cod FLOWSERVE ~~ Flow Control Division Installation, Operation, Maintenance Instructions Valtek Mark Oneand Mark Two Control Valves GENERAL INFORMATION The following instructions are designed to assist in Unpacking, instaling and performing maintenance as required on Valtek® Mark One and Mark Two control valves. Product users and maintenance personnel should thoroughly review this bulletin prior to installing, operating or performing any maintenance on the valve. Separate installation, operation, maintenance instruc- tions cover additional features (such as special trim, diaphragm actuator, handwheel and extension bonnets). This publication does not contain information on Valtek positioners. Referto the appropriate Installation, Opera- tion, Maintenance Instructions for installing, maintain- ing, troubleshooting, calibrating and operating Valtek positioners. To avoid possible injury to personnel or dam- age to valve parts, WARNING and CAUTION notes must be strictly followed. Modifying this product, substituting non-factory parts or us- ing maintenance procedures other than out- lined could drastically affect performance and be hazardous to personnel and equipment and may void existing warranties. WARNING: Standard industry safety practices must be adhered to when working on this or any other process control product. Specifically, per- sonal protective and lifting devices must be used as warranted. Valtek No, 49011 NOTE: Selecting the proper fastener material is the responsibility of the customer. Typically, the supplier does not know what the valve Service conditions or environment may be. Flowserve's standard body bolt- ing material is 87/2H. B8 (stainless stee)) is optional for applications more than 800° F / 425° C and with slainless steel or alloy body valves. The customer therefore must consider the material's resistance to ‘stress corrosion cracking in addition to general corro- sion. As with any mechanical equipment, periodic inspection and maintenance is required. For more information about fastener materials, contact your Flowserve representative. Unpacking 1. While unpacking the valve, check the packing list against materials received. Lists describing valve and accessories are in each shipping container. 2, When lifting the valve from shipping container, posi- tion the lifting straps through the yoke legs to avoid damage to the tubing and mounted accessories. WARNING: When lifting an actuator with lifting straps through the yoke legs, be aware that the center of gravity may be above the lifting point. Therefore, support must be given to prevent the actuator from rotating. Failure todo socancause serious injury to personnel, damageto the valve or nearby equipment. Flowserve Corporation, Valtok Control Products, Tel USA 801 489 8611 43. Contact your shipper immediately if there is shipping damage. 4, Should any problem arise, call your representative. Installation 1, Before installing the valve, clean the line of dirt, welding chips, scale or other foreign material. 2. 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. CAUTION: Do not insulate extension bonnets that are provided for hot or cold services. Table |: Overhead Clearance Requirement Valve Size| Clearancel] Valve Size] Clearance (inches) | (inches) || (inches) | (inches) ‘et | 3/76 6 10/254 1%,2 5/127 8 13/330 3 6/152 |) 10 14/356 4 8/203 |) 12 15/381 3. Be sure to provide proper overhead clearance for the actuator to allow for disassembly of the plug from the valve body. Refer to Table | for the necessary clear- ance needed for valve disassembly. 4, Double-check flow direction to be sure the valve is installed correctly. Flow direction is shown by the arrow attached to the body flange. Standard air-to- open valves close on air failure and should be installed so the flow tends to close the valve, except in rare circumstances that will be clearly indicated. Standard air-to-close valves open on air failure and should be installed with the flow tending to open the valve. 5. If welding the valve into the line, use extreme care to avoid excess heat buildup in the valve. 6. Ifthe valve has separable end flanges, the half rings misstbe installed on the valve body before bolting the valve into the line to ensure a tight connection. WARNING: Failure to install half rings on the valve body can cause serious personal injury. 7. Connect air supply and instrument signal (air or mA) lines. Throttling control valves are equipped with a valve positioner. Two connections are marked: one for the air supply and the other for the instrument signal. Both the actuator and the positioner are suitable for 150 psi / 10.3 Bar air supply. An air regulator is not required unless the supply pressure exceeds 150 psi / 10.3 Bar. An air filer should be installed before the positioner unless supply air is clean and dry. All connections must be free of leaks. CAUTION: On valves equipped withairfilters, the air filter must point down to perform properiy. NOTE: In sume rare cases, the air supply must be limited to less than 150 psi! 10.3 Bar. This is ind- cated ona sticker found near the upperairporton the actuator cylinder. An air regulator should be installed to ensure the supply pressure does not exceed the line pressure indicated on the sticker. Table Il: Common Lubricants , Temperature | Lubricant | Manufacturer | "Range Description Applications Krytox206 | El. DuPont | -5°to 650° F/ | Fluorinated general purpose grease; handles common -20° 10 285°C liquids and gases; good lubricity in harsh mediums; | nonfiammable, chemically inert; will not harm plastic |_ or metal parts GP 460 Graphite | 32°to 1000°F/ | Graphite in petrolatum:; high pressures; ant-galing, Products Co. | 0°10 540°C graphite remains above 600° F /316° C ‘Aeroshell | Shell Oil Co. |-100°t0 300° F/ | Synthetic oil based; low temperature applications Grease 7 75° to 150°C Garlock | Garlock inc. | 32° to 500° F/ | General purpose molybdenum disulfide lubricant Luball 0°10 260°C economical; good in water, steam and common chemicals; not good in harsh mediums where Krytox 206 is recommended 12 Flowserve Corporation, Valtek Control Products, Tel, USA 801 489 8611‘Adjusting Screw (tem No. 210) Spring (tem No, 228) Piston Stem O-ring (iam No. 272) Cylinder (em No, 202) Piston (tem No, 225) Piston O-ring (tom No. 271) Yoke O-ring (tem No. 274) Stem Clamp (tem No, 248) Gland Flange {tem No. 80) Upper Packing (tom No. 88) Yoke Clamp (iter No. 76) Packing Spacer(s) (om Nos. 94-99) Bonnet (tem No. 40) Bonnet Flange (tem No. 70) Anti-Extrusion Spacer (tem No. 83) Seat Retainer tiem Ho. 20) FF Seat Ring . _ \ \ - Adjusting Screw Gasket (tem No, 248) / Spring Button (tem No. 227) / Actuator Stem Locknut (tern No. 348) / Actuator Stem Spacer (ter No, 228) - Actuator Stem Bushing” (Wem Nos. 2537254) Actuator Stem O-ring (tem No, 275) _- Actuator Stem (tem No. 213) ~ Cylinder Retaining Ring (am No. 258) Stroke Plate (tem No. 213) Stem Bellows. (ter No. 247) - Yoke (tem No. 201) ~ Upper Stem Guide (tem No, 87) ~ Upper Stem Guide Liner (tem No. 86) Anti-Extrusion Spacer {item No, $3) __ Bonnet Flange ~ Stud and Nut (tom Nos. 108/114) Bonnet Gasket (tem No, 58) {tiem No, 20) Seat Ring _ Gasket (tem No. 85) Body (tem No, 1) Half Ring “ (em No, 14) End Flange (tem No. 10) ~ Lower Packing (tem No. 88) ~ Lower Stem Guide (ter No. 83) Figure 1: Mark One Control Valve Lower stem Guide Liner {tem No. 82) Plug (tem No. 50) NOTE: tam numbers conespond directly fo the valve's bill of material. Refer tit for specie part numbers. Flowserve Corporation, Vaek Control P Products, Tel. USA 801 489.8611 13