Manual No. 1878-YGB-BL-1
Issued: November 26, 2002
Revision B
INSTRUCTION MANUAL
for
½" thru 2" 1878 lb. Y-Pattern Globe Valves
with T-Handle and Bellows Seal
Flowserve Corporation
Flow Control Division
1900 S. Saunders Street
P.O. Box 1961
Raleigh, NC 27603
Phone: (919) 832-0525
FAX: (919) 831-3369
TABLE OF CONTENTS
1.0 Physical Description and Operation of Equipment
2.0 Design Conditions
3.0 Operating Conditions
4.0 Test Conditions
5.0 Operating Precautions and Limitations
6.0 Installation Instructions
7.0 Maintenance Requirements
8.0 Periodic Inservice Testing Recommendations
and Procedures
9.0 Maintenance Instructions
10.0 Storage Requirements
11.0 Reference Drawings
12.0 Customer Assembly Drawing(s)
2
Manual No. 1878-YGB-BL-1
REVISION RECORD
Revision Section Description Date
- All Original Issue 11/26/2002
A 9.1.2 Added Gland nut torque 04/07/2005
Values
B 11.0 Updated Figure 1 02/01/2008
B 7.2, 9.2, 9.4 Replaced all references to part 02/01/2008
“110A” with “110”
B 9.1 Replaced all references to part 02/01/2008
“024L” with “025”
B 9.1.1, 9.4 Replaced all references to part 02/01/2008
“024U” with “024”
B 9.3.1 Removed 1st paragraph with 02/01/2008
reference to lapping tool dwg.
B 9.4-C Expanded troubleshooting 02/01/2008
3
1.0 PHYSICAL DESCRIPTION AND OPERATION OF EQUIPMENT
1.1 GLOBE VALVES (Figure 1)
These valves are primarily designed for tight shutoff and throttling service
where control of the velocity of th e fluid is necessary. If required, they can
also serve as a means of isolating a portion of a system. Their use however,
is limited to those systems where head losses are not critical as the internal
flow passage creates a pressure drop across the valve. With the disc in the
full open or any intermediate position, the fluid is allowed to flow through
seat area at a rate determined by the position of the disc. With the disc in
the closed position, the force of the stem provides a mechanical seal
between the disc and seat and effects a shutoff at the valve.
The ½”-2” Y-Globe valves have a precision cast body. It is an investment
casting and offers smooth flow passages for minimum pressure drop and
minimum turbulence. A bellows is provided as a primary sealing device.
The ½”-2” Y-Globe valves can be provided with a variety of disc styles to
provide different throttling flow characteristics. The following three distinct
disc styles are available: quick plug type, parabolic, cage type. A circular
plate below the tee handle/handwheel nut indicates the type of disc .
All ½”-2” Y-Globe valves are supplied with a tee-handle actuator and a
bellows seal. To operate these valves, turn the tee-handle in a clockwise
direction for closure and counterclockwise for opening.
2.0 DESIGN CONDITIONS
Refer to the applicable drawings in Section 12.0 of this manual.
3.0
OPERATING CONDITIONS
Refer to the applicable drawings in Section 12.0 of this manual.
4
4.0 TEST CONDITIONS
4.1 Each valve covered by this manual has received the following hydrostatic
tests:
4.1.1 Shell hydrostatic test at 1.5 times the 100°F pressure rating.
4.1.2 A disc closure test at 110% of the 100°F pressure rating.
4.1.3 A seat leakage test at 110% of the valves specified maxim um "delta
P".
4.1.4 A backseat leakage test at 110% of the 100°F pressure rating.
4.1.5 A packing test at 110% of the 100°F pressure rating.
5.0 OPERATING PRECAUTIONS AND LIMITATIONS
5.1 Maximum hydrostatic test pressure shall not exceed the va lues imposed by
the ASME Code.
6.0 INSTALLATION INSTRUCTIONS
6.1 LIFTING AND HANDLING REQUIREMENTS AND LIMITATIONS
6.1.1 Good judgment should be exercised in selecting a lifting device that
will safely support the unit's weight.
6.2
INSTALLATION
6.2.1 Although the valves have been shipped in a clean condition, prior to
installing the valves, examine the lines and the valve ports for foreign
matter and clean them thoroughly if they have been exposed to the
elements. (BEFORE CLEANING IN THIS FASHION, CHECK AT
THE SITE TO SEE IF A SPECIFIC CLEANING PROCEDURE
SHOULD BE FOLLOWED.) Open the valves fully and flush them out
with water if possible; otherwise blow them out with air or steam.
In performing this cleaning procedure, the ports should be vertical,
the stem horizontal to assure complete removal of all matter which
might have accumulated during storage.
6.2.2 Ensure that there is no line sag at the point of installation. Eliminate
any pipeline deviation by the proper use of pipeline hangers or similar
device.
5
6.0 INSTALLATION INSTRUCTIONS (Continued)
6.2.3 Where possible, install the valves with the stem vertical.
6.2.4 The valves should then be blocked or slung into position with
apparatus that is sufficient to hold the valve assembly weight while
the valve is being welded into the line. WELDING SHOULD TAKE
PLACE WITH THE DISC IN THE OPEN POSITIO N. Care should be
taken during welding to ensure that foreign material or dirt does not
enter the valve and cause interference with subsequent operation.
6.2.5 Valves are normally shipped pre-packed; if specified otherwise, the
packing is shipped loose with the valve, and should be installed at
this time.
With the valve fully backseated, install the packing, carefully placing
the joint of each ring approximately 180° from the preceding piece. It
will probably be necessary to slightly flatten each packing ring prior to
installation to allow easy insertion within the stuffing box. The flange
gland can be used to seat the packing in position, one ri ng at a time.
Upon completely filling the stuffing box, replace the gland stud nuts
(234) and very carefully draw the packing down. (Refer to Section
9.1.2 for bolt torque values). Stroke the valve several times and then
retighten the nuts.
Special attention should be observed to assure the flange is drawn
evenly and that the bore of the flange is concentric with the valve
stem. If the flange is drawn unevenly, scoring of the stem may result.
6.3 PRE-OPERATIONAL CHECKS
6.3.1 After installation the operation of manual valves should be verified by
closing the valve. The valve should seat tightly with less than 40 lbs.
of push/pull force on the handwheel. If the valve does not close
tightly
DO NOT apply extra leverage; instead refer to Para. 9.4 A and
B.
6.4
OPERATION
6. 4.1 After the valves are heated and run in, it may be necessary to draw
the packing to eliminate leakage. In adjusting the packing, the flange
gland should be drawn in as evenly as possible. This can be
accomplished by alternately tightening the gland stud nuts one-half
turn until the packing is tight.
6
7.0 MAINTENANCE REQUIREMENTS
7.1 PREVENTATIVE MAINTENANCE
7.1.1 Check all nuts and bolts periodically to ensure tightness and to
forestall possible leaks. (See applicable assembly drawing for
recommended bolt torque values).
7.1.2 Keep the valve stem clean and properly lubricated.
7.1.3 Check condition of the packing and replace as necessary.
7.2 RECOMMENDED SPARE PARTS
7.2.1 Recommended spare parts are Packing Rings (110,112), Disc (004),
Pin (Disc/Skirt)(265) and Rapid Change Kit (802). The
recommended quantity is 1 set of packing for every 2 valves of a
particular type but not less than 1 set of each type. One complete set
of the other parts is recommended for every 10 valves of a particular
type.
7.3 LUBRICATION
7.3.1 Apply a light coating of lubricant (Dow Corning Molykote 111, Dow
Corning Molykote P37 paste or equal) when necessary to the
threaded area of the upper stem. Before lubricating in this fashion,
check at the site to see if a special lubrication procedure should be
followed.
8.0
PERIODIC INSERVICE TESTING RECOMMENDATIONS AND PROCEDURES
8.1 It is recommended that the valve be operated from full open to full close at
least once every six months.
7
9.0 MAINTENANCE INSTRUCTIONS
9.1 DISASSEMBLY and REASSEMBLY
The following instructions c over the disassembly and reassembly of the ½”-
2” Y- Globe valves.
WARNING
Prior to performing disassembly, close off the line pressure to
the valve, and release all pressure in the valve.
Extreme care should be taken to ensure that the lower stem (025) and disc
(004) do not separate when removed as one unit until both are adequately
supported. Failure to do so may cause the disc to fall off the stem, and may
cause damage to the disc and/or injury to personnel.
After removal of the disc from the valve, care should be taken to protect the
seating surface from damage. The disc should be placed in a clean area
until it is ready for replacement. THE SLIGHTEST NICK OR SCRATCH ON
A SEATING SURFACE MAY PREVENT COMPLETE SHUTOFF AND
NECESSITATE EXTENSIVE REWORK OR REPLACEMENT.
9.1.1 Valve Disassembly (Refer to figure 1 for reference part numbers)
(1) Relieve pressure from valve.
(2) Place the valve in the closed position and then open the tee-
handle (175) 1-2 revolutions.
(3) Remove the Handwheel Nut (240) from the Upper Stem
(024).
(4) Remove the Tee-Handle (175) and Thrust Washer (147) from
the upper stem.
(5) Remove the Gland Stud Nuts (234), and then remove the
corresponding Gland Studs (205).
(6) Remove the Stanchion Capscrews (280) and Stanchion
Lockwashers (251).
(7) Remove the Yoke Cap (019). Remove the Thrust Washers
and Needle Bearing (168) (356) if applicable. Rotate the Yoke
Sleeve (017) in a counterclockwise direction to remove it from
the Upper Stem (024)
(8) Remove the Stanchions (427) from the Body (001).
8
9.0 MAINTENANCE INSTRUCTIONS (Continued)
(9) Loosen the Stem Clamp Setscrews (221) and remove the
Stem Clamp (029) and Stem Clamp Key (255).
(10) Lift the Flange Gland (133) upward and remove the Packing
(110, 112) from the stuffing box. Removal of the packing is
best accomplished with a packing hook or similar device.
(11) Loosen the Gland Retainer Setscrews (220) until they do not
make contact with the Gasket Retainer (033). Then turn the
Gland Retainer (131) counterclockwise off the Bonnet (002).
Turn the Gasket Retainer (033) out of the Body (001).
Note: The bellows is seal welded to the bonnet and stem and is an
assembly. The assembly is referred to as a Rapid Change Kit,
and is comprised of all trim parts, stem, bellows, bonnet, and
pressure seal gasket. The Rapid Change Kit is a complete
assembly and must be removed and replaced as such.
(12) Remove the Pressure Seal Gasket (030) by carefully lifting the
Upper Stem (024), (including the attached bellows assembly)
from the Body (001). It is imperative that the bellows
assembly be lifted out of the body as straight as possible to
eliminate the possible scoring of the stem. If the bonnet is
wedged into position, carefully lift up on the stem until the
gasket and bonnet come free.
Note: The Disc (004) and Disc Skirt (005) ar e attached to the stem
by the use of a Stem Retainer (028) and Disc Skirt Pin (265).
(13) The Disc (004), and Disc Skirt (005), can now be removed
from the stem.
WARNING
Be careful when removing the assembly from the valve body.
After removal from the valve, care should be taken to protect the
seating surface of the disc from damage. The disc should be
placed in a clean area until ready to replace in the valve. THE
SLIGHTEST NICK OR SCRATCH ON A SEATING SURFACE MA Y
PREVENT COMPLETE SHUTOFF AND NECESSITATE
EXTENSIVE REWORK OR REPLACEMENT
(14) Remove the Disc Skirt Pin (265) from the Skirt (005).
Unthread the Disc (004) from the Disc Skirt (005). Place the
disc (004) where it won’t become damaged or scratched.
Remove the Stem Retaine r (028) and Disc Skirt (005).
9
9.0 MAINTENANCE INSTRUCTIONS (Continued)
(15) At this time, the disc and seat ring may be lapped if required.
The seating surface should be inspected to determine if
scratches or minor imperfections may be corrected by lapping
and/or if replacement parts are necessary. (ref er to Para. 9.3
for lapping instructions).
9.1.2 REASSEMBLY
REASSEMBLY OF THE VALVES is simply the reverse of the
disassembly task; also read the following special instructions.
First, all dirt, scale and foreign matter should be removed from inside
the valve body and bonnet.
Before reassembling the valve, check the seating surfaces to
determine that no scratches or minor imperfections are on the disc or
seat ring. If any are evident - lap these surfaces until no
imperfections are visible. (Reference Para. 9.3).
Prior to installing the Rapid Change Kit or Bellows Assembly, ensure
that the keyhole in the stem clamp is lined up with the keyway on the
stem. Ensure that the stem clamp is parallel with two of the
stanchion holes to prevent interference with the stanchions once
installed and rotation of the bellows assembly for line up, once
installed into the body.
The following torque values serve only as a guide in determining
approximate gland bolt nut torque values for 1878 Bellows-Sealed
Globe Valves. It should not be necessary to exceed the following
gland bolt nut torques for pressures up to 2735 psi .
VALVE SIZE APPROXIMATE TORQUE
½" thru 1" 6 ft-lbs
1½" & 2" 17 ft-lbs
After tightening gland bolt nuts, stroke the stem and retighten the nuts
as required.
10
9.0 MAINTENANCE INSTRUCTIONS (Continued)
9.2 REPLACEMENT OF PACKING (Refer to Figure 1 for reference part
numbers)
(1) Remove the two Gland Nuts (234) and raise Gland Flange (133)
allowing the Gland Studs (205) to be removed.
(2) Lift the Gland Flange (133) upward and away from the stuffing box
area.
(3) Use a packing hook or similar device to remove the old packing.
(4) Install the Packing (110, 112) one ring at a time - carefully placing the
joint of each ring approximately 180° from the preceding piece to
prevent a leakage path. It might be necessary to slightly flatt en each
packing ring prior to installation to allow easy insertion within the
stuffing box. Do not use a pointed instrument to push the rings into
position. The Gland Flange (133) can be used for this purpose.
(5) Upon completely filling the stuffing box, lubricate the bolt threads,
replace the nuts and very carefully draw the packing to assure that
the gland flange is even and that the bore of the gland flange is
concentric with the upper stem. (If the Gland Flange (133) is drawn
unevenly, scoring the upper stem may result; or the gland mi ght be
tilted which could cause binding.)
(6) After tightening the gland stud nuts to the above specified torque
values, stroke the stem and retighten the nuts as required.
(7) Check the packing periodically (6-month intervals), replacing it as
needed.
11
9.0 MAINTENANCE INSTRUCTIONS (Continued)
9.3 REFINISHING SEALING SURFACES
Minor discontinuities in the seat sealing surface, which may cause leakage,
can, in many cases, be removed by lapping. Major defects such as cracks
or deep gouges will generally require replacement of the part.
Minor discontinuities on the valve disc sealing surface may be removed by
re-machining the surface to remove a few thousandths of material. Major
defects will generally require replacement of the disc.
NOTE: Lapping is a polishing process where a sealing surface is
ground with an abrasive held in place by a special fixture. The
abrasive is commonly found in paste form or bonded to a
paper backing. Detailed instructions on the use of lapping
abrasives and fixtures, normally supplied with such
equipment, should be adhered to.
In order to maintain seat tightness in globe valves, the sealing surface
angles on both the disc and seat ring must be kept within close tolerance
(30° [+1/2°] for the seat and 29° [-1/2°] for the disc). It is important when
lapping to use fixtures that will maintain these angles. Flowserve does not
recommend lapping the disc directly to the seat. A good seal is dependent
on line contact. Direct contact lapping will result in excessive seat widths.
9.3.1 Globe Valve Seat Lapping Tool
Lapping tools and tool drivers for the Series 1878 globe valve seats
are available thru Flowserve Corporation. Contact your nearest
Flowserve Representative for information.
To lap the seat ring, simply apply two (2) to five (5) lbs of force to the
tool as it grinds. Three (3) or four (4) two (2) second cycles should be
sufficient. Visually check the seat ring surface for a fine line blue dye
check with the disc should assure tight sealing. Flowserve
recommends that the disc be turned in a lathe with 16 rms finish at
29º [-1/2°]
12
9.0 MAINTENANCE INSTRUCTIONS (Continued)
9.4 TROUBLESHOOTING
A. Excessive Tee-Handle (175) Effort or Binding
Excessive tee-handle effort or binding would indicate that the Upper
Stem threads or Yoke Sleeve (024) (017) needs to be lubricated; or
the Gland Flange (133) is too tight as a result of the gland nuts being
tightened unevenly. Lubrication (Para. 7.3) should be checked at
regular intervals of 6-months. To tighten the gland nuts evenly, they
should be loosened and retightened in even increments while
checking concentricity between the stem and gland bore.
B. Leakage Between the Disc (004) and Seat (013)
This could be an indication that there is foreign matter on the seating
surfaces in which case the valve should be opened and closed ONE
TIME in an attempt to dislodge any matter that may have
inadvertently lodged there. DO NOT OPEN AND CLOSE THE
VALVE MORE THAN ONCE AS THIS MAY TEND TO CAUSE
PERMANENT DAMAGE TO THE SEATING SURFACES IF THE
FOREIGN MATTER IS SECURELY LODGED IN PLACE. Instead,
disassemble the valve and remove the source of the trouble.
If no foreign matter is found, inspect the seating surfaces of the valve
for signs of a scarred or damaged seat - in which case the seating
surfaces of the Disc (004) and Seat Ring (013) should be refinished
until no visible defects remain. (Refer to Para. 9.3)
C. Leakage A round Up per S tem (0 24) an d th ru the S tuffi ng Box
Indicates worn Packing (110, 112) and failed Bellows (163). Tighten
the packing, (reference paragraph 9.2(6)) and replace the Packing
and Bellows at the earliest opportunity. The Bellows and Packing
may be replaced with a Rapid Change Kit (reference paragraph
9.1.1(11) and Section 11.0 Figure 1-Note 10).
13
10.0 STORAGE REQUIREMENTS
The v alves have been shippe d in t he closed posit ion. Upon r eceipt of the v alves at
destination, the crates should be examined thoroughly for signs of mishandling or
damage during shipment. With the valves strapped to the shipping skids, all bolting
should be checked to ensure that the joints are secure. Bolting on occasion may
become loosened during shipment and handling.
The valves should then be stored in a sheltered area to protect them from the
elements, dirt and foreign material. They should not be exposed to the
atmosphere, uncrated or removed from the shipping skids except in a clean area
just prior to installation.
If the valves are not to be installed within a short period of time after receipt, and will
require long-term storage, the following guideline should be adhered to:
(a) In their storage condition, the valves should be wrapped in polyethylene to
prevent accumulation of dust or foreign matter.
The shelf life for grafoil and graphite filament packing is indefinite.
14
SECTION 11.0
REFERENCE DRAWING(S)
15
FIGURE 1:
16
SECTION 12.0
CUSTOMER ASSEMBLY DRAWING(S)
17
Loading...