Flowserve 4 Series User Manual
Installation, Operation, Maintenance Instructions
Pneumatic and
Electropneumatic Actuators
Series 4, Types 37, 38, 39, 3D and 47, 48, 49, 4D
Flow Control Division
Kammer Control Valves
Index
1 Using Kämmer valves and actuators correctly.
2Unpacking
3 Installation
4 Quick check / Maintenance
5 Methode of operation
6 Remove and install actuator
7 Disassemble and assemble actuator
8 Calibration / Technical data
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.
STOP!
WARNING:
and/or substantial property damage can occur if
proper precautions are not taken.
CAUTION:
In most cases Kämmer valves and actuators
indicates that death, severe personal injury
indicates that death, severe personal injury
indicates that minor personal injury and/
or property damage can occur if proper precautions
are not taken.
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, 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:
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.
indicates and provides additional technical
Before installation check the order-no,
KMEIM0006-00 - 08.03
1
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 deterioration 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
STOP!
Before products are returned to Kämmer
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 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:
If slings are used, be aware that the cen-
tre of gravity of the valve may be above the lifting
STOP!
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 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 (see following table).
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
3.4 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.
2
Flow Control Division
Kammer Control Valves
4 QUICK CHECK / MAINTENANCE
4.1 QUICK CHECK
Before operating, check the valve as follows:
4.1.1 Open and close the valve, and observe the movement
of the actuator stem. The movement must be smooth
and linear.
4.1.2 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).
4.1.3 Check all air connections for leaks.
4.1.4 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.
4.1.5 Check fail-safe position. To do this, close supply
pressure and observe whether the valve opens or
closes as defined.
4.1.6 After use at fluctuating temperatures, re-tighten all
bolt connections and check for leaks.
4.2 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“.
4.2.1 Examine gaskets for leaks and if necessary re-tighten
bolts (see Fig. 1).
4.2.2 Check bellows gasket and test connection - if present
- for external leaks.
4.2.3 Check valve for damage caused by corrosive residues
or corrosive vapours.
4.2.4 Clean valves and repaint as necessary.
STOP!
Warning:
clean the actuator/valve with a damp cloth only.
To prevent a buildup of electrostatic charge
4.2.5 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.
4.2.6 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.
STOP!
WARNING:
all moving parts. Failure to do so can lead to serious
Keep hands, hair, clothing, etc. away from
injury.
4.2.7 Check all accessories for firm seating.
4.2.8 If possible, close supply pressure and check the failsafe position.
4.2.9 Check stem boot for wear.
4.2.10 Check actuator for leaks. To do this, spray housing,
air connections and plug stem guide with leak spray
and check for any bubble formation.
4.2.11 Clean plug stem.
4.2.12 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.
3
5 Method of operation (actuators with integral Kämmer positioner)
5.1 P/P Actuator
The actuator with integrated pneumatic positioner works on the force balance principal, which ensures that the
position of the actuator stem is proportional to the value of the input signal (see figs. 1 and 2).
An increased signal to the double diaphragm assembly creates an unbalanced condition. The pilot valve then
moves to cover the vent, increasing the positioner output pressure to the actuator diaphragm until the forces of
the positioner spring and the double diaphragm are equal. The positioner output is then stabilized at an amount
necessary to maintain the desired valve position.
Flow Control Division
Kammer Control Valves
Signal input
Fig. 1: P/P - Positioner
Supply
To actuator
Vent
4
Range adjustment screw
(max. 3 turns)
Flow Control Division
Kammer Control Valves
Supply output to
actuator diaphragm
Supply input
1.4–4.2 bar (20–60 psi)
Pilot plug
(see detail below)
Signal input
0.2–1.0 bar
(3–15 psi)
Double diaphragm
Adjusting nut
Seat ring
Vent
Positioner spring
Supply input
1.4 – 4.2 bar
(20 – 60 psi)
Pilot valve
Supply to
actuator diaphragm
Balancing plate
Pilot plug
Fig. 2: P/P - Positioner
Vent
5
5.2 I/P Actuator
The I/P transducer, which is an integral part of the actuator, converts the standard electric signal
(0/4 – 20 mA) into a standard pneumatic signal (0.2 – 1.0 bar) by means of a system of light weight moving
parts. This form of signal conversion is extremely insensitive to shocks. The pneumatic signal is supplied to the
integrated pneumatic positioner.
The pneumatic positioner works on the force balance principal, which ensures that the position of the actuator
diaphragm is always directly proportional to the value of the instrument input signal pressure (see figs. 3 and 4).
An increased signal to the double diaphragm assembly creates an unbalanced condition. The pilot valve then
moves to cover the vent, increasing the positioner output pressure to the actuator diaphragm until the forces
of the positioner spring and the double diaphragm are equal. The positioner output is then stabilized at an amount
necessary to maintain the desired valve position.
Flow Control Division
Kammer Control Valves
Signal
To actuator
Supply
Vent
Fig 3: I/P Positioner
6
Transducer
Flow Control Division
Kammer Control Valves
Signal
0/4 – 20 mA
Signal input
0.2–1.0 bar (3–15 psi)
Range adjustment screw
(max. 3 turns)
Double diaphragm
Adjusting nut
Seat ring
Supply output to
actuator diaphragm
Supply input
1.4–4.2 bar (20–60 psi)
Pilot plug
(see detail below)
Vent
Positioner spring
Supply input
1.4 – 4.2 bar
(20 – 60 psi)
Pilot valve
Balancing plate
Fig. 4: I/P Positioner
Supply to
actuator diaphragm
Vent
Pilot plug
7
Flow Control Division
Kammer Control Valves
2
1
Series 47 / 48 / 49
(without positioner)
2
1
3
4
Series 37 / 38 / 39
(with positioner)
Fig. 5
8
Loading...