Flowserve 45 User Manual

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

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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

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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

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2" 720-780 60-65

1

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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

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/

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

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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