Installation, Operation, Maintenance Instructions
Standard Valves with Bellows Seal
Series 035 300 Globe Valves
Series 031 300 Angle Valves
Series 033 300 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
Actuator stem
Coupling
Coupling screw
Yoke plate
Yoke plate nut
Bonnet fastner
Anti rotation pin
Coupling insert
Locknut
Gland nut
Slotted nut
Plug stem
Bonnet
Test connection
(rotated 90°)
Extension
Bellows seal
Valve body
Fig. 1
Typical actuator and valve configuration
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REMOVE AND INSTALL ACTUATOR
Flow Control Division
Kammer Control Valves
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.
3.1 Remove actuator
(see Fig. 1)
3.1.1 Shut off air supply.
WARNING: 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.
3.1.2 Disconnect all tubing.
3.1.3 Remove 2 screws and remove coupling.
3.1.4 Remove yoke rod retaining nuts and lift actuator
assembly from the valve.
3.1.5 Remove coupling insert and it’s locknut from plug
stem.
3.2.4 Refit the coupling, ensuring that the arrows, embossed
on the coupling halves, point upward towards the
actuator, and secure with 2 retaining screws.
3.4.5 Apply supply pressure resp. vent actuator to half stroke
and refit and tighten yoke rod retaining nuts (15).
3.4.6 Connect all tubing.
Attention: Ensure that the plug assembly is not
rotated with the plug seated. This may cause
irreparable damage to the seating faces.
3.2 Install actuator
(see Fig. 1)
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.
3.2.1 Screw coupling insert locknut and coupling insert as
far as possible onto plug stem.
3.2.2 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.
3.2.3 Unscrew the coupling insert until the yoke rods are
raised from the lower yoke plate by around 2 mm.
Attention: Ensure that the plug assembly is not
rotated with the plug seated. This may cause
irreparable damage to the seating faces.
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Locknut
Gland nut
Clamping nut
Packing follower
Flow Control Division
Kammer Control Valves
Top gasket
bellows seal
Packing kit see
spare parts list
Nut
Lockwasher
Bonnet
Stud
(test connection)
Gasket
Plug
Extension
Nut
Lockwasher
Stud
Lower gasket
bellows seal
Trim see
spare parts list
Seat ring
Body
Fig. 2
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4 DISASSEMBLE AND ASSEMBLE VALVE
Flow Control Division
Kammer Control Valves
4.1 Disassemble Valve
(see Fig. 2)
IMPORTANT: As poisonous or hazardous materials
may be present, the system must be depressurized
and all processing materials must be drained. If
necessary, decontaminate the valve. Keep hands,
hair, clothing, etc. away from all moving parts. Wear
face and eye protection. Failure to do so can lead
to serious injury.
4.1.1 Carefully loosen test connection and check whether
medium has collected in the bellows seal bonnet
(defective bellows).
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 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 remains in the seal housing, the bellows
can be carefully levered out using two screwdrivers
inserted in the outer groove of the bellows upper part.
4.1.4 Without stretching the bellows, remove the plug/
bellows assembly from the bonnet and remove
carefully and upright out of the extension. Do not
lose anti-rotation pin. Using a drift, press guides,
packing and packing follower from below (the drift
must have a slightly larger diameter than the plug
stem).
4.1.5 With soft seat version, loosen plug tip with
appropriate tool and remove soft seat gasket.
IMPORTANT: When the tip of the plug is loosened,
medium residue may be released, which has
diffused through the gasket.
4.1.6 Remove bellows seal extension bolts/nuts and
remove extension..
4.1.7 Unscrew seat ring with seat ring tool.
4.1.8 Check seal faces of seat ring and plug for damage.
Gasket surfaces 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 seating 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
re-machining 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 Insert seat ring and tighten. For torques, see following
table.
Size Body Torque
material
DN 15/25 (1/2/1") 1.4581 cast 125 Nm
1.4571
1
DN 40/50 (1
DN 80 (3") 1.4581 230 Nm
DN 100 (4") 1.4581 400 Nm
DN 150 (6") 1.4581 450 Nm
/2/2") 1.4581 200 Nm
1.4571 250 Nm
1.4571 270 Nm
1.4571 500 Nm
1.4571 600 Nm
forged 125 Nm
4.2.3 With soft seat, using a new soft seat gasket, screw
plug tip back on.
4.2.4 Insert new gasket for bellows seal extension.
4.2.5 Position bellows seal extension slowly and upright
into the bonnet and tighten retaining screws/nuts
alternating crosswise.
4.2.6 Insert lower bellows gasket.
4.2.7 Carefully insert plug/bellows assembly in bellows seal
extension and install anti-rotation pin.
4.2.8 Insert upper bellows gasket in bellows seal bonnet.
4.2.9 Position bellows seal bonnet (test connection
forwards) and uniformly tighten screws/nuts handtight, alternating crosswise.
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Flow Control Division
Kammer Control Valves
4.2.10 Using a torque wrench, gradually tighten all screws/
nuts to the prescribed torques (see following table),
alternating crosswise.
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
4.2.11 Replace packing by inserting packing rings one at a
time tapping each one down with a suitable bushing.
Trouble-shooting Chart
Fault Possible Cause Remedy
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.
6.2.12 Insert packing follower. Fit gland nut for transport
purposes only. Gland nut to be fitted correctly and
tightened down when actuator is mounted.
4.2.13 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.
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. Bonnet loose 1. See step 4.2.5 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 3.2.4
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 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
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
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©09.2000 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation
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