Flowserve 051 000 User Manual

1

Flow Control

Kämmer Control Valves

®

Installation, Operation, Maintenance Instructions

Tank Flush Valve

Series 051 000, without bellows seal

KMEIM5100-00 02.05

1

USING KÄMMER VALVES 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: 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.

1.3 Protective clothing

Kämmer products are often used in problematic

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.).

1.4 Qualified personnel

Qualified personnel are people who, on account of

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.

1.5 Installation

DANGER: Before installation check the order-no,

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

Do not insulate extensions that are provided for hot

or cold services.

Pipelines must be correctly aligned to ensure that the

valve is not fitted under tension.

STOP!

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

2

Flow Control

Kämmer Control Valves

®

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).

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.

1.6 Spare parts

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.

STOP!

STOP!

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

Flow Control

Kämmer Control Valves

®

4 QUICK CHECK:

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).

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 function 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.

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.

5.4 Clean valves and repaint as necessary.

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 (when fitted) 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.

Table 1: Standard torque values for gland nut

STOP!

STOP!

Thread

Stem Ø

(mm)

Torque in Nm

PTFE Graphit

M20 x 1,5 6 2,5 6,0
M30 x 1,5 10 7,0 15,5
M38 x 1,5 16 17,0 38,0
M45 x 1,5 16 19,0 48,0

4

Flow Control

Kämmer Control Valves

®

Coupling

Coupling screws

Coupling insert

Locknut

Yoke plate

Yoke nuts

Actuator series 2

Fig. 1a

Zero adjustment locknut

Actuator stem

Travel indicator

Yoke plate

Yoke nuts

Cap

Locknuts
Gland nut
Clamping nut

Plug stem

Actuator series 4

Fig. 1

5

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)
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. Reus­able 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“ valves:

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“ valves:
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.

6

Flow Control

Kämmer Control Valves

®

Fig. 2

Stem/plug

Seat ring

Gasket

Valve body

Bushing

Packing

Slotted nut

Gland nut

Locknut

Drip protection

7

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 actuator from the valve (section 3)

NOTE: heavy assemblies may require a hoist

7.1.2 For a tank valve with an extending plug ( plug opens
into the vessel ), the plug needs to be removed before
the seat ring can be removed.

7.1.3 For complete maintenance the valve must be removed
from the tank because the seat ring serves also as
the flange facing for the flange connection. Remove
the valve from the tank. Remove the locknut and drip
protection. Unscrew the gland nut. Extract the plug
carefully from the valve.

NOTE: If the seat ring is not secured with a retaining

screw it might also detach from the valve body when
the plug is removed.

7.1.3 Check seating faces of seat ring and plug for damage.
Gasket surfaces must be clean and free of damage.

7.1.4 Remove the packing follower, packing and guide using
a drift.

7.1.5 If a seat surfaces require 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
renewed.

7.2.2 Replace the bushing.

Extending plug

7.2.3 Fit new gasket and replace the seat ring. If a retaining
screw is provided, tighten this screw to secure the
seat ring in position.

7.2.3.1 Insert the plug stem through the seat ring into the
valve. Be careful not to damage the guide bushing.

Retracting plug

7.2.4 Insert the plug stem into the valve. Be careful not to
damage the guide bushing.

7.2.4.1 Fit new gasket and replace the seat ring. If a retaining
screw is provided, tighten this screw to secure the
seat ring in position.

7.2.5 Replace slotted nut. Replace packing by inserting the
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 of the
packing box (gaps not in line).

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

7.2.7 Refit the actuator (see section 6.2 and 6.4).

8

Flow Control

Kämmer Control Valves

®

8 Trouble-shooting Chart

All data subject to change without notice

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

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. Worn or damaged 1. Re-machine or replace seat ring/plug.
leakage seat ring/plug

2. Inadiquate actuator thrust 2. Check air feed. If air feed is OK, contact dealer.

3. Plug incorrectly adjusted 3. Correctly adjust plug according to step 6.2.4

4. Incorrect direction of flow 4. Check specification. Contact dealer

5. Handwheel incorrectly 5. 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

Regional Headquarters

Flowserve EMA Flowserve America Flowserve Asia

Burrell Road, Hayward Heath 1350 N. Mt. Springs Prkwy. 12 Tuas Avenue 20
West Sussex, RH16 1TL Springville, UT 84663 638824
England USA Republic of Singapore
Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: [phone] Facsimile: [phone]

Main Sales Offices EMA (Europe, Middle East, Africa)

Flowserve France Flowserve Switzerland Flowserve Germany Flowserve Eastern Europe

7 Avenue de la Libération Allee du Quartz 1 Manderscheidtstr. 19 12, av. du Québec
63300 Thiers Cedex CH-2300 La-Chaux-de Fonds 45141 Essen 91965, Courtaboeuf Cedex
France Switzerland Germany France
Telephone: [phone] Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: [phone] Facsimile: [phone] Facsimile: [phone]

Flowserve South Africa Flowserve Middle-East Flowserve Austria Flowserve Benelux

Unit 1 C/O Saleh & Abdulaziz Abahsain Kasernengasse 6 Van Leeuwenhoekweg 6
12 Director Road P.O. Box 209
Spartan Ext 2, Kempton park
Gauteng Al Khobar 31952 9500 Villach 3225 LX Hellevoetsluis
South Africa Saudi Arabia Austria The Netherlands
Telephone: [phone] Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: 9663 859 5284 Facsimile: [phone]/51 Facsimile: [phone]

Flowserve Italy Flowserve Spain Flowserve Portugal Flowserve Scandinavia

Via Prealpi, 30 Luis Cabrera, 86-88 Av. Dr. Antunes Guimaraes, 1159 Gelbgjutaregatan
Cormano (Milano) E-28002 Madrid Porto 4100-082 58933 Linköping, Östergötland
Italy Spain Portugal Sweden
Telephone: [phone] Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: [phone] Facsimile: [phone] Facsimile: [phone]