Cashco 964 User Manual
INSTALLATION, OPERATION, & MAINTENANCE MANUAL (IOM)
MODEL 964
GLOBE-STYLE
PNEUMATIC CONTROL VALVE UNIT
BODY IOM
SECTION l
I. DESCRIPTION AND SCOPE
The Model 964 is a pneumatically actuated, sliding
stem globe-style control valve. Sizes are 1/2",3/4",
1", 1-1/2", & 2". Available in Cast Iron and Cast Steel
body ma te ri als.
Failure position is determined by actuator for:
"D" = Direct action; on increasing air loading pressure,
the actuator stem extends. Fail-safe position is with
the stem retracted.
"R" = Reverse action; on increasing air loading pres-
sure, the actuator stem retracts. Fail-safe position is
with the stem extended.
IOM-964
12-13
The valve is designed primarily for general service
or utility applications such as steam, air, oil, gas and
water.
SECTION II
II. REFERENCES
Refer to Technical Bulletin 964-TB for complete
tech ni cal specifi cations of a Model 964 coupled with
either Cashco Actuator Model C27 or C53.
www.cashco.com/techbulletins/964.pdf
Refer to following Installation, Operation & Main te nance Manuals (IOM’s) for either actuator and/or
devices that maybe mounted to a Model 964:
Actuators: www.cashco.com/IOM/C27-C53.pdf
Positioners:
P/P: www.cashco.com/techbulletins/9540l.pdf
I/P: www.cashco.com/techbulletins/srd991.pdf
I/P: www.cashco.com/iom/PS2iom.pdf
Model 964
with ATO - FC Actuator
ABBREVIATIONS
ATC–FO – Air–to–Close, Fail Open
ATO–FC – Air–to–Open, Fail Close
CCW – Counter Clockwise
CW – Clockwise
D or DIR – Direct Acting
IAS – Instrument Air Supply
LOAD – Positioner Output Air Pressure
R or REV – Reverse Acting
SIG – Output Signal from Instrument
V – Vent
SECTION III
CAUTION
For welded installations, all internal trim parts and
seals, must be removed from body prior to welding
into pipeline. The heat of fusion welding will dam age
non-metallic parts if not re moved. NOTE: This does
not apply to units equipped with extended pipe nip ples.
III. INSTALLATION
A. Orientation:
1. Recommended ori en ta tion when in stalled in
a hor i zon tal pipeline with the stem ver ti cal.
Valves may also be in stalled in ver ti cal pipe lines with stems hor i zon tal.
3. If pipe reducers are located before and/or after
the valve body, keep the reducers as close as
prac ti cal to the valve body; this is especially
important where the reducers are more than
one line size larger than the valve body size,
which is common in gaseous ser vice.
4. Clean the piping of all foreign debris, in clud ing
chips, weld scale, weld spatter, oil, grease,
sand or dirt prior to in stall ing the control valve.
This is an absolute re quire ment for valves
supplied with composition soft seats. System
start-up strain ers, for removal shortly after
initial start-up, are rec om mend ed.
5. Field hydrostatic testing the com plet ed piping
system to 1-1/2 x CWP in psig indicated on the
nameplate, including the 964, is ac cept able.
If hydro test pressure exceeds the 1-1/2 x
CWP limit, the 964 must be re moved for such
testing. Before pres sur iza tion, the valve plug
should be lifted from the seat if of ATO-FC
action. Tighten packing as re quired.
Figure 1: Typical Control Valve Station
2. Outdoors, all in stal la tions may be ori ent ed any
angle from hor i zon tal-to-vertical.
3. Valves are not recommended for in stal la tion
with the actuator oriented down wards..
B. Piping System:
1. It is recommended that the control valve unit
be in stalled with a double-block and bypass
as in di cat ed in Figure 1. This ar range ment is
rec om mend ed es pe cial ly where main te nance
will be done on the valve body while still installed in the pipeline.
2. Pipe unions are recommended for NPT
screwed or socket welded installations to al low
complete removal from sys tem. If re mov al
for main te nance is by cutting torch for socket
welded valves, leave suffi cient pipe nipple
space be tween the 964 body and the next
piping com po nent up or down stream to allow
socket weld couplings for re-in stal la tion.
6. In placing thread sealant on pipe ends prior
to en gage ment, ensure that excess ma te ri al
is removed and not allowed to enter the valve
upon start-up.
7. Flow Direction: Install so the fl ow direction
match es the arrow marked on the valve body.
8. For best performance, install in well drained
hor i zon tal pipe, properly trapped if a steam
service ap pli ca
tion.
9. Valves are not to be direct buried un der ground.
10. Insulation may be applied as in di cat ed in Figure 2. Drain age away from the packing area
must be ensured when fully in stalled, sealed
and lagged for outdoors in stal la tion.
Limit of
Bonnet
Insulation
Figure 2: Body Insulation
IOM-9642
11. Undue piping stress/strain or bend ing
torques may not be trans mit ted thru the
valve body. One pipe (inlet or outlet) should
be an chored rig id ly for pip ing that is “hot” or
“cold” with respect to ambient tem per a ture;
the re main ing pipe (in let or out let) should
be sup port ed and guid ed to ensure uni di rec tion al ex pan sion/con trac tion.
C. Air Supply:
1. Use a desiccant dried, instrument quality
air supply. Such a supply is recommended
for outdoor installations, and is required in
areas of freezing weather conditions.
IV. START-UP
A. General:
1. Ensure that the Model 964 unit has been
prop er ly adjusted and cal i brat ed, in clud ing
the po si tion er, if in stalled.
2. Recommend startup to be in a “man u al”
mode. This pro ce dure assumes dou ble
block (iso la tion) and bypass valves for the
“control valve station”. See Fig ure 1.
3. Start with either of the two block valves
closed, with the other open. The bypass
valve should be closed. Pres sur ize sys tem,
if pos si ble/prac ti cal.
4. Back out the airset’s adjusting screw until
loose.
2. If air supply contains moisture and /or lubricating oil, the air should be fi ltered with
a coalescing type of fi lter prior to use in
stroking the actuator.
3. Failure to remove moisture will cause corrosion to the internals of the actuator casings.
4. Connections for the air supply are 1/4" female
NPT. Use a suitable pipe thread sealant
when installing the pipe or tube fi tting. DO
NOT allow sealant to enter the tube/pipe.
SECTION IV
CAUTION
DO NOT WALK AWAY AND LEAVE A MANUALLY CONTROLLED CONTROL VALVE UNATTENDED!
8. Confi rm that action of con trol ler and po si-
tion er - direct or reverse - are producing
the de sired re sponse in the con trol unit.
Con fi rm that the con trol valve “fail” po si tion
is as re quired.
9. Hereafter, the procedure as sumes that ac tu al
fl uid fl ow may be established. This may not
be practical / pos si ble in all cas es; if so, vary
procedure as re quired.
Always “heat” or “cool” down the system
pip ing SLOW LY by open ing the control valve
sta tion by pass valve in small in cre ments.
IOM-964
5. Turn on air supply pressure.
6. Adjust the air supply airset (fi l ter-reg u la tor)
to the proper lev el as in di cat ed as follows:
Bench Setting Airset Output
psig (Barg) psig (Barg)
5–15 (.34–1.0) 20 (1.4)
15–60 (1.0–4.1) 75 (5.2)
7. Place loop controller into “man u al” mode.
Vary setting from minimum - mid-range max i mum SIG output. Ob serve re sponse of
con trol valve unit to these chang es of input
SIG. The valve should fully stroke at the
vari a tion from min i mum SIG to max i mum
SIG; the mid-range SIG should have the
valve stem travel at/near 1/2 open.
10. With one of the control valve station block
valves still closed, and the loop con trol ler
still in “man u al” mode, open by pass valve
and vary fl ow rate man u al ly to ob serve the
re sponse of the con trol ler and control valve
unit to geth er.
11. Attempt to develop manual con trol of the
loop by opening/clos ing the man u al by pass
as re quired, or by manually con trol ling main stream fl ow as re quired.
12. When the control valve is partially open, crack
open slowly the closed block valve while
si mul ta neous ly clos ing the by pass valve.
Con tin ue this pro ce dure until the bypass is
closed and the block valves are both fully
open. The system is still under “man u
al”
3
mode control, but all fl ow is pass ing through
the control valve.
13. Vary controller “manual” SIG output until
match ing the “au to mat ic” SIG output, then
V. MAINTENANCE
change the mode of the controller over to
“automatic”, and the loop will ex pe ri ence a
min i mum of upset con di tions, and will be in
au to mat ic control.
SECTION V
WARNING
SYSTEM UNDER PRES SURE. Prior to per form ing any
maintenance, isolate the valve/actuator from the sys tem
and relieve all pressure. Fail ure to do so could result in
personal injury.
A. General:
1. Maintenance procedures here in af ter are
based upon re mov al of the valve/ac tu a tor
unit from the pipe line where in stalled.
2. Owner should refer to Owner’s pro ce dures for
re mov al, handling and cleaning of non-re us able parts, i.e. gaskets, suitable sol vents, etc.
3. Valves supplied from the factory use a
gasket sealant, Federal Process Company,
PLS2, or equal. Owner may use such aids
provided the aids are com pat i ble with the
Owner’s fl uid.
4. All indicated Item Numbers that are with
re spect to the actuator assembly (AA) are
in pa ren the sis and un der scored; i.e (20).
All Item Num bers that are with respect to
the body assembly (BA) of a Model 964
are not un der scored; i.e. (32). Reference
with respect to the po si tion er is in double
parentheses; i.e. ((AP)).
5. Special care must be exhibited when
ro tat ing the stem (3) of the valve to
not mar that portion of the surface of
the stem (3) where it contacts with the
pack ing (6). To rotate the stem (3), use
the jam nuts (18) or grasp stem with softjawed pliers. NOTE: When using the jam
nuts (18) to rotate the stem (3), use the
upper jam nut to rotate the stem CW, and
the lower jam nut to rotate the stem CCW,
when viewed from above valve stem.
6. Hereafter, whenever text has the fol low ing
no ta tion, “(Note PA.)”, the fol low ing text is
to be ap plied;
“For ATO-FC reverse action units,
connect a temporary air source to the
actuator and pres sur ize to a level suf fi cient to initiate travel to ap prox i mate ly
mid-stroke.
7. Hereafter, whenever text has the fol low ing
no ta tion, “(Note RP.)”, the fol low ing text is
to be applied:
“For ATO-FC reverse action units, re lease all tem po rary air pressure.
B. Actuator Removal:
1. Secure the body (1) in a vise with the actuator as sem bly (AA) oriented ver ti cal ly. Place
matchmarks between the body (1) bon net
fl ange, the bonnet (2) fl ange, and the yoke
(3) to assist in fi nal ori en ta tion when the
body is dis as sem bled and/or the ac tu a tor
removed. If actuator has handwheel - see
Actuator IOM for removal instructions.
2. (Note PA.) Using blunt end tool, ham mer
rap the tool to loosen yoke nut (29) turning
CCW (viewed from above) ap prox i mate ly 2
rev o lu tions. Secure the ac tu a tor stem (6).
Loos en the stem jam nuts (18) by rotating
CW (viewed from above) one-at-a-time to
base of stem (3) threads.
3. Fully loosen any accessory de vic es that
are con nect ed to the stem (6) or (3) such
as ac ces so ry plate ((AP)) for po si tion
4. Loosen packing (6) by rotating nuts (15)
CCW 2-3 rev o lu tions. (Note RP.).
er.
IOM-9644
NOTE: To fully disengage the actuator stem (6)
from the plug/stem (3) is a two-step pro ce dure.
Be aware of the valve’s stroke length as in di cat ed
on the name plate (40) before be gin ning dis en gage ment. During the dis en gage ment, mea sure
the dis tance ex tend ed, and stay at least 1/8" (3
mm) away from the full stroke length. Count and
record the number of rev o lu tions for each step in
the box below:
For Steps 5 and 6: Count the number of revolutions
to disengage plug/stem from actuator stem:
Step A. Step B.
TOTAL:
5. For ATO-FC Reverse Action Units:
a. (Note PA.)
b. Step A. Rotate plug/stem (3) CW (viewed
from above) to disengage the ac tu a tor
stem (6) from the plug/stem (3), while
holding the actuator stem (6). Record
the num ber of plug/stem rev o lu tions for
Step A above. When the dis en gage ment
reach es about 50% of full stroke trav el
Step A is com plet ed. (Note RP).
c. Step B. Support the actuator as sem-
bly (AA) from above. Fully loosen
yoke nut (29). Lift the actuator as sem bly (AA) up wards ap prox i mate ly
1/4"-3/8" (6-8 mm). Again, rotate plug/
stem (3) CW (viewed from above) to
dis en gage the ac tu a tor stem (6) from the
plug/stem (3) while holding the ac tu a tor
stem (6). Record the number of plug/
stem (3) rev o lu tions for Step B above.
This should allow the stems (6) (3) to
fully dis en gage.
NOTE: Take notice of the parts “dan gling
loosely” about the plug/stem (3), the order
of their lo ca tion and their proper orientation.
d. Fully raise the actuator assembly (AA)
from the valve body assembly (BA).
Re move cautiously to prevent dan gling
parts - position indicating washer (26),
ac ces so ry plate ((AP)), yoke nut (29) from fall ing.
6. For ATC-FO Direct Action Units:
a. Step A. Rotate plug/stem (3) CW (viewed
from above) to disengage the ac tu a tor
stem (6). Do not rotate the plug (3)
into the seat (11). Record the number
of plug/stem (3) rev o lu tions for Step
A above. When the dis en gage ment
reach es about 75% of full stroke travel,
Step A. is com plet ed.
b. Step B. Support the actuator as sem bly
(AA) from above. Fully loosen yoke nut
(29) and remove. Lift the actuator as sem bly (AA) upwards ap prox i mate ly 1/4" 3/8" (6-8 mm). Again, rotate plug/stem
(3) CW (viewed from above) to dis en gage the ac tu a tor stem (6) from the plug/
stem (3), while holding the actuator stem
(6). Record the number of plug/stem
rev o lu tions for Step B. This should allow the stems (6) (3) to fully disengage.
NOTE: Take notice of the parts “dangling
loosely” about the stem (3), the order of their
lo ca tion and their proper orientation.
c. Fully raise actuator assembly (AA) from
the valve body assembly (BA). Re move
cau tious ly to prevent dan gling parts – po si tion indicating washer (26), ac ces so ry
plate ((AP)), yoke nut (29) - from falling.
C. Actuator Replacement:
1. Secure body assembly (BA) in a vise with
the plug/stem (3) oriented ver ti cal ly. Push
plug/stem (3) down until the plug touches
the seating surface in the body.
2. Secure the actuator assembly (AA) from
above. Use matchmarks from B.1. previous
to assist with (BA) and (AA) alignment.
3. This procedure assumes that the bonnet (2)
has been bolted to the body (1), with stem
jam nuts (18) threaded on the plug/stem (3).
4. Lower actuator assembly (AA) until the plug/
stem (3) penetrates the opening in the yoke
(3). Re po si tion the “dangling parts” - yoke
nut (29), ac ces so ry plate ((AP)) or in di cat ing washer (26) - over threaded end of plug/
stem (3). Con tin ue to lower the actuator
assembly (AA) until there is ap prox i mate ly
1/4" (6 mm) space between the two stems
(6) (3).
IOM-964
5
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