Worcester Controls
CAUTION: Flowserve recommends that all products which must be
stored prior to installation be stored indoors, in an environment
suitable for human occupancy. Do not store product in areas where
exposure to relative humidity above 85%, acid or alkali fumes,
radiation above normal background, ultraviolet light, or
temperatures above 120°F or below 40°F may occur. Do not store
within 50 feet of any source of ozone.
A. INSTALLATION
1. Valve may be installed for flow or vacuum in either direction. Valves
with upstream relief hole (V3 option) are one-way valves. Use care to
exclude pipe sealants from valve cavity.
2. For weld end style valves (SW, BW):
Note: Prior to welding, THOROUGHLY CLEAN ALL JOINT SURFACES to
prevent contamination.
The PT59 and PT45 “AG” & “GG”, and the 2" PT59 “AZ” & “GZ”
valves (identified with V67 option code) are compatible with welding
temperatures and therefore are weld-as-is and do not have to be
disassembled prior to being welded inline. A red welding tag will be
attached to the valve. If for some reason these valves are
disassembled, new “S” gasket, grafoil laminated gasket or GraphLock body seals, and new seat back seals must be used to prevent
leakage. When welding these valves, the ball must be open to
prevent adhesion of weld spatter to the ball. Use STICK or MIG
welding and allow valve and joint to cool to the touch between
passes. All other valves are not compatible with welding
temperatures and must be welded inline as follows:
a. Tack weld valve in place.
b. With the valve open, remove all of the body bolts or studs and
remove the center section from the valve. Note: For 2" AF59
valves, spread pipe ends to clear centering rings. Close valve and
remove the ball, seats and both body seals. Return the body back
to its original position in the pipeline and temporarily secure it with
two body bolts or studs diagonally opposite each other.
c. Proceed to weld valve inline. If gas welding, do not play flame on
valve body.
d. Allow valve to cool, remove two body bolts or studs and
reassemble the valve. Note that all valves with Teflon or UHMWPE
body seals are reassembled using the original white Teflon or
opaque white UHMWPE body seals, while 2
1
/
2" 45 and 2" 59 valves
with “S” gasket body seals are reassembled using new “S”
gaskets, 2" 59 valves with Graph-Lock body seals are reassembled
using new Graph-Lock body seals, and valves with Grafoil
laminated gaskets are reassembled using new gaskets. “S”
gaskets, Graph-Lock body seals and Grafoil laminated gaskets are
shipped separately from the valve and the temporary seals, found
in the valve as received, are not to be reused. The wide flange of
the “S” gaskets must face the valve body.
e. Tighten the body bolts or studs evenly and diagonally opposite each
other, alternating in a criss-cross pattern to the following torques:
3. CAUTION
a. The “S” gasket body seals (G & M) and Graph-Lock body seals (Z),
found in some 2
1
/
2" 45, 2" 59 valves, Grafoil laminated gaskets (G),
and the seat back seals (used with “A” or “G” seated valves) are not
reusable. Upon disassembly of the valve, the seals must be
replaced. Also ensure that the Teflon coating of the “S” gasket is not
scratched or damaged during installation. Light lubrication of these
seals and gaskets can help to prevent damage.
b. If graphite parts are used, handle them gently on the flat surfaces
rather than the O.D. These parts can be easily damaged by
squeezing the O.D. These parts will not work if they are cracked or
broken. Light flaking of the material is acceptable.
c. The ball used in “A” or “G” (filled metal) seated valves has a
special anti-galling coating. DO NOT use uncoated balls with filled
metal seats. To ensure proper contact with the seat, do not drop,
dent or scratch the ball during handling.
18484-F
21/
2" – 6" 45, 2" – 4" 59
Three-piece Ball Valve Including PT Series
Installation, Operation and Maintenance Instructions
Carbon Steel Bolts or Studs Stainless Steel Bolts or Studs
Bolt Dia. in-lbs ft.-lbs Bolt. Dia. in-lbs ft.-lbs
7
/
16" 480-540 40-45
7
/
16" 336-384 28-32
1
/
2" 720-780 60-65
1
/
2" 504-552 42-46
9
/
16" 1080-1140 90-95
9
/
16" 682-730 57-61
5
/
8" 1370 -1430 114-119
5
/
8" 972-1020 81-85
3
/
4" 1800-1860 150-155
3
/
4" 1402-1450 117-121
2 18484-F
B. OPERATION
1. The operation consists of turning the handle and/or stem 1/
4 turn
clockwise to close and
1
/
4
turn counter-clockwise to open. When stop
plate pointer and/or stem flats or groove is in line with the pipeline,
the valve is open. This valve may also be automated.
2. Worcester valves will provide bubble-tight shutoff when used in
accordance with Worcester’s published pressure/temperature ratings.
Valves with “G” seats meet the leakage rates of ANSI B16.104 Class VI.
3. It is not good practice to leave a ball valve partly open (throttling
operation) without knowledge of the pressure drop and flow at that
position. This information can be obtained from the factory.
4. As shipped from the factory, valves (except oxygen prepared (V20,
V33 or prefix code “x”) and valves with V38 or V46 option) contain a
silicone-based lubricant. This is for break-in purposes and may be
removed with a solvent if found to be objectionable for a particular
application. Lacquer thinner will remove the lubricant. “A” or “G”
(filled metal) seated valves should not be operated without a break-in
lubricant.
5. Media which can solidify, crystallize or polymerize should not be
allowed to stand in valve cavities.
6. Torque Requirements: Operating torque requirements will vary
depending on the length of time between cycles, line pressure, type of
valve seats, and the media in the system. For a detailed analysis of
valve torque requirements, see the Worcester Actuator Sizing Manual.
C. MAINTENANCE
If seepage is noted at stem, tighten retaining nut 1/
6 turn at a time until
seepage stops.
CAUTION: Excessive tightening causes higher torque and shorter
stem seal life.
D. REBUILDING
a WARNING: BALL VALVES CAN TRAP PRESSURIZED FLUIDS IN
BALL CAVITY WHEN CLOSED.
Special handling and cleaning procedures are necessary for oxygen and
vacuum service valves. Refer to industry practices when overhauling
these units.
If the valve has been used to handle hazardous media, it must be
decontaminated before disassembly. It is recommended that the
following steps be taken for safe removal and disassembly:
• Relieve the line pressure. Operate the valve prior to attempting
removal from line.
• Place valve in half open position and flush the line to remove any
hazardous material from valve body.
• All persons involved in the removal and disassembly of the valve
should wear the proper protective clothing such as a face shield,
apron, etc.
1. A standard repair kit may be ordered for these valves consisting of
seats, seat back seals (for use with “A” or “G” seats only), body
seals, thrust bearing stem seal(s), and Belleville washers (used with
graphite stem seal or V51 option only.) Specify the valve size and
series, the material of the seat and body seal and the “R” number
(Revision No.) of the valve or for non-standard valve, the “P”
number, “T” number, “C” number or similar number. The information
is found on either the stop plate, mounting bracket nameplate or the
nameplate on the valve body. Some Series, such as PT, AF and V51
option have their own repair kits, which are ordered by the prefix or
adding V51 suffix. If valve body is stainless steel, place a “6” after
valve size in repair kit ordering code.
NOTE: The V51 high-cycle stem packing option can not be used with AF
Series, or oxygen service valves, or valves with “X” or “G” seats.
Repair Kit Ordering Examples:
3" RK 45 RT R2
3" RK 59 PT R2 V51
4" RK 45 PT TO914
2" 6AF RK59 PZ RO
CAUTION: If the seats and seals installed differ from those
removed, the valve nameplate or stop must be replaced or
remarked to indicate the altered materials and ratings or valve
tagged to so indicate.
2. Disassembly of Valve:
a. Place valve in open position. Remove all body nuts and bolts or
studs and lift out center section from between pipe ends. The 2"
AF59 valve requires spreading the pipe ends to clear the pipe end
centering rings. Remove handle assembly (if any) by unscrewing
hex head screw.
b. With valve in closed position, remove old seats, seat retainer(s) (if
present), seat back seals (if any), body seals and ball.
c. Prevent stem from turning by holding inside body. (The ball can
be inserted and prevented from rotating with a non-metallic rod
such as a screwdriver handle. This will hold the stem stationary
without damaging the ball.)
d. Remove retaining nut, and stop (or spacer, if actuated valve) from
stem.
e. Push stem into body cavity and remove. Retain follower and
centering washer(s). There are no washers on 2" and 2
1
/
2" valves.
f. Remove and discard stem seal(s), stem seal protector (if any) and
thrust bearing, which may be stuck on the stem or in the body
cavity. Remove Belleville washer(s) (if any).
3. Visual Inspection:
a. The ball and the surfaces against which the seats and seals are
installed should be clean, undamaged, and free of pit marks and
scratches. Light marring from the action of the ball against the seats
is normal and will not affect the operation of the valve. Visible
tracking is normal. Tracking which can be felt is a potential problem.
b. The stem and body surfaces that the thrust bearing and stem
seals contact must be undamaged, clean, and free of pit marks
and scratches.
Flow Control Division
Worcester Controls
18484-F 3
Flow Control Division
Worcester Controls
1 1 Hex Head Bolt
2 1 Wrench Block
3 1 Wrench Extension
4 1 Retaining Nut
5 1 Stop
6 1 Follower
7 1 or 3 Stem Seal (See Note 1)
19 6 Body Nut (21/
2" & 3" 45, 2" 59)
8a 1 Centering Washer (3"–6" Only)
8b* 1 Centering Washer (3"–6" Only)
9 1 Thrust bearing
10 1 Stem
11 1 Body
12 2 Body Seal (See Note 2)
13 1 Ball
14 1 Seat Retainer (See Note 3)
15 2 Seat
16 2 Stop Screw
17 2 Pipe End (BW, SE, SW)
18 6 Body Bolt (21/
2" & 3" 45, 2" 59)
8 Body Bolt (4" 45, 3" 59)
8 Body Studs (6" 45, 4" 59)
4 Body Bolt (2" 59 4-Bolt Design)
19 6 Body Nut (21/
2" & 3" 45, 2" 59)
8 Body Nut (4" 45, 3" 59)
16 Body Nut (6" 45, 4" 59)
4 Body Nut (2" 59 4-Bolt Design)
20 1 Spacer (Actuated Valves Only –
See Note 1)
21 1 or 2 Belleville Washer (See Note 1)
22 2 Centering Ring (2" AF59 only)
23 1 Stem Seal Protector
(V51 Option Only)
24 2 Seat Back Seal
(Used with “A” or “G” Seats Only)
*This washer is not used on all 3"–6"
valves. Reuse existing washer when
present.
NOTE 1:
(1) GRAPHITE STEM SEAL IS USED
WITH 2" AF59 AND VALVES WITH
FILLED METAL (G) OR HIGH-PER
FILL (X) SEATS, INCLUDING (1) OR
(2) BELLEVILLE WASHERS.
(3) POLYFILL STEM SEALS, (1)
PEEK STEM SEAL PROTECTOR, (1)
POLYFILL THRUST BEARING AND
(2) BELLEVILLE WASHERS ARE
USED WITH EXTENDED DUTY V51
OPTION STEM BUILD.
WHEN (2) BELLEVILLE WASHERS
ARE USED THE SPACER IS
DELETED.
NOTE 2:
SOME 2" AND 2
1
/
2
" VALVES MAY USE
METAL “S” GASKETS.
NOTE 3:
MOST 2" 59 4-BOLT VALVES DO NOT
USE SEAT RETAINERS. FOR 2" 59 4BOLT VALVES WITH FILLED METAL
(A) OR (G), OR HIGH-PER FILL (X)
SEATS, TWO-SEAT RETAINERS ARE
USED (ONE ON EACH END OF
VALVE).
Item Qty. Description Item Qty. Description Item Qty. Description
Flow Control Division
Worcester Controls
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function
safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial
service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore
assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation
Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of
satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve
is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning
these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.
For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.
FLOWSERVE CORPORATION
FLOW CONTROL DIVISION
1978 Foreman Drive
Cookeville, Tennessee 38501 USA
Phone: 931 432 4021
Facsimile: 931 432 3105
www.flowserve.com
© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation. 18484-F 9/03 Printed in USA
4. Reassembly:
NOTE: Valves with a pressure relief hole in the ball (V3) must be reassembled with the hole upstream when valve is closed, to ensure that
cavity relief is upstream. Any valve with this V3 option will have an
arrow on the body pointing downstream. This arrow is stamped on the
body or on a metal tag welded to the body.
a. Lightly lubricate the ball, seats, body seals, seat back seals (if
used), stem seal(s), stem seal protector (if any) and thrust bearing
with a lubricant compatible with the media being handled, except
for valves with V20, V33 or V38 options which are assembled dry.
White petroleum jelly is a good general-purpose lubricant. For
oxygen prepared valves (prefix code “X”) use a PTFE-based
lubricant such as Fluorolube S-30 or equivalent.
For valve repair kits with “A” or “G” seats, the filled metal seats
will be lubricated at the factory. If they are not, they should be
lubricated as noted in paragraph section B.4 and also as stated
above. DO NOT operate a newly rebuilt valve using filled metal
seats without break-in lubricant. The seat back seals will be preassembled to the seat backs.
b. On 3", 4" and 6" valves, reinstall stem centering washer(s) into the
recesses in the body. When only one washer is used, it goes
inside recess at top of the body and under the stem seal(s).
c. Place new thrust bearing on stem and insert through body cavity.
The thrust bearing can be distinguished from the stem seals by
the darker color of the 25% filled fluorocarbon used in the thrust
bearing. Thrust bearings and stem seals are the same color and
size, and are interchangeable on 2
1
/
2
" size valves only. For valves
with graphite stem seal and thrust bearing, the stem seal is
metallic sliver gray and thicker than the thrust bearing. See
paragraph section A.3 for handling of graphite parts.
d. Install new stem seal(s) over the top of the stem and down into the
recess in the top of the body. The follower is installed on the top of
the stem seal(s). Place stop (or spacer) onto the valve stem.
If a graphite stem seal is used and does not easily seat into the
body recess, use the follower to gently push it in place. Add new
Belleville washer, concave side up over follower (Belleville
washer is used with graphite stem seal only).
For valves with V51 high cycle stem packing option, the thrust
bearing and stem seals are the same size and color, and they are
interchangeable. A stem seal protector of PEEK material and tan
in color is also used and installed over stem seals.
Two Belleville washers are used with this V51 option and also
with automated valves that have a graphite stem seal, and they
are installed over the follower with the larger diameter sides
touching each other. The stem spacer is not used.
e. Replace retaining nut onto stem. Using handle or wrench to
prevent stem rotation, tighten the retaining nut to fully compress
packing, then back off
1
/
6 turn. Excessive tightening causes higher
torque and shorter stem seal life. For valves with graphite stem
trim tighten retaining nut to fully flatten Belleville(s), then back off
1
/
6 turn.
f. Replace handle assembly (wrench block and wrench extension)
and tighten hex head screw (manual valves only).
g. With the valve in the closed position, (stop plate pointer and/or stem
flats or groove going across pipeline) install ball, new seats, seat back
seals (if any), and seat retainer(s) (if used). Open the valve and install
new body seals or gaskets. The optional “S” gasket body seals (2" and
2
1
/
2" sizes only) are installed with the wide flanges facing inward.
Before putting the center section back between the pipe ends, make
sure that the seat back seals (if any) are located properly inside the
seat groove. If not, seal damage and valve leakage will result.
For 2" AF59 valves, insert centering rings into pipe ends before
installing center section of valve.
h. Place center section between pipe ends and replace bolts or studs
and torque to figures in paragraph section A.2.e.
After the valve is assembled it should be cycled a few times to
ensure that the valve operates smoothly with no chattering of the
ball. The normal operation is an initial high torque to “break”
from the closed position to a smooth running lower torque midcycle, to a high torque at the end of the 90° cycle or open
position. The torque is similar when closing.
When ordering parts, please provide the part name and the
following information from the valve stop plate or welded on
nameplate:
1. Valve size, style and revision number:
e.g., 3" 45 46 RT SE R2 Stem
2. Valve size, style and five-character code, known as a “P”
number, “T” number, “C” number, or similar number the
designation for a non-standard product:
e.g., 4" 4566 RT SW TO914 Ball.
The terminology shown in the parts listings on the previous page
is standard.
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