Chart make eyele smer
17. ired For more information about fastener 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 applications to keep the packing isolated from the flowing medium permitting the packing temperature 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 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 3 3 8 3 9 A Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 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 WARNING Failure to install half rings on the valve body can cause serious personal injur
18. lusys Corrective Action a packing the packing box nuts to slightly over finger tight service temperature is beyond operating 2 limits of trim design Recontirm service conditions and contact factory Check for leaks in air supply or instrument signal system Inadequate air supply tighten loose connections and replace leaky lines A 4 Maltunctioning positioner Refer to positioner User Instructions Refer to step 7 11 Assembly and Installation section for a Improperly tightened bonnet correct tightening procedure Worn or damaged seat ring Disassemble valve and replace or repair seat ring a Worn or damaged seat or bonnet gasket Disassemble and replace gaskets Check for adequate air supply to actuator if air supply is 4 Inadequate actuator thrust adequate reconfirm service conditions and contact factory Refer to steps 7 9 to 7 11 Assembly and Installation section Incorrectly adjusted plug for correct plug adjustment 6 Improper flow direction Refer to original specifications or contact factory re Improper handwheel adjustment acting as a Adjust handwheel until plug seats properly limit stop 8 Wom or damaged pressure balanced seals Disassemble and replace pressure balanced seals Check for leaks in air supply or instrument signal system x Inadequate air supply pressure tighten loose connections and replace leaky lines eee Refer to steps 7 9 to 7 11 Assembly and Installation section Improper plug adjustment limiting stroke for correct plug adjustm
19. n stem clamp nut NOTE Refer to the appropriate User Manuals when adjusting positioners and providing maintenance to actuators Current User Manuals are available at www flowserve com Verify that the takeoff arm and follower arm are not binding at either end of the stroke The follower arm attached to the positioner should be free to move slightly when the valve is at both ends of the stroke Ensure all accessories brackets and bolting are securely fastened If possible remove air supply and observe actuator for correct fail safe action Check rubber actuator bellows for splits cuts or wear 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 necessary Drain any moisture accumulated in the air filter Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 6 Valve Disassembly 6 1 A 6 2 6 3 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 bon
20. nd that 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 Xa 1 5 Qualified Personnel Qualified personnel are people who on account of their training experience and instruction and their knowledge 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 training schools 1 6 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 corrosion or deterioration before putting them into use 1 7 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 Maintenance Instructions could drastically affect performance be hazardous to personnel and equipment and may void existing warranties Between the actuator and the val
21. net 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 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 sleeve may stick to the plug and fall during disassembly causing possible 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 Table I Common Packing Lubricants a Lubricant Manufacturer Application Description Krytox Acheson Colloids E I DuPont 5 to 550 Chesterton 20 to 285 32 to 2600 0 to 1425 Fluorinated general purpose grease handles common liquids and gasses good lubricity in harsh mediums nonflammable chemically inert will not harm plastic or metal parts Graphite in petrolatum high pressure
22. ng the seat flowserve com rr FLOWSERVE Soft Seat Retainer Soft Seat _ Figure 4 Soft Seat Assembly Wrong Correct Figure 5 Actuator Stem Stem Clamp Alignment Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 71 7 2 1 3 7A Ko aa NOTE Separate User Manuals with instructions on assembling 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 through 9 and proceed as follows If the packing has been removed refer to the appropriate 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
23. nt 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 flowserve com rr FLOWSERVE Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 we 8 Severe Service Trim Options 8 1 CavControl 8 1 1 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 8 1 2 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 surfaces Check for plugged holes in the retainer Plugs and retainer mating surfaces should be examined for damage Repair Figure 6 Mark One with CavControl Trim Body Assembly and replacement of damaged parts is critical to maintaining cavitation resistance A CAUTION To function properly CavControl is always installed flow over 8 2 ChannelStream 8 2 1 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 disassem
24. r s operating manual The actuator limit switches will need to be readjust ed 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 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 7 10 7 11 7 12 7 13 7 14 7 15 Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 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 bonnet flange becomes tight against t
25. s the standard Mark One retainer with a drilled hole retainer see Figure 9 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 examined 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 retainers cannot be disassembled Repair and replacement of damaged parts is critical to maintaining noise control CAUTION To function properly MegaStream is always installed flow under 8 5 Stealth 8 9 1 Stealth replaces the standard Mark One retainer with a braised Stacked disk retainer see Figure 10 Several of the parts includ ing 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 Stealth retainers plugs 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 disassembled Repair and replace ment 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 t
26. signed to assist in unpacking installing and performing maintenance as required on Flowserve products Product users and maintenance personnel 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 contacting the manufacturer The product Installation Operation and Maintenance Instructions provides important additional safety information 1 2 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 instructions cannot claim to cover all details of all possible product variations nor can they provide information for every possible example of installation operation or maintenance This means that the instructions normally include only the directions 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 appropriate Flowserve sales office All Flowserve User Manuals are available at www flowserve com 1 3 Terms Concerning Safety 1 3 1 The safety terms DANG
27. tallation 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 Co Ltd 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 Makkah Road Phase 4 i 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 Plot 10 amp 12 2nd Industrial City matter with respect to this product Because Flowserve is continually improving and upgrading its product design the specifications dimensions and information contained my i 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 Dam man Ki ngd om of Saudi worldwide operations or offices Arabia 2015 Flowserve Corporation Irving Texas USA Flowserve is a registered trademark of Flowserve Corporation Phone 966 3 857 31 50 ext 243 Fax 966 3 857 4243 flowserve com
28. ve there are moving parts To avoid injury 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 directives valid in the country of use all recognized regulations for safety and good engineering practices must be followed flowserve com rr FLOWSERVE Body Bolting Item 108 114 Bonnet Flange Item 70 Bonnet Item 40 Body me Booy i Valtek Mark One and Mark Two Control Valves FCD VLENIM001 02 AQ 8 15 Upper Guide Ra T Item 87 Upper Packing Item 88 Packing Spacers Item 94 99 Lower Packing Item 83 Lower Guide Item 83 Bonnet Gasket Item 58 a seat Ring Seat Item 20 Retainer Item 30 meal Basket f e ai Optional angle body A Figure 1 Mark One Control Valve Body Assembly WARNING Before products are returned to Flowserve for repair 2 U n pac ki n o or service Flowserve must be provided with a certificate that confirms that the product has been decontaminated and is clean 241 While unpacking the valve check the packing list against the Flowserve will not accept deliveries if a cleaning certificate has not materials received Lists describing th
29. ves equipped with separable end flanges 6 3 3 By applying air below the piston retract the plug until the plug do not machine body gasket surfaces Machining could head is freed from the sleeve Once the plug is free from the cause failure of the separable flange lip causing end gasket Sleeve remove the plug and bonnet assembly from the body leakage and valve failure 6 3 4 Lift the pressure balanced sleeve out of the valve body using A CAUTION When using separable end flanges and spiral lifting points on the top of the sleeve wound gaskets use gaskets with outer backup rings Failure NOTE In many small Mark One valves the seat retainer and to do so could result in excess stress in some applications pressure balancer sleeve are one and the same part In larger 6 10 Check to see the seating surfaces on both the seat ring and valves there are Separate pressure balancer sleeves and seat plug are free of damage to ensure tight shutoff Make sure retainers the gasket surfaces on the seat ring bonnet and body are 6 4 Lift retainer seat ring and gaskets free of the body Care must clean and undamaged Examine the plug stem and bonnet be taken not to damage the gasket surfaces in the body when bore for scoring scratches pitting or other damage the gaskets are removed 6 11 Refer to the appropriate actuator User Manual for detailed 6 5 Valves with soft seats see figure 4 require the seat ring to instructions on actuators be inspected and possibl
30. y Connect the air supply and instrument signal lines Throttling control valves are equipped with a valve positioner Refer to the appropriate positioner bulletin for connections maxi mum 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 4 Quick check Prior to start up check the control valve by following these steps 4 1 4 3 4 4 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 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 details on maintaining the style of packing
31. y disassembled Check to see that seating surfaces on the plug and seat assemblies are free of Asse mM D ly an d n stal lati on damage If the seat insert is worn remove it from the assembly Since the plug seating surface does not come Table Il Suggested Bonnet Bolting Torque Values in contact with the seat insert retainer it is not necessary Bolt Size inches Bolt Stud Material to correct any minor damage to that part The plug seating Bolt Size a Sigel surface can be re machined to a 30 degree angle Lapping is inches aiaa alabi not required when proper reassembly procedures are followed i 5 8 6 6 Loosen the stem clamp and unscrew the plug from the 3 4 actuator stem A 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 6 Remove the packing gland bolting yoke clamps and remove the actuator 11 2 1320 1139 6 8 If the seat surfaces need re machining both surfaces on plug LO eni 1000 Usa All values are 10 and seat ring must be reworked The seat angle on the plug is 30 degrees 36 degrees for CavControl and ChannelStream valves the seat ring 33 degrees Lapping is not necessary if proper assembly procedures are followed A 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 machini
Download Pdf Manuals
Related Search