41005 Series - Corona Control
Contents
1. 4 1 4 Actuator removal neces 4 2 OPENING PRESSURIZED CHAMBER enne 4 3 PLUG STEM DISASSEMBLY eese 4 4 AUXILIARY PILOT PLUG DISASSEMBLY 5 MAINTENANCE REPAIR eren 5 5 1 PACKING BOX rotor cttneniea 5 1 1 PTFE packing 5 1 2 Graphite packing enceinte etienne 5 2 REPAIR OF PARTS inci occi aeaaeae 5 2 1 Guiding s rfaces necant teneas 5 2 2 Sealing surfaces eene ene 5 2 3 Gasket seating surfaces sennrsrnvrvnnnnenvnnenenvnnenennenenernenener 5 2 4 Seal rings and Gaskets eene 5 2 5 Valve plug and stem eese 6 VALVE REASSEMBLY eese 7 6 1 PINNING THE VALVE PLUG STEM enn 7 6 1 1 Reference marking on the valve plug stem 7 6 1 2 Screwing in the valve plug stem 7 6 1 3 Drilling pin hole m 6 1 4 PINNING iiieieseserisuesicixiap ssh ani pao rri dada tba riora k ana ta ar rata E 6 2 SEAL RING ASSEMBLY tiieceiee tei peaini ctetu 8 6 2 1 Model 41305 eite rere ten eterenieceed 8 6 2 2 Models 41405 and 41505 eene 9 6 2 3 Model 41605 neret trecenti ieteseciod 9 6 2 4 Model 41905 eterne netten 9 6 32. These valves have spring energized seal rings which must be assembled based on the specific valve operation see Figure 9A To insert the ring in the valve plug groove place it over the conical top of the plug then push down evenly from all sides until the gasket slips into the groove see Figure 9B 6 1 3 Drilling pin hole Figures 7 and 8 For this operation it is recommended clamping the valve plug stem assembly by the plug shank to avoid damaging the guiding surfaces Particular care must be taken so that the pin hole goes through the valve plug axis If the valve plug is new drill a hole of diameter C at a dis tance D from the end of the valve plug Choose diameter C from Figure 7 according to the pin diameter used Flow to Open Flow to Close If the hole is already drilled in the valve plug use the hole as a guide to drill through the valve stem 6 1 4 Pinning Insert the pin into the hole and press fit into the plug and stem Make sure the pin is recessed by the same amount from both sides as shown in Figure 8 Place the assembly in the soft jaw chuck of a lathe to check alignment of the two parts Correct any alignment defects by tapping it lightly with a plastic or rubber mallet Figure 9A Fold WS Seal shown installed for FTO operation Figure 9B 6 2 2 Models 41405 and 41505 Figures 14 and 15 These valves are equipped with m
3. Instruction No EH3600 07 02 41005 Series Valves G Unscrew the plug stem until the valve plug is in contact with the seat Do not turn the valve plug on the seat as this could damage the sealing surfaces H Screw the 2 nuts 1 as far as they will go and check that operation is correct 7 3 Connecting Type 87 No 10 16 and 23 Actuators Figure 17 A Tightly assemble hex nut 1 onto the plug stem B Screw the top stem connector assembly tightly onto the actuator stem C Push down the actuator and screw on the yoke nut 33 at the same time Then assemble the bottom stem connector assembly by screwing until it comes into contact with the hex nut 1 D Push down the actuator and tighten the yoke nut E Supply the actuator with air at the initial pressure indicated on the spring scale F Position the stem connector assembly at distance X indicated in Figure 13 G Use the pointer 7 to set the travel scale 9 to the valve open position H Supply the actuator with air at a high enough pressure to obtain a travel equal to the nominal travel of the valve CAUTION For Model 41405 valves reduce the travel by value A indicated in Figure 12 I With the plug correctly positioned on the seat unscrew the bottom stem connector assembly until it comes into contact with the top stem connector Tighten the socket head cap screws 5 hex nut 1 and lock nut 32 and check that the operation is corre
4. 20 Figure 10 10 For valve sizes 6 to 16 assemble either the cage gasket 36 or the conical spring washer 17 with the concave side upwards depending on the type of valve Then place the body gasket into the valve body making sure that it is centered properly 6 5 Bonnet Assembly Make sure the packing 6 packing spacer 5 and guide bushing 22 have been removed from the bonnet Position the bonnet 7 above the valve body so that the pack ing flange studs 2 are perpendicular to the flow direction of the valve Assemble the bonnet 7 over the valve stem 1 and push it down carefully until it is positioned correctly over the valve body studs 21 Grease the threads of the valve body studs 21 and the bear ing surfaces of the body stud nuts 8 Assemble the body stud nuts by hand Hand tighten the nuts evenly so that the internal parts are held in place The face of the bonnet should be parallel to the upper face of the body Slide the guide bushing 22 onto the valve plug stem and let it drop to the bottom of the packing box 6 6 Tightening Body Stud Nuts 6 6 1 Alignment of internal parts In order to achieve perfect alignment of the body and the internal components the plug stem should be loaded during tightening of the body nuts to obtain correct positioning of the various parts The force can be applied with the pneumatic actuator as follows Place the actuator
5. 41405 VALVE PLUG AND CAGE ASSEMBLY 9 6 3 1 Valve plug and auxiliary pilot plug assembly 9 6 3 2 Cage assembly 6 4 COMPLETING VALVE BODY ASSEMBLY nee 9 6 5 BONNET ASSEMBLY ees 10 6 6 TIGHTENING BODY STUD NUTS nnensvessvessvensvnnsensvensvensennsenseensvenseense 10 6 6 1 Alignment of internal parts esse 10 6 7 PACKING BOX ASSEMBLY mmrnreevsvenusvensvvensseensvennsvenssvennsvenssvenusvenssennn 11 PRC TUAT OR cc 11 7 1 CONNECTING TYPE 88 NO 6 ACTUATOR 11 7 2 CONNECTING TYPE 87 NO 6 ACTUATOR 11 7 3 CONNECTING TYPE 87 NO 10 16 AND 23 ACTUATORS 11 7 4 CONNECTING TYPE 88 NO 10 16 AND 23 ACTUATORS 12 7 5 CONNECTING TYPE 37 ACTUATOR ene 12 7 6 CONNECTING TYPE 38 ACTUATOR 12 FIGURE OF BODY SUB ASSEMBLY esses 13 14 FIGURE OF ACTUATOR menvnenevnnenerennnnnnnnnnnnnnennnenenenenenenenevennennnnnnvennnenenene 15 MASONEILAN DIRECT SALES OFFICES BACK COVER Instruction No EH3600 07 02 41005 Series Valves IMPORTANT This document contains all the instructions required for the installation operation and maintenance of the equipment Regular maintenance strict observance of these instructions and the use of manufacturer s replacement parts will guarantee optimum operation a
6. Assemble the seat ring or internal diffuser seat Assemble the cage or the cage valve plug stem assembly in the case of 41405 valves into the valve body n the case of valves other than 41405 valves insert the valve plug stem ring assembly into the cage taking particular care as it goes past the ring or spring energized seal ring For valve sizes less than 2 to 4 assemble the body cage gasket into the valve body Make sure it is centered as well as possible Instruction No EH3600 07 02 41005 Series Valves TORQUE Body Bonnet Bolting Requirements VALVE SIZE Body Nuts Assembly Torque Nominal m Pressure Size Quantity N in rating in 104 450800 sa in 600 smr 6 163 220 900 79 s 156 20 150 7s s 22 30 350509 310 8 12 1 eoo sa s 16 220 9 imas 6 se 76 150 rus 6 es mo 35000 e9 e 170 20 600 78s s s 360 ooo rms 6 ss 1200 150 fanes 6 1970 1850 45000 18 s om 40 320 1850 1850 150300 1148 8 526 710 600 1148 12 481 650 m 900 1348 8 1370 1850 1500 1348 8 1778 2400 1150 1150 1850 2200 1250 1150 1250 2200 1150 1250 1500 2600 150 300 8 60 1128 12 900 13 48 12 1370 150 1348 12 150 500 1128 8 600 1128 12 900 128 16 1500 13 8 16 150 500 11 28 12 600 1128 16 90 1128 20 1500 13 48
7. Cap Screw socket head 32 Lock Nut 52 Coupling Screw 72 Spring Barrel Cap 6 Connector Insert 33 Drive Nut 7 Pointer Not provided for Size 6 Actuator Figure 16 Figure 17 SPRING AND DIAPHRAGM SPRING DIAPHRAGM ACTUATOR ACTUATORS Type 37 38 Type 87 88 Multispring 15 DIRECT SALES OFFICE LOCATIONS BELGIUM INDIA Phone 32 2 344 0970 Mumbai Fax 32 2 344 1123 Phone 91 22 8354790 Fax 91 22 8354791 BRAZIL New Delhi Phone 55 11 2146 3600 Phone 91 11 2 6164175 Fax 55 11 2146 3610 Fax 91 11 5 1659635 CANADA ITALY Ontario Phone 39 081 7892 111 Phone 905 335 3529 Fax 39 081 7892 208 Fax 905 336 7628 JAPAN CHINA Chiba Phone 86 10 8486 4515 Phone 81 43 297 9222 Fax 86 10 8486 5305 Fax 81 43 299 1115 FRANCE KOREA Courbevoie Phone 82 2 2274 0748 Phone 33 1 4904 9000 Fax 82 2 2274 0794 Fax 33 1 4904 9010 KUWAIT GERMANY Phone 965 9061157 Viersen Fax 965 3987879 Phone 49 2162 8170 0 Fax 49 2162 8170 280 MALAYSIA Frankfurt Phone 60 3 2161 0322 Phone 49 69 439350 Fax 60 3 2163 6312 Fax 49 69 4970802 MEXICO Phone 52 5 310 9863 Fax 52 5 310 5584 Aftermarket Value Services THE NETHERLANDS Phone 31 10 438 4122 Fax 31 10 438 4443 RUSSIA Veliky Novgorod Phone 7 8162 15 7898 Fax 7 8162 15 7921 Moscow Phone 7 495 585 1276 Fax 7 495 585 1279 SAUDI ARABIA Phone 966 3 341 0278 Fax 966 3 341 7624 SINGAPORE Phone 65 6 6861 6100 Fax 65 6 68
8. associated retail point of sale systems and air and gas handling equipment Leading brand names within the Dresser portfolio include Dresser WayneQ retail fueling systems Waukesha natural gas fired engines Masoneilan control valves Mooney regulators Consolidated pressure relief valves and Roots blowers and rotary gas meters It has manufacturing and customer service facilities located strategically worldwide and a sales presence in more than 100 countries The company s website can be accessed at www dresser com Dresser Masoneilan 85 Bodwell Street Avon MA 02322 1190 Tele 508 586 4600 Fax 508 941 5497 Email sales 9 masoneilan com 2008 Dresser Inc All rights reserved Dresser Masoneilan With its breadth of products unequaled global presence and advanced process control expertise Dresser Masoneilan is uniquely positioned to be the leading provider of flexible best fit control valve solutions Supported by an integrated network of sales offices Dresser Masoneilan provides the widest range of valve solutions and services for virtually every process control application p Masoneilan WWW dresser com EH41005 07 02
9. be used as well Re machining of the pin holes in the existing parts often prevents satisfactory results from being obtained and can seriously impair the mechanical strength of the plug stem assembly 6 1 1 Reference marking on the valve plug stem Make a reference mark on the valve plug stem at a distance X Figures 7 and 8 equivalent to the stem recess in the valve plug Note This marking procedure is unnecessary for shouldered plug stems which provide a fixed mechanical stop 6 1 2 Screwing in the valve plug stem To carry out this operation the valve plug must be prevented from moving by holding the plug shank with an appropriate tool Screw two nuts onto the end of the new plug stem and lock them together Screw the valve plug stem solidly into the plug checking that the reference mark is level with the end of the plug shank Instruction No EH3600 07 02 41005 Series Valves diameter diameter Pin diameter Pin length rester istance Wrench size Non shouldered Shouldered stem stem 37 5 118 118 Figure 7 Two flats of wrench size E s Eli Shouldered stem x A 0 n EE os mm Standard Plug shank Shouldered pr stem E stem Stem Standard stem pin Figure 8 For shouldered stems apply torque T using a wrench of 6 2 Seal ring assembly dimension E 6 2 1 Model 41305 Figures 9A and 9B
10. making sure that the concentricity and or the thread of the bonnet is not damaged 4 2 Opening pressurized chamber Figures 14 and 15 The valve must always be reassembled with new packing sets and gaskets Before disassembly make sure that the appropri ate parts are available A Remove the packing flange nuts 3 then remove the pack ing flange 4 and the packing follower 23 B Check that the exposed part of the valve plug stem 1 is clean enough for the bonnet 7 to be removed easily C Remove the body stud nuts 8 D Lift the bonnet 7 up and disassemble it from the valve body 18 During this operation the valve plug stem 1 must be pushed downwards so that the valve plug remains in the valve body 18 E Remove the spring washer 17 or cage gasket 36 and the body gasket 10 F For Model 41305 41505 41605 and 41905 valves remove the valve plug stem 1 and valve plug 15 assembly from the cage by pulling the valve plug stem upward Then dis assemble the cage 16 from the body 18 Caution Because of the piston seal ring the cage may be lifted along with the valve plug If this should happen press down on the cage so that it remains in the body If the cage is lifted along with the valve plug it could slip during handling and become damaged G In the case of a 41405 valve remove the valve plug and body cage assembly by pulling the valve plug stem upward In this design the v
11. 61 7172 SOUTH AFRICA Phone 27 11 452 1550 UNITED ARAB EMIRATES Phone 971 4 8838 752 Fax 971 4 8838 038 UNITED KINGDOM Uxbridge Phone 44 1895 454 900 Fax 44 1895 454 919 UNITED STATES Massachusetts Phone 508 586 4600 Fax 508 427 8971 Corpus Christi Texas Phone 361 881 8182 Fax 361 881 8246 Dresser Direct Deer Park Texas Phone 281 884 1000 Fax 281 884 1010 Contractor Sales Houston Texas Fax 27 11 452 6542 Phone 832 590 2303 Fax 832 590 2529 SOUTH amp CENTRAL California AMERICA AND THE Phone 562 941 7610 CARIBBEAN Fax 562 941 7810 Phone 832 590 2303 Fax 832 590 2529 SPAIN Phone 34 93 652 6430 Fax 34 93 652 6444 Dresser Masoneilan a leading manufacturer of automated process control solutions offers world class global aftermarket services Consistent and high quality services executed through a network of fully authorized and certified third party service centers as well as company owned facilities include Valve Repair Technical Training Field Support Spare Parts Supply Complete Equipment Replacement and Comprehensive Diagnostics About Dresser Inc Dresser Inc is a leader in providing highly engineered infrastructure products for the global energy industry The company has leading positions in a broad portfolio of products including valves actuators meters switches regulators piping products natural gas fueled engines retail fuel dispensers and
12. 6150 500 7 2 5 Prior to reassembly examine parts carefully for any scratches unusual wear or other damage Figure 3 E Reassemble the packing follower 23 and the packing 5 2 1 Guiding surfaces flange 4 Guiding surfaces of the cage valve plug guide bushing plug F Tighten the packing flange nuts 3 without over com stem and auxiliary pilot plug must be checked If there is only pressing the packing rings slight wear indications then use a light abrasive to smooth out G Put the valve back into service and check for leakage guiding surfaces Otherwise the part must be replaced see Tighten packing flange nuts 3 as required paragraph on spare parts 5 1 2 Graphite packing To carry out this operation the valve plug stem must be dis connected from the actuator stem See chapter on actuator disassembly Guiding Guiding surface surface A Loosen and remove packing flange nuts 3 B Remove packing flange 4 and packing follower 23 from the plug stem Seating surface Pilot C Remove packing rings 6 being careful not to damage the sealing surface of the packing box or plug stem Cage Graphite Packing Figure 5 Number of Rings 5 2 2 Seating surfaces Figure 6 Braided Graphite Braided If the surface of the auxiliary pilot plug 20 is damaged the auxiliary pilot plug must be replaced see paragraph on spare parts 2 50 1 4 1 Th
13. The valve is typically equipped with an actuator Actuators and other valves accessories have their own instruction manuals which provides information on the electric and pneumatic connections The instruction manuals to be used for standard actuators are ER3000 for type 37 38 and ER8788 for type 87 88 Actuator Type mm Body Series Seal Type Design Trim Type Characteristic Series Spring Diaphragm direct 41 Cage air to close fail open action Spring Diaphragm reverse air to open fail to close Balanced Ring Oylinder spring return direct air to close single or double acting fail open action Oylinder spring return reverse air to open single or double acting fail to close Cylinder double acting without spring air to open or air to close action Spring Diaphragm direct air to close fail open action Spring Diaphragm reverse air to open fail close action Undefined Guided Pressure Energized Globe PTFE Seal Auxiliary Shut off Plug Pilot Metal Seal Ring PTFE Seal Ring Graphite Seal Ring Undefined Standard Cage Linear Standard Cage Equal Lo dB Anti Cav Single Stage Linear Lo dB Anti Cav Single Stage with Diffuser Linear Lo dB Multi Stage Linear VRT stack Type S Linear VRT partial stack Type S Modified VRT cage Type C Linear Anti Cav Multi Stage Linear 5 Refer to applicable product instructions manual for cylinder type actu
14. alve plug has a shoulder which prevents the cage from falling Remove the valve plug from the cage by pushing on the end of the valve plug stem H Remove the seat ring 13 and the seat ring gasket 14 from the valve body 18 I Remove the packing set 6 the packing spacer 5 and the guide bushing 22 from the bonnet 7 Note A packing spacer 5 is only required for a bonnet with a leak detector connection 4 3 Plug stem disassembly 1 The valve plug stem is screwed and pinned into the valve plug 15 To disassemble the stem the valve plug must be held as shown below taking care not to damage the guiding surfaces Disassemble the plug stem pin 9 from the assembly By means of flats or using a nut and counter nut on the end of the stem unscrew the stem from the plug taking care not to apply a bending moment which could deform it Cylindrical machining diameter of the jaw plug shank diameter Dia A pl Lt Tight only on this Soft non guiding metal surface vise jaw Stop pin integrated in vise jaw and inserted Do not into a tighten on plug hole the plug skirt Figure 1 Instruction No EH3600 07 02 41005 Series Valves 4 4 Auxiliary pilot plug disassembly Model 41405 Figure 14 For size 2 3 or 4 50 80 or 100 mm valves Exert a sufficient force on the auxiliary pilot plug 20 to com press the spring washers 12 The retaining ring 19 can then be removed a
15. ator Engineered trim options are also available for high temperature and high pressure drop applications including Multi Stage Anti Cavitation Trim Please consult factory for details Instruction No EH3600 07 02 41005 Series Valves 3 Installation 3 1 Piping cleanliness Before installing the valve in the line clean piping and valve of all foreign material such as welding chips scale oil grease or dirt Gasket mating surfaces must be thoroughly cleaned to insure leak free joints 3 2 Isolation bypass valve To allow for in line inspection maintenance and removal of the valve without service interruption provide a manually operat ed shutoff valve on each side of the control valve and a manu ally operated throttling valve in the bypass line 3 3 Heat insulation In case of a heat insulated installation do not insulate the valve bonnet and take protective measures relative to personal safety 3 4 Hydraulic test and cleaning of lines During this operation the control valve must not be used as an isolating valve This means that the valve must always be opened before carrying out pressure tests in the process line cleaning of pipes etc Otherwise equipment damage or failure of the seal rings could result 3 5 Flow direction The valve must be installed so that the process fluid will flow through the valve in the direction indicated by the flow arrow located on the body 4 Disassembly 4 1 Actuator
16. ct Plug Stem N1 Diameter turn Figure 11 Reverse Actuators valve seating Instruction No EH3600 07 02 41005 Series Valves 7 4 Connecting Type 88 No 10 16 and 23 Actuator Figure 17 A B Tightly assembly hex nut 1 onto the plug stem Tightly screw the top stem connector assembly onto the actuator stem Push down the actuator and screw on the yoke nut 33 at the same time Then assemble the bottom stem connector assembly by screwing until it comes into contact with the hex nut 1 D Push down the actuator and tighten the yoke nut 2 Unscrew the top stem connector in accordance with dimension X in Figure 13 With the plug correctly positioned on the seat unscrew the bottom stem connector assembly to bring it into contact with the top stem connector Supply air to the actuator until the stem has travelled at least 0 40 inches 10 mm Unscrew the top stem connector by the number of turns N1 specified in Figure 11 then lock manually with hex nut 1 CAUTION For 41405 valves use the N2 values to insure seating tightness of the pilot plug Release the pressure in the actuator Use pointer 7 to set the travel scale 9 to the actuator supply pressure so that the two stem connectors come into contact Then tighten the socket head cap screws 5 hex nut 1 and lock nut 32 Shut off the closed valve pressure and check that opera tion is correct Valve Size Valu
17. e A 4 Pressure Rating inches 150 300 or 600 0 1 150 300 or 600 900 or 1500 10 12 amp 16 Figure 12 Pilot plug travel 7 5 Connecting Type 37 Actuator Figure 16 A B Push down on the plug stem 1 until the plug is seated Attach the actuator to the valve bonnet with the yoke nut 83 or attachment screws Apply a sufficient pressure to the diaphragm to extend the actuator stem by the normal valve travel for valves 41305 41505 41605 and 41905 and the travel minus the value of A in Figure 12 for 41405 valves 12 11 X LE Actuator 87 11 X 3 Actuator 88 Actuator Travel Figure 13 Position of top stem connector Assemble the two parts of the stem connector 51 and the travel indicator 58 The number of threads inside the stem connection must be approximately equal for each stem Tighten screw s 52 Check that the travel of the actuator stem corresponds to the normal travel of the valve and that the closed position is obtained for the maximum spring range indicated on the serial plate Shut off the air pressure Use the pointer 58 to set the travel scale 56 The pointer 58 must indicate open when the air pressure is off 7 6 Connecting Type 38 Actuator Figure 16 A Connect a temporary air supply line to the actuator Apply sufficient pressure to the diaphragm to retract the actuator stem completely Attach the actuator to the valve bonnet with the yoke
18. e seat ring seating surface 13 valve plug seating 3 4 180 100 1 6 1 surfaces 15 and the auxiliary pilot plug seat 20 must be completely free of dents wear and scratches 6 16 1150 500 1 4 1 Any seating surfaces showing signs of slight deterioration Figure 4 may be touched up on a lathe in accordance with the follow ing guidelines A maximum of 010 0 25 mm of metal removal from seating surfaces is allowable for valve sizes 2 3 or 4 50 80 or 100 mm A maximum of 015 0 4 mm of metal removal from seating surfaces is allowable for valve sizes 6 to 16 150 to 400 mm Make sure that the seating angles indicated in Figure 6 are within tolerance Guiding surface Seating surface N Guiding surface Plug seat Pilot seat 41405 only Seat ring seat Figure 6 If a slight defect exists on any of the above seating surfaces lapping can be applied per the following instructions Place the seat ring 13 in the body noting the seating angle For Models 41305 41505 41605 and 41905 assemble the cage 16 onto the seat ring Spread a fine layer of high quality sealing compound on the seating surface For Model 41405 valves assemble the valve plug 15 cage 16 and stem 1 For Models 41305 41505 41605 and 41905 assemble the valve plug 15 and stem 1 Assemble the bonnet 7 and the guide bushing 22 Place an appropriate tool on the va
19. ed without having to separate the valve plug stem from the actuator stem A Unscrew and remove the packing flange nuts 3 B Lift the packing flange 4 and packing follower 23 up along the valve stem Instruction No EH3600 07 02 41005 Series Valves C By means of a puller remove the packing 6 and packing spacer 5 being careful not to damage the sealing surface of the packing box or the valve plug stem og Replace the packing rings placing the cut in each ring about 120 apart from the adjacent ring Press rings in one at a time in accordance with the table in Figure 3 PTFE Packing Number of Rings With Leak Detector No Leak DE Detector On top of Under packing spacer D Replace new packing set 6 First assemble a back up ring Carbon Graphite Inconel braided ring Then assem ble the expanded graphite rings smooth rings in accordance with Figure 4 Finally assemble an additional braided back up ring E Reassemble the packing follower 23 and packing flange 4 F Moderately tighten the packing flange nuts 3 G Reassemble the valve plug stem to the actuator stem see chapter on actuator reassembly H Open and close the valve several times then tighten the packing as required packing spacer I Put the valve back into service and check for leakage 2 50 6 2 4 Tighten packing flange nuts 3 as required did sus NN d 5 2 Repair of parts 6 1
20. etal seal rings The inner ring has a straight cut while the outer ring has a staggered cut To insert the rings into the plug groove open the rings slightly by hand and slide them along the plug without damaging any of the parts Assemble the inner and outer rings separately Note The cuts in the outer and inner rings should be placed approximately 180 apart 6 2 3 Model 41605 Figure 15 These valves are equipped with an inner elastomeric ring and an outer PTFE ring Insert the elastomeric back up ring 41 into the groove Place the PTFE seal ring 40 in boiling water for a few minutes Slide the seal ring along the plug until it slips into the groove For optimum insertion of the ring a Serflex type ring compres sor can be used to compress the ring in the groove for several minutes 6 2 4 Model 41905 Figure 15 These valves are also equipped with an inner and outer ring arrangement The inner metal ring has a straight cut and the outer ring is made of graphite Replacement graphite seal rings 45 are supplied in a closed ring form and a notch must be cut before being assembled to the plug Caution Graphite seal rings are fragile so the following operations must be carried out very carefully Instruction No EH3600 07 02 41005 Series Valves Using a sharp blade make a notch in the graphite ring Hold the ring on either side of the notch between the thumb and index and bend until i
21. llowing for disassembly of the auxiliary pilot plug and spring washers For size 6 to 16 150 to 400 mm valves To carry out this operation safely screws with diameters and lengths indicated in the table in figure 2 must be used Thread the socket head cap screws through the holes in the auxiliary pilot plug 20 Tighten until the retaining ring 19 can be removed Loosen the screws gradually then remove the auxil iary pilot plug and the spring 12 Pilot Dismounting Screw Sizes z Qty Eengin Diameter in mm in mm 6 150 2 2 25 57 1 4 20 UNC 2A 8 200 2 2 75 70 10 250 2 2 50 63 5 3 8 16 UNC 2A 12 300 3 4 00 101 5 16 400 3 2 50 63 5 Figure 2 5 Maintenance Repair 5 1 Packing box Tight sealing within the packing box is obtained by compres sion of the packing 6 Compression must be achieved by evenly tightening the packing flange nuts 3 on the packing flange 4 Periodic re tightening of the packing flange nuts is required to maintain proper sealing Be careful not to over tighten the packing as this could prevent proper operation of the valve If leakage persists after maximum packing compression then the packing needs to be changed A packing spacer 5 is only required for a bonnet with a leak detector connection 5 1 1 PTFE packing Kevlar PTFE carbon PTFE and pure PTFE packing rings are cut in such a way that they can be replac
22. lve plug stem 1 thread to allow for manual rotation Lap by slightly rotating the valve plug or the auxiliary pilot plug in alternate directions After several rotations lift the valve stem turn it 90 and repeat the operation Instruction No EH3600 07 02 41005 Series Valves Lapping can be repeated but should be limited as much as possible so that the seat remains sufficiently narrow to guarantee tightness After lapping disassemble the parts to clean them and then reassemble making sure that the seating angles are within tolerance 5 2 3 Gasket seating surfaces Gasket seating surfaces must be free of dents scratches and corrosion 5 2 4 Seal rings and gaskets Spiral wound gaskets Items 10 14 and 36 must always be replaced after disassembly Piston seal rings Items 31 35 40 and 45 can be reused if they are free of scratches ero sion corrosion or other damage 5 2 5 Valve plug and stem If the valve plug needs to be replaced then the stem must also be completely changed to guarantee correct pinning of the assembly If only the valve stem needs to be replaced then the valve plug can be reused 6 Valve reassembly 6 1 Pinning the valve plug stem The valve plug 15 and stem 1 assembly consists of a stem threaded into the valve plug and pinned in place If the valve plug 15 or the auxiliary pilot plug 20 in the case of a 41405 valve needs to be replaced then a new stem should
23. nd reduce maintenance costs 1 General and repair of its equipment Contact the local Masoneilan 1 1 Scope The following instructions are designed to guide the user through the installation and maintenance of the 41005 series cage guided valves for all sizes and pressure classes This instruction manual describes all the standard options in the 41005 valve series Special supplements or addendums to this instruction manual may be required for special designs developed to meet specific customer requirements 1 2 Serial plate The serial plate is usually fixed to the side of the actuator yoke It indicates amongst other things the size and type of valve the pressure class the body and bonnet material and the maximum supply pressure of the actuator 1 3 After Sales Service Masoneilan offers After Sales Service comprised of highly qualified technicians to support the operation maintenance 2 Numbering System representative or Masoneilan factory located closest to you 1 4 Spare parts Only Masoneilan replacement parts should be used when car rying out maintenance operations Obtain replacement parts through our local representatives or Spare Parts Department When ordering spare parts the model and serial numbers indicated on the manufacturer s serial plate must be given The recommended spare parts are indicated in the parts list included in this instruction manual 1 5 Actuator and accessories
24. nut 33 or attachment screws Shut off the air pressure completely Increase the air pressure to retract the actuator stem by the value of a in Figure 11 Assemble the two stem connectors 51 and the pointer 58 The number of threads inside the stem connection must be approximately equal for each stem Tighten screw s 52 Check that the travel of the actuator stem corresponds to the effective travel of the valve and that the closed position is obtained for the minimum spring range indicated on the serial plate Shut off the air pressure Use the pointer 58 to set the travel scale 56 The pointer 58 must indicate closed when the air pressure is off Instruction No EH3600 07 02 41005 Series Valves Figure 14 41405 Internal Parts Pilot Trim for Valve Sizes Pilot Trim for Valve Sizes 2 to4 6 to 16 FERE Internal Diffuser Option for Valve Sizes 6 to 16 13 Instruction No EH3600 07 02 41005 Series Valves Figure 15 Body Sub Assembly Packing with lateral connections 2 to 4 6 to 16 XT 36 without with conical spring conical spring 41405 amp 41505 41305 FTO Double cage Ref inti Ref inti Ref Im Ref Hn No Description No Description No Description No Description 1 Valve Plug Stem 9 Plug Stem Pin 18 Valve Body 36 Cage Gasket 2 Packing Flange Stud 10 Body Gasket 19 Re
25. on the valve bonnet 7 by means of the yoke nut 33 or attachment screws and connect the valve plug stem to the actuator stem See chapter on actuators for installation instructions Caution During this operation make sure that the plug does not turn when it is seated If the plug travel is very small and there is a large amount of plug stem inside the actuator it may be necessary to remove the yoke nut and lift the actuator so that the plug is not touching the seat Align the internal parts as follows For air to extend actuators supply air to the actuator at the maximum pressure indicated on the serial plate In the case of spring to extend actuators do not supply air to the actua tor so that the optimum positioning of the valve plug and seat can be obtained Tighten the body nuts 8 evenly by applying the torque and tightening sequence indicated in the table in Figure 10 6 7 Packing Box Assembly Assemble the packing box components per the maintenance in 7 7 structions in paragraphs 5 1 1 or 5 1 2 Actuator 1 Connecting Type 88 No 6 Actuator Figure 17 A B Tightly assemble the 2 hex nuts 1 onto the plug stem Push down the actuator and screw on the yoke nut 33 at the same time Then assemble the bottom stem connector 2 As soon as it becomes possible insert the valve stem into the actuator stem The stem must be inserted far enough so that when there is no air in the actuator
26. presser Masoneilan instuctions EH41005 07 02 41005 Series Control Valves Complete Line of Heavy Duty Balanced Cage Guided Globe Valves with Lo dB Anti Cavitation Capabilities Instruction No EH3600 07 02 41005 Series Valves TABLE OF CONTENTS 1 GENERAL eren nennen tnter etna 3 1 1 SCOPE i ssnicsastssassisascisssocsasieiaesessaiscassdasnatsacedesststsnvsianisaantaaiedsncndaan 1 2 SERIAL PLATE iniri suinann assa cusan mimk n aurata ca Sauer 1 3 AFTER SALES SERVICE nenonenonvrvnenvvervrvnnnvnnnnennnnnenenenenerenevenenen 1 4 SPARE PARTS rnnvonvvrvnenennneneneneneverenervnnsnnnennvnnnnennnenenenenenevenernnnnnn 1 5 ACTUATOR AND ACCESSORIES sess 2 NUMBERING SYSTEM eene 3 3 INSTALLATION eren 4 3 1 PIPING CLEANLINESS eese 3 2 ISOLATION BYPASS VALVE tette tette 3 3 HEAT INSULATION eese nnne tette tnnt ttd 3 4 HYDRAULIC TEST AND CLEANING OF LINES 3 5 FLOW DIRECTION eene tete tette 4 DISASSEMBLY reete 4 4 1 ACTUATOR REMOVAL mnnnnornonnvnnnnvnnvnnnnnennnnennennennnnennennnnvnnnnnenner 4 1 1 Disconnect instruments 4 1 2 Plug stems screwed into the actuator stem 4 1 3 Stems attached with a stem connector
27. removal Figures 16 and 17 Access to the internal components of the body should be accomplished with the actuator removed To carry out this operation follow the instructions below and refer to the specif ic actuator instructions reference ER 8788 for type 87 88 actuators and ER 3000 for type 37 38 actuators 4 1 1 Disconnect instruments Disconnect all mechanical connections between the positioner and the other instruments Disconnect the valve stem actuator stem coupling as described in the following sections 4 1 2 Plug stems screwed into the actuator stem For air to retract actuators apply sufficient air pressure to the actuator to retract the stem completely Caution During this operation make sure that the plug does not turn when it is seated If the plug travel is very small and there is a large amount of plug stem inside the actuator it may be necessary to remove the yoke nut and lift the actuator so that the plug is not touching the seat 4 1 3 Stems attached with a stem connector For air to retract actuators apply sufficient air pressure on the actuator to retract the stem completely Loosen the screws and remove the stem connector Caution Prior to disassembly vent the process pressure and isolate the valve if necessary 4 1 4 Actuator removal Disconnect all the air and electrical connections from and to the actuator Loosen the yoke nut or attachment screws and lift the actuator
28. t breaks Using a very fine file adjust each end of the ring so that its external circumference corresponds to the internal circumfer ence of the inside diameter of the cage 16 To adjust the length of the ring correctly insert the new graphite ring into the cage with the ring against the inner wall of the cage allowing for minimum play between the two ends of the ring First assemble the inner metal ring into the cage groove then assemble the graphite ring over the metal ring Be careful not to damage the parts Note The cuts on each ring should be placed approximately 180 apart 6 3 41405 Valve Plug and Cage Assembly Figure 14 6 3 1 Valve plug and auxiliary pilot plug assembly Assemble either the flat spring washers sizes 2 to 4 or the coil springs sizes 6 to 16 then assemble the valve plug and stem assembly Using the same tools as those used for disassembly see chapter on disassembly compress the springs so that the retaining ring can be installed into the groove in the main plug 6 3 2 Cage assembly Assemble the cage over the valve plug assembly from the top of the plug stem Make sure the seal ring in the plug groove stays positioned correctly 6 4 Completing Valve Body Assembly Figures 14 and 15 Proceed as follows After checking that the sealing surfaces are clean assem ble the seat ring gasket in the valve body Make sure the gasket is centered properly in the body
29. taining Ring x 40 PTFE Seal Ring 3 Packing Flange Nut 12 Pilot Spring s 20 Auxiliary Pilot Plug x 41 Nordel amp Backup Ring 4 Packing Flange 13 Seat Ring 21 Valve Body Stud a e45 Graphite Seal Ring 5 Packing Spacer 14 Seat Ring Gasket 22 Guide Bushing a 46 Ni resist amp Backup Ring e 6 Packing 15 Valve Plug or Piston 23 Packing Follower A50 Washer Body nuts 7 Bonnet 16 Cage 31 Tec Seal 75 Double cage 8 Valve Body Nut 17 Conical Spring O 35 Ni resist amp Seal Ring 76 Pin On 41405 Series Valves Only On 41605 Series Valves Only 3 On 41905 Series Valves Only On6 to 16 Valves Sizes Only Recommended Spare Parts O On 41405 505 Series Valves Only 150 to 400 mm 14 Instruction No EH3600 07 02 41005 Series Valves 1 4 NPT Plug stem coupling by actuator size see details Type 88 Coupling parts Coupling parts No 10 16 23 No 18 amp 18 L actuators No 24 actuators PARTS REFERENCE PARTS REFERENCE R r Description nee Description nel Description Bet Description 1 Valve Plug Stem 53 Coupling Nut 1 Hex Nut 8 Screw Pan head 26 Actuator Stem 56 Travel Indicator Scale 2 Stem Connector bottom 9 Scale Travel 33 Drive Nut 57 Machine Screw 3 Cap Screw Hex head 10 Actuator stem 36 Spring Adjuster 58 Travel Indicator 4 Stem Connector top 31 Yoke machining 51 Coupling 5
30. the valve plug does not touch the seat Tighten the yoke nut Unscrew the valve plug stem until the valve plug comes into contact with the seat Do not turn the valve plug on the seat as this could damage the sealing surfaces Supply air to the actuator until the stem has travelled at least 40 inches 10 mm Unscrew the plug stem by the number of turns N1 speci fied in Figure 11 CAUTION For Model 41405 valves use the N2 valves in Figure 11 to insure seating tightness of the pilot plug G H T Screw the 2 nuts 1 as far as they will go and check that operation is correct Use the pointer 7 to set the travel scale 9 to the valve closed position 2 Connecting Type 87 No 6 Actuator Figure 17 A B Tightly assemble the 2 hex nuts 1 onto the plug stem Push down the actuator and screw on the yoke nut 33 at the same time Then assemble the bottom stem connector 2 As soon as it becomes possible insert the valve stem into the actuator stem The stem must be inserted far enough so that when there is no air in the actuator the valve plug does not touch the seat Tighten the yoke nut D Supply air to the actuator at the final pressure Use the pointer 7 to set the travel scale 9 to the valve open position Supply the actuator with air at a sufficiently high pressure to obtain a travel equal to the nominal travel of the valve less dimension A in Figure 12 11
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