Flowserve 035 000 Series, 031 000 Series Installation, Operation & Maintenance Instructions Manual

Flow Control

Kämmer Control Valves

®

Installation, Operation, Maintenance Instructions

STOP!

Standard Valves

Series 035 000 Globe Valves
Series 031 000 Angle Valves

Index

1 Using Kämmer valves and actuators correctly.
2 Unpacking
3 Installation
4 Quick check
5 Maintenance
6 Remove and install actuator
7 Disassemble and assemble valve
8 Trouble-shooting chart

1 USING KÄMMER VA LVES AND ACTUATORS

CORRECTLY

1.1 General

The following instructions are designed to assist in

unpacking, installing and performing maintenance as
required on Kämmer products. Product users and
maintenance personnel should thoroughly review this
bulletin prior to installing, operating or performing any
maintenance.

DANGER: In most cases Kämmer valves and actuators

are designed for specific applications (e.g. with regard
to medium, pressure, temperature). For this reason
they should not be used in other applications without
first contacting the manufacturer.

1.2 Terms concerning safety

The safety terms DANGER, 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.

WARNING: indicates that death, severe personal injury

and/or substantial property damage can occur if proper
precautions are not taken.

CAUTION: indicates that minor personal injury and/or

property damage can occur if proper precautions are
not taken.

NOTE:

1.3 Protective clothing

Kämmer products are often used in problematic

1.4 Qualified personnel

Qualified personnel are people who, on account of

1.5 Installation

DANGER: Before installation check the order-no,

Do not insulate extensions that are provided for hot

Pipelines must be correctly aligned to ensure that the

indicates and provides additional technical

information, which may not be very obvious even
to qualified personnel. Compliance with other,
not particularly emphasised notes, with regard to
transport, assembly, operation and maintenance and
with regard to technical documentation (e.g. in the
operating instruction, product documentation or on
the product itself) is essential, in order to avoid faults,
which in themselves might directly or indirectly cause
severe personal injury or property damage.

applications (e.g. extremely high pressures, dang­erous, toxic or corrosive mediums). In particular
valves with bellows seals point to such applications.
When performing service, inspection or repair
operations always ensure, that the valve and actuator
are depressurised and that the valve has been cleaned
and is free from harmful substances. In such cases pay
particular attention to personal protection (protective
clothing, gloves, glasses etc.).

their training, experience and instruction and their
knowledge of relevant standards, specifications,
accident prevention regulations and operating
conditions, have been authorised by those responsible
for the safety of the plant to perform the necessary
work and who can recognise and avoid possible
dangers.

serial-no. and/or the tag-no. to ensure that the valve/
actuator is correct for the intended application.

or cold services.

valve is not fitted under tension.

KMEIM3501-00 02.05

1

2

Flow Control

Kämmer Control Valves

®

1.6 Spare parts

STOP!

STOP!

Use only Kämmer original spare parts. Kämmer cannot

accept responsibility for any damages that occur from
using spare parts or fastening materials from other
manufactures. If Kämmer products (especially sealing
materials) have been on store for longer periods check
these for corrosion or deterior-ation before using these
products. Fire protection for Kämmer products must
be provided by the end user.

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 nonfactory parts,
or using maintenance procedures other than outlined
in this instruction could drastically affect performance
and be hazardous to personnel and equipment, and
may void existing warranties. Between actuator and
valve 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 recognised regulations for safety
and good engineering practices must be followed.

WARNING: Before products are returned to Kämmer

for repair or service Kämmer must be provided with
a certificate which confirms that the product has been
decontaminated and is clean. Kämmer will not accept
deliveries if a certificate has not been provided (a form
can be obtained from Kämmer).

1.8 Storage

In most cases Kämmer Products are manufactured

from stainless steel. Products not manufactured
from stainless steel are provided with an epoxy resin
coating. This means that Kämmer products are well
protected from corrosion. Nevertheless Kämmer
products must be stored adequately in a clean, dry
environment. Plastic caps are fitted to protect the
flange faces to prevent the ingress of foreign materials.
These caps should not be removed until the valve is
actually mounted into the system.

1.9 Valve and actuator variations

These instructions cannot claim to cover all details of

all possible product variations, nor in particular 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 where the product
is being used for is 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.

2 UNPACKING

2.1 Each delivery includes a packing slip. When unpacking,
check all delivered valves and accessories using this
packing slip.

2.2 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.

WARNING: 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.

2.3 Report transport damage to the carrier immediately.

2.4 In case of discrepancies, contact your nearest
FLOWSERVE sales office.

3 INSTALLATION

3.1 Clean tubing prior to installing.

3.2 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.

NOTE: Do not insulate extension bonnets that are

provided for hot or cold services

3.3 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

3.4 If the valve is to be welded into the line, make sure
that the valve is shielded from excessive heat.

3.5 Connect supply pressure and signal lines. Control
valves are 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.

Flow Control

Kämmer Control Valves

®

4 QUICK CHECK:

STOP!

STOP!

5.4 Clean valves and repaint as necessary.

Before operating, check the valve as follows:

4.1 Open and close the valve, and observe the movement
of the actuator stem. The movement must be smooth
and linear.

4.2 Check for maximum stroke through change of signal
(for pneumatic positioners, 0.2 - 1.0 bar or corre­sponding split-range values; for IP positioners, 4-20
or 0-20 mA).

4.3 Check all air connections for leaks.

4.4 Tighten packing nut (see table 1).

Torque Nm

Thread PTFE Grafoil

M20 x 1,5 3.5 6.0
M30 x 1,5 7.0 17.5
M38 x 1,5 11.5 20.5
M45 x 1,5 27.0 48.0

Table 1

NOTE: An excessively tightened gland nut can cause

excessive packing wear and can hinder the free move­ment of the plug stem.

4.5 Check fail-safe position. To do this, close supply pres­sure and observe whether the valve opens or closes
as defined.

4.6 After use at fluctuating temperatures, re-tighten all bolt
connections and check for leaks.

5 MAINTENANCE

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
„Disassembly and Assembly of Valve“.

5.1 Examine gaskets for leaks and if necessary re-tighten
bolts (see Fig. 1).

Warning: To prevent a buildup of electrostatic charge

clean the actuator/valve with a damp cloth only.

5.5 Check gland nut for correct torque (see table 1).

NOTE: An excessively tightened gland nut can cause

excessive packing wear and can hinder the free move­ment of the plug stem.

5.6 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.

WARNING: Keep hands, hair, clothing, etc. away from

all moving parts. Failure to do so can lead to serious
injury.

5.7 Check all accessories for firm seating.

5.8 If possible, close supply pressure and check the fail­safe position.

5.10 Check stem boot for wear.

5.11 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and check for any bubble formation.

5.12 Clean plug stem.

5.13 Check air filter, if present, and if necessary replace
insert.

NOTE: For further information regarding service and

maintenance please contact your nearest FLOWSERVE
office.

DANGER: On actuators with aluminium cases the

actuator springs must be renewed with original spare
parts every 10 years or after 50.000 operating hours
which ever occurs first.

5.2 Check bellows gasket and test connection - if present

- for external leaks.

5.3 Check valve for damage caused by corrosive residues
or corrosive vapours.

3

4

Flow Control

Kämmer Control Valves

®

Cap

Travel indicator

Zero adjustment locknut

Actuator stem

Locknuts
Gland nut
Clamping nut

Yoke plate

Yoke nuts

Plug stem

Actuator series 4

Fig. 1

Coupling

Coupling screws

Coupling insert

Locknut

Yoke plate

Yoke nuts

Actuator series 2

Fig. 1a

Flow Control

Kämmer Control Valves

®

6 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 an installed
condition.

6.1 Remove series 4 actuator

(see Fig 1 + 2)
To remove series 2 actuator see 6.3

6.1.1 Shut off air supply.

DANGER: Depressurise the line to atmospheric

pressure and drain all fluids from the valve before
working on the actuator. Failure to do so can cause
serious injury.

6.1.2 As required remove any outside tubing.

6.1.3 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. If
the actuator is fitted with a handwheel this can be used
to relieve the plug from actuator spring pressure.

6.1.4

Using a wrench, secure the actuator stem against

turning and using a second wrench loosen the stem
locknuts. If the actuator is fitted with a coupling refer
to the procedure described in the maintenance instruc­tions for the I/P actuator.

NOTE

: the actuator stem must not be rotated, as this

will cause damage to the diaphragm.

6.1.5 Loosen gland and clamp nuts.

6.1.6 Secure plug stem against turning and unscrew actuator
from plug stem by rotating counter-clockwise.

NOTE

: Ensure that the plug assembly is not rotated with

the plug seated. This may cause irreparable damage to
the seating faces.

6.1.7

Remove actuator and remove at the same time locknut,

travel indicator disc, gland nut and clamp nut.

6.2 Install series 4 actuator

Information:

• Before the actuator is installed, it must be calibrated
according to section 8 of the instructions „Pneumatic
and Electro-pneumatic Actuators“.

• All worn or damaged parts must be replaced. Reus
able parts must be clean.

6.2.1 Position actuator with clamp nut, gland nut, locknuts
and travel indicator disc on the valve.

6.2.2.1

Only for „spring-to-close“ actuators:

Screw actuator onto plug stem by rotating clockwise,

until the yoke plate just touches the valve housing and
the actuator is aligned forward. If the actuator is fitted
with a coupling refer to the procedure described in the
maintenance instructions for the I/P actuator.

NOTE: Ensure that the plug assembly is not rotated

with the plug seated. This may cause irreparable dam­age to the seating faces.

6.2.2.2

Only for „spring-to-open“ actuators:

Lift plug stem and screw it into the lower coupling half

until the distance between „plug in seat“ and „plug
raised“ approximately corresponds to the specified
stroke.

6.2.3 Tighten clamp nut and gland nut.

6.2.4 Adjust seat tightness by screwing/unscrewing the plug
stem in/out of the actuator stem.

NOTE: Ensure that the plug assembly is not rotated

with the plug seated. This may cause irreparable dam­age to the seating faces. Open valve, make adjustment,
close valve and check for leaks. If the valve is fitted
with a bellows seal the plug stem may NOT be rotated
at all. In the case of a bellows seal adjustments are
made with the coupling.

6.2.5 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.

6.3 Remove series 2 actuator

(see Fig. 1a)
For series 4 actuator see 6.1

6.3.1 Shut off air supply.

DANGER: Depressurise the line to atmospheric

pressure and drain all fluids from the valve before
working on the actuator. Failure to do so can cause
serious injury.

6.3.2 Disconnect all tubing.

6.3.3 Remove 2 screws and remove coupling.

6.3.4 Remove yoke rod retaining nuts and lift actuator
assembly from the valve.

6.3.5 Remove coupling insert and it’s locknut from plug
stem.

NOTE: Ensure that the plug assembly is not rotated

with the plug seated. This may cause irreparable
damage to the seating faces.

6.4 Install series 2 actuator

-

(see Fig. 1a)
The actuator stem must be fully extended:
Actuators with air-to-open action must be fully

vented. Actuators with air-to-close action apply
supply pressure.

Manually depress the plug stem to ensure the plug

is fully seated.

6.4.1 Screw coupling insert locknut and coupling insert as
far as possible onto plug stem.

6.4.2 Place the actuator assembly on the valve engaging the
yoke rod threads in the lower yoke plate and ensuring
the actuator faces in the correct direction.

5

6

Flow Control

Kämmer Control Valves

®

Locknut

Gland nut

Packing follower

Clamping nut

Nut

Bonnet

Bolt/stud

(depends on design)

Gasket

Packing kit see
spare parts list

Body

Trim see
spare parts list

Fig. 2

Bore for
hooked spanner

Bore for adjustable
face pin tool

Fig. 3

Flow Control

Kämmer Control Valves

®

6.4.3 Unscrew the coupling insert until the yoke rods are
raised from the lower yoke plate by around 2 mm.

NOTE: Ensure that the plug assembly is not rotated with

the plug seated. This may cause irreparable damage
to the seating faces.

6.4.4 Refit the coupling, ensuring that the arrows, embossed
on the coupling halves, point upward towards the
actuator, and secure with 2 retaining screws.

6.4.5 Apply supply pressure resp. vent actuator to half stroke
and refit and tighten yoke rod retaining nuts (15).

6.4.6 Connect all tubing.

7 DISASSEMBLE AND ASSEMBLE VALVE

7.1 Disassemble Valve

(see Fig. 2)

7.1.1 Remove bonnet flange bolting and raise bonnet and

plug assembly.

NOTE: heavy assemblies may require a hoist

7.1.2 Unscrew seat ring using seat ring tool and carefully

press plug stem evenly out of the upper body.

7.1.3 With valves DN 80 / kv 63 and larger, the plug head

can be unscrewed (see Fig. 3). Remove plug head
from stem by securing valve stem against rotation
with a hooked spanner and turning plug head with
an adjustable face pin tool.

7.1.3 Check seating faces of seat ring and plug for damage.

Gasket surfaces must be clean and free of damage.

Press guides, packing and packing follower from be-

7.1.4

low using a drift (the drift must have a slightly larger
diameter than the plug stem).

NOTE: To prevent damage to the plug or plug stem,

follow the above instructions precisely.

7.1.5 If a seat surfaces need 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.

NOTE: When re-machining the plug, protect plug stem
from damage. The seat surface must be concentric
to the plug stem. When re-finishing the seat, the
seat surface must be concentric to the seat outer
diameter.

7.2 Assemble Valve
(see Fig. 2)

7.2.1 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.

7.2.2 Insert seat ring and tighten. For torques, see following
table:

Size Body Torque
material

DN 15/25 (½ /1") 1.4581 cast 125 Nm

1.4571
DN 40/50 (1 ½ /2") 1.4581 200 Nm

1.4571 255 Nm
DN 80 (3") 1.4581 230 Nm

1.4571 270 Nm
DN 100 (4") 1.4581 400 Nm

1.4571 500 Nm
DN 150 (6") 1.4581 450 Nm

1.4571 600 Nm

forged 125 Nm

7.2.3 If necessary, screw plug head back on to stem and
carefully guide plug stem through the bonnet, to avoid
damage.

7.2.4 Insert new bonnet gasket.

7.2.5 Position bonnet slowly and absolutely upright on body
to avoid damage to seat/plug.

7.2.6 Tighten bonnet flange bolts alternating crosswise fin­ger-tight and then tighten with a wrench. For 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

7.2.7 Replace packing by inserting packing rings one at a
time tapping each one down with a suitable bush­ing.

NOTE: ensure that the gaps in the packing rings are

distributed evenly around the circumference in the
packing box (gaps not in line).

Different packings and fitting sequencess are shown

in the spare parts list.

7.2.8 Insert packing follower. Fit gland nut for transport
purposes only. Gland nut to be fitted correctly and
tightened down when actuator is mounted (see table 1).

7

Flow Control

Kämmer Control Valves

®

8 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. Re-
tighten the connections, if necessary replace leaky lines

4. Positioner defective 4. See operating instructions for positioner

Excessive 1. Bonnet loose 1. See step 7.2.6 for correct tightening of bonnet.
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 6.2.4

6. Incorrect direction of flow 6. Check specification. Contact dealer

7. Handwheel incorrectly 7. Adjust handwheel
adjusted (acts like end stop)

Inadiquate flow 1. Plug incorrectly adjusted 1. Correctly adjust plug according to step 6.2.4
(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 6.2.4

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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8

©09.2003 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation

All data subject to change without notice