Flowserve 3 Series P6 User Manual
Installation, Operation, Maintenance Instructions
Pneumatic Diaphragm On-Off Actuators
Series 3, Type: P6
Flow Control Division
Kammer Control Valves
Index
1 Using Kämmer valves and actuators correctly.
2Unpacking
3 Installation
4 Quick check
5 Maintenance
6 Remove and install actuator
7 Disassemble actuator
8 Assemble actuator
9 Reverse actuator action
10 Troubleshooting chart
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:
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:
and/or substantial property damage will occur if proper
precautions are not taken.
WARNING:
STOP!
jury and/or substantial property damage can occur if
proper precautions are not taken
CAUTION:
property damage can occur if proper precautions are
not taken.
In most cases Kämmer valves and actuators
indicates that death, severe personal injury
indicates that death, severe personal in-
.
indicates that minor personal injury and/or
NOTE:
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, dang-erous,
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:
rial-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.
indicates and provides additional technical
Before installation check the order-no, se-
KMEIM0004-00 - 08.03
1
1
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Flow Control Division
Kammer Control Valves
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:
for repair or service Kämmer must be provided with a
STOP!
certificate which confirms that the product has been
Before products are returned to Kämmer
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 and 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:
STOP!
tre of gravity of the valve may be above the lifting
If slings are used, be aware that the cen-
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 lowtemperature 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 pro-
vided 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.
3.4 After installing, check direction of flow again. The
direction of flow is shown by the arrow on the
housing.
3.5 If the valve is to be welded into the line, make sure
that the valve is shielded from excessive heat.
3.6 Connect supply pressure and signal lines. Control
valves are supplied with a positioner. The end
connections for supply pressure and signal are clearly
marked. Series 4 actuators and positioners 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.
STOP!
WARNING:
Prevent other items of equipment from
making mechanical contact with the actuator housing.
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
2
(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
Thread PTFE Grafoil
M20 x 1,5 1 3
M30 x 1,5 6 15
M38 x 1,5 15 35
M45 x 1,5 17 40
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).
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 valve/actuator and repaint as necessary.
Warning:
STOP!
clean the actuator/valve with a damp cloth only.
5.5 Check gland nut for correct torque (see table 1).
To prevent a buildup of electrostatic charge
Flow Control Division
Kammer Control Valves
NOTE: With graphite packing, irregular movement of
the plug stem is normal.
STOP!
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.
5.9 Check stem boot for wear.
5.10 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and check for any bubble formation.
5.11 Clean plug stem.
5.12 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.
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.
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