Installation, Operation, Maintenance Instructions
Split Body Valves with Bellows Seal
Series 025 300 Globe Valves
Series 027 300 Angle Valves
Series 028 300 3-Way-Valves
Flow Control Division
Kammer Control Valves
1 GENERAL INFORMATION
These instructions are designed to support you when
unpacking, installing and per-forming maintenance
work on the valves. Users and maintenance personnel should carefully read these instructions before installing, operating or performing main-tenance work.
There is a separate set of instructions for accessories
(special seat/plug fittings, diaphragm actuators, handwheels, special seats, etc.).
These instructions do not contain any information on
Kämmer positioners. For this, see corresponding instructions for the installation, maintenance, troubleshooting, adjustment and operation of Kämmer positioners.
To avoid damage or injury to personnel or equipment, always heed all warnings and instructions.
Unprofessional re-conditioning, the use of foreign
replacement parts or the performance of other maintenance steps than those described here, may cause
a loss of efficiency or lead to personnel injury or
damage to parts, and render the warranty void
1.1 UNPACKING
1.1.1 Each delivery includes a packing slip. When unpacking, check all delivered valves and accessories using
this packing slip.
1.1.2 Larger valves can be lifted using slings on the yoke
rods or, if present, on the lugs provided for this purpose. If slings are used, attach them so that the outer
tubing or attaching parts are not damaged.
Important: If slings are used, be aware that the centre of gravity of the valve may be above the lifting
point. In this case, secure or support the valve
against rotating, to prevent damage or personnel
injury.
1.1.3 Report transport damage to the carrier immediately.
1.1.4 In case of discrepancies, contact your nearest dealer.
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Flow Control Division
Kammer Control Valves
1.2 INSTALLATION
1.2.1 Clean tubing prior to installing.
1.2.2 If possible, install the valve in an upright position (actuator on top), to ease maintenance. An upright installation position is important with low-temperature
applications, in order to keep the distance between
the packing material and the medium as large as possible. The packing material then retains the ambient
temperature as much as possible.
Important: Do not insulate extension bonnets that
are provided for hot or cold services
1.2.3 Make sure that sufficient overhead clearance above
the actuator is maintained, to allow for disassembly
of plug from the valve body (see following table).
Actuator Clearance Actuator Clearance
size (mm) size (mm)
37/47 95 P2 140
38/48 140 P3 140
39/49 140 P4 140
39D/49D 140 P5 140
1.2.4 After installing, check direction of flow again. The direction of flow is shown by the arrow on the housing.
1.3 QUICK CHECK:
Before operating, check the valve as follows:
1.3.1 Open and close the valve, and observe the movement of the actuator stem. The movement must be
smooth and linear.
1.3.2 Check for maximum stroke through change of signal (for pneumatic positioners, 0.2 - 1.0 bar or corresponding split-range values; for IP positioners, 420 or 0-20 mA).
1.3.3 Check all air connections for leaks.
1.3.4 The packing gland nut must always be tightened
slightly more than finger-tight.
IMPORTANT: An excessively tightened gland nut
can cause excessive packing wear and can hinder
the free movement of the plug stem.
1.3.5 Check fail-safe position. To do this, close supply pressure and observe whether the valve opens or closes
as prescribed.
1.3.6 After using at fluctuating temperatures, re-tighten all
bolt connections and check for leaks.
2 MAINTENANCE
1.2.5 If the valve is to be welded into the line, make sure
that the valve is shielded from excessive heat.
1.2.6 Connect supply pressure and signal lines. Control
valves can be supplied with a positioner. The end connections for supply pressure and signal are clearly
marked. Actuator and positioner are suitable for max.
4.2 bar (60 psi) supply pressure. If the supply pressure exceeds the pressure specified on the nameplate,
a pressure reducing station is required. If instrument
air is not available, install an oil separator/air filter in
the air inlet line. All connections must be leak free.
Check valves for correct functioning at regular
intervals (at least once every 6 months) as follows.
This check can be made when installed and in many
cases without interrupting production. If internal
defects are suspected, see section on „Disassembly
and Assembly of Valve“.
2.1 Examine gaskets for leaks and if necessary re-tighten
bolts (see Fig. 1).
2.2 Check bellows gasket and test connection - if present - for
external leaks.
2.3 Check valve for damage caused by corrosive residues
or corrosive vapours.
2.4 Clean valves and if necessary repaint.
2.5 Check packing bolts for correct tightening. Gland nuts
on packing may only be tightened slightly more than
finger-tight, or only tight enough to ensure a proper
seal.
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IMPORTANT: An excessively tightened gland nut can
cause excessive packing wear and can hinder the
free movement of the plug stem.
2.6 If possible, open and close valve and check for maximum stroke and smooth movement of the plug stem.
Irregular movement of the plug stem may indicate
internal defects.
Note: With graphite packing, irregular movement of
the plug stem is normal.
IMPORTANT: Keep hands, hair, clothing, etc. away
from all moving parts. Failure to do so can lead to
serious injury.
2.7 Check all accessories for firm seating.
2.8 If possible, close supply pressure and check the failsafe position.
Flow Control Division
Kammer Control Valves
2.10 Check stem boot for wear.
2.11 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and note any bubble formation.
2.12 Clean plug stem.
2.13 Check air filter, if present, and if necessary replace
insert.
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Flow Control Division
Kammer Control Valves
Zero adjustment locknut
Actuator stem
Bellows coupling
Locknut
Gland nut
Plug stem
Clamp nut
Bonnet
test connection
(turned 90°)
Upper body
Bellows seal
Lower body
Typical actuator and valve configuration
Fig. 1
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Flow Control Division
Kammer Control Valves
REMOVE AND INSTALL ACTUATOR
General Information
We recommend separating the actuator from the valve during
all repair work.
However, many maintenance and adjusting operations can
be carried out in installed condition.
3.1 Remove Actuator
For actuators with spring-to-close, go to 3.1.1
For actuators with spring-to-open, go to 3.1.2
3.1.1 Remove cap and nameplate. Tighten zero adjusting
nut until it just touches the surface of the spring
housing. This relieves the plug from actuator spring
pressure.
3.1.2 Using a wrench, secure the actuator stem against
turning and using a second wrench loosen the
locknuts.
IMPORTANT: The actuator stem must not be turned,
as this will cause damage to the diaphragm.
3.1.3 Loosen gland and actuator clamp nuts.
3.1.4 Secure plug stem against turning and unscrew
actuator from plug stem by turning counterclockwise.
IMPORTANT: Ensure that the plug assembly is not
rotated with the plug seated. This may cause irreparable damage to the seating faces.
3.1.5 Remove actuator and remove at the same time
locknut, travel indicator disc, gland and clamp nuts.
3.2 Install actuator
Information:
• Before the actuator is installed, it must be
calibrated according to section 3 of the instructions
on „Pneumatic and Electro-pneumatic Actuators“.
Only for „spring-to-close“ actuators:
3.2.2 Screw actuator onto plug stem by rotating clockwise,
until the yoke plate just touches the valve housing and
the actuator is aligned forwards.
IMPORTANT: Ensure that the plug assembly is not
rotated with the plug seated. This may cause irreparable damage to the seating faces.
Only for „spring-to-open“ actuators:
Lift plug stem and screw into the actuator stem until
the distance between „plug in seat“ and „plug raised“
approximately corresponds to the specified stroke.
3.2.3 Tighten clamp and gland nuts.
3.2.4 Adjust the valve plug for seat off by making
adjustments with the coupling.
Note:
Standard coupling
Due to different threads used within the coupling,
rotating the adjusting nut will lengthen or shorten the
connection between actuator stem and plug stem
.
D-actuator coupling
Screw couplings on or off actuator/plug stems to
lengthen or shorten the connection between actuator
stem and plug stem
.
IMPORTANT: The plug stem must not be turned with
the valve closed, as this can cause damage to the
seal edges of the valve plug and seat ring.
Open valve, make adjustment, close valve and check
for leaks.
3.2.5 After adjusting, secure the locknuts and the travel
indicator disc lying between them against actuator stem
and align the travel indicator on the yoke rod.
• All worn or damaged parts must be replaced.
Reusable parts must be clean.
3.2.1 Position actuator with clamp nut, gland nut, locknuts
and stroke indicator disc on the valve.
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Travel indicator disc
Bellows coupling
(see Fig. 3+4)
Locknut
Gland nut
Clamping nut
Packing follower
Flow Control Division
Kammer Control Valves
Packing kit see
spare parts list
Screw
lockwasher
Bonnet
Bottom gasket
bellows seal
Upper body
Gasket
Plug
(test connection)
Top gasket
bellows seal
Trim see spare
parts list
Seat ring
Lower body
Lockwasher
Fig. 2
6
Screw
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Flow Control Division
Kammer Control Valves
4 DISASSEMBLE AND ASSEMBLE VALVE
4.1 Disassemble Valve
(see Fig. 2)
IMPORTANT: As poisonous or hazardous materials
may be present, the system must be depressurized
and all process materials drained. If necessary, decontaminate the valve. Keep hands, hair and clothing well away from moving parts. Wear face and
eye protectors. Failure to do so can lead to serious
injury.
4.1.1 Carefully loosen test connection and check whether
medium has collected in bellows seal bonnet (bellows defective).
4.1.2 Remove bolts/nuts from bellows seal bonnet and remove bellows seal bonnet.
Note: Due to the friction coefficient of the packing,
the bellows/plug assembly usually also comes out
when the bonnet is removed. In this case, hold the
bellows to ensure that it does not drop and be damaged.
4.1.3 If the bellows/plug assembly remains in the extension, it can be carefully levered out by inserting two
screwdrivers into the outer groove of the upper part
of the bellows.
4.1.8 Check seal faces of seat ring and plug for damage.
Gasket surfaces of the upper and lower body parts,
seat ring and bonnet must be clean and free of damage.
IMPORTANT: To prevent damage to the seat, plug,
or plug stem, follow the above instructions precisely.
4.1.9 If a sealing surface needs re-machining , seat and
plug seating surfaces must be reworked. The seat
angle on the plug is 30°, on the seat ring 25°. If the
valve is correctly assembled, lapping is not required.
Important: When re-machining the plug, protect plug
stem and bellows from damage and support upper
part of bellows towards plug stem. The seat surface must be concentric to the plug stem. When remachining the seat, the seat surface must be concentric to the seat outer diameter.
4.2 Assemble Valve
(see Fig. 2)
4.2.1 All worn or damaged parts must be replaced. Reusable parts must be clean. Expendable parts such as
gaskets, packing and O-rings should always be replaced.
4.2.2 For soft seat version, insert new soft seat and assemble seat/plug.
4.2.3 Insert seat ring in lower body using new gaskets.
4.1.4 Carefully remove bellows/plug assembly from the
extension without stretching bellows, and carefully
remove it absolutely upright from extension. Do not
lose anti-rotation pin. Press out guides, packing and
packing follower using a drift (the drift must have a
slightly larger diameter than the plug stem).
4.1.5 Remove body bolts and remove upper body.
4.1.6 Lift out seat ring using two screwdrivers inserted in
the outer groove of the seat.
4.1.7 If the plug is a soft seat version, loosen tip of plug
using suitable tool and remove soft seat.
IMPORTANT: When the tip of the plug is loosened,
medium residue may be released, which has diffused through the gasket.
If the seat is a soft seat version, remove the soft seat
cover and then remove the soft seat.
4.2.4 Position upper body carefully and absolutely straight
on lower body, and tighten retaining bolts alternating
crosswise finger-tight.
4.2.5 Insert lower bellows gasket.
4.2.6 Carefully insert bellows/stem assembly in the extension and install anti-rotation pin.
4.2.7 Insert upper bellows gasket.
4.2.8 Attach bellows seal bonnet (test connection towards
front) and uniformly tighten retaining bolts alternating crosswise finger-tight.
4.2.9 Place lower stem guide of packing set into packing
space, to provide better guidance for plug stem when
tightening halves of housing.
4.2.10 Tighten housing bolts uniformly alternating crosswise
hand-tight, moving plug stem to and fro several times
to check that plug is not jammed in seat.
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Actuator stem
Travel ind. disc
Locknut
Adjusting nut
Locknut
Plug stem
Flow Control Division
Kammer Control Valves
5 mm initial dimension
prior to adjustment
M 16 / M 10
or
M 16 / M 6
or
M 10 / M 6
Actuator stem
Fig. 3
Bellows coupling 1000 daN thrust and below
Lock nut M 16
Lock nut M 16
Plug stem
Fig. 4
Bellows coupling over 1000 daN thrust
90°90°
Fig. 5
When tightening, the body halves must be
parallel at all times
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4.2.11 Using torque wrench, gradually tighten all bolts alternating crosswise to following torques (see following
table).
Hex bolt Waisted bolt Studs
Thread DIN 933 DIN 2510 DIN 939
A2-70 1.7709 1.7258 CK 35
M 8 20 Nm – – –
M 10 35 Nm – – 20 Nm
M 12 60 Nm 44 Nm 36 Nm 35 Nm
M 16 145 Nm 115 Nm 92 Nm 80 Nm
M 20 280 Nm – – –
M 24 250 Nm – – 270 Nm
Flow Control Division
Kammer Control Valves
Note: When the housing bolts are tightened, the halves
of the housing must always be parallel (see fig. 5).
4.2.12 Replace packing by inserting packing rings one at a
time tapping each one down with a suitable bushing.
IMPORTANT: ensure that the gaps in the packing
rings are distibuted evenly around the circumferance
in the packing box (gaps not in line).
Note:
different packings and fitting sequence is shown
in the spare parts list.
6.1.13 Insert packing follower. Fit gland nut for transport
purposes only. Gland nut to be fitted correctly and
tightened down when actuator is mounted.
4.2.14 When performing subsequent pressure test, note the
max. permissible pressure for the bellows. After the
check for leaks, close off test connection with plug or
suitable gauge.
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Kammer Control Valves
Trouble-shooting Chart
Fault Possible Cause Remedy
Stem motion 1. Packing excessively tightened 1. Tighten gland nut slightly more than „finger-tight“
impeded 2. Operating temperature too 2. Note operating data and contact dealer
high for selected trim
3. Supply pressure inadiquate 3. Check system for leaks in the supply pressure or signal lines. Retighten the connections, if necessary replace leaky lines
4. Positioner defective 4. See operating instructions for positioner
Excessive 1. body halves loose 1. See step 4.2.5 for correct tightening of body halves.
leakage 2. Worn or damaged 2. Re-machine or replace seat ring/plug.
seat ring/plug
3. Gaskets damaged 3. Replace gaskets
4. Inadiquate actuator thrust 4. Check air feed. If air feed is OK, contact dealer.
5. Plug incorrectly adjusted 5. Correctly adjust plug according to step 3.2.4
6. Incorrect direction of flow 6. Check specification. Contact dealer
7. Handwheel incorrectly 7. Adjust handwheel
adjusted (acts like end stop)
Flow Control Division
Inadiquate flow 1. Plug incorrectly adjusted 1. Correctly adjust plug according to step 3.2.4
(short stroke)
2. Positioner defective 2. See operating instructions for positioner
3. Operating requirements 3. Check operating data. Contact dealer
too high
Plug slams 1. Plug adjustment incorrect 1. Correctly adjust plug according to step 3.2.4
2. Inadiquate supply pressure 2. Check supply pressure, seal leaks, remove blockage
3. Trim too large for 3. Replace trim
flow rate
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Flowserve Essen GmbH
Manderscheidtstrasse 19
D - 45141 ESSEN
Tel.: +49 (0) 201 89 19 - 5 • Fax: +49 (0) 201 89 19 - 600
All data subject to change without notice
©09.2000 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation
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