Flowserve 50165 User Manual

USER INSTRUCTIONS

Nordstrom

Figure 50165 and 50169
Dynamic Balance® Iron Plug Valve

FCD NVENIM2006-00 09/05 (Replaces IOM-50169)

Installation

Operation

Maintenance

Experience In Motion

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Contents

1 Valve Selection 4

Introduction
Pressure/Temperature Rating
Bending Strength
Pressure Surge
Throttling Service
Temperature Changes
Over-pressurization
Trapped Pressure
Material Compatibility
Operating Effort

2 Shipping and Storage

Introduction
Handling
Storage

3 Installation 1

Introduction 1
Inspection 1
Flanged Joint Assembly 1
Testing and Adjustment 1

4 Operation and Maintenance 1

Introduction 1
Operation, Manual Valves 1
Operation, Power Actuated Valves 1
Fluid Dynamics of Shutoff Valve Operation 1
Noise 1
Maintenance 1

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5 Dynamic Balance Iron Plug Valve Maintenance 18

Notice 1
Economics of Valve Repair 1
Customer Service 1
Field Service 1
Video Tapes 1
When You Call or Write... 2
Introduction 2
Basic Construction Principles 2
Sealant System 2
Design Features 2
Valve Front Identification 2
Gearing 2
Sealants 2
VXX Valve Purge 2
Sealant Injection Equipment 2
Valve Maintenance 2
Basic Sealant Injection 2
Valve Maintenance: Troubleshooting 2
Detail Sketch: Stem End Detail – Wrench Operated Valve 3
Detail Sketch: Stem End Detail – Gear Operated Valve 3
Detail Sketch: Cover End Detail – Ball Seat Arrangement 3
Technical Data: Procedure for Tightening Cap Screws 3

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Valve Selection

1

Introduction

It is beyond the scope of this manual to make recommendations for specific applications because
misapplication of a valve type could result in operating problems that adversely affect system safety and
efficiency. This manual is intended to call attention to important considerations in the selection of valves.
The manual addresses the important subjects of Shipping and Storage, Installation, and Operation and
Maintenance. Observance of the recommendations and cautions offered herein will provide increased
assurance of satisfactory valve performance.

The valve industry offers a wide variety of valve types and materials for use in industrial piping
applications. There are usually several possible choices for a given requirement; any one valve may offer
significant advantages and/or limitations compared to another valve. It is good practice to consult the
manufacturer regarding specific requirements. The purchasing function includes the responsibility for
securing the required valves at the lowest cost, but must also ensure that the valves purchased are in
fact satisfactory for the intended service. The lowest total user (life cycle) cost criteria should be used
only in choosing between alternatives that are known to satisfy the service requirement.

Pressure/Temperature Rating

The pressure/temperature rating of the valve must be properly selected for the service requirement.
If the service involves a temperature above 100ºF (38ºC), the valve pressure rating at the service
temperature must be verified as meeting the requirements of the application.

If system testing will subject the valve to a pressure in excess of its working pressure rating, then the
intended testing pressure and a statement explaining whether the test pressure is through the opened
valve or a differential across the closed valve, should be included in the purchase specification.

Some Source References for Pressure-Temperature Ratings: MSS SP-78; Cast Iron Plug Valves,

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Flanged and Threaded Ends

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Bending Strength

Piping systems are subject to mechanical constraints at fixed support points such as rigid nozzles,
anchors, etc. Cold springing at assembly and system temperature changes, together with gravity,
possible inertia loads, landslides, non-uniform subsidence in buried lines, etc. all potentially affect the
bending moment at various points in the piping.

Valves are also subjected to the bending moment occurring in the adjacent pipe that is in addition to the
normal pressure loading. Bending loads can cause deformation in valve bodies that can be detrimental
to valve functional performance. It is therefore a recommended design practice to avoid locating valves
at points of large bending loads.

In many cases, normal valve design practice results in a body strength greater than the strength of the
adjoining pipe thereby providing inherent protection against valve damage. In other cases, piping condi­tions or systems designs may actually increase the possibility of harmful valve body deformation.

The following are examples of possible problems.

a) Basic “standard” valves that are made into “venturi” type valves by providing enlarged end connec

tions on the smaller standard basic valves.

b) Any “standard” valve installed in heavy-wall “overweight” piping where the extra thickness may e

the pipe to be stiffer and stronger than the valve.

Valve designs having a high body bending strength should be used if there is reason for concern
regarding possible high bending loads.

Pressure Surge

Closure of a valve in a flowing fluid line causes the velocity of the fluid to be reduced to zero. If the fluid
is a relatively incompressible liquid, the inertia of an upstream column produces a pressure surge at the
valve whose mag nitude is inversely proportional to the time required for closure. The surge pressure
is also proportional to the length of the upstream fluid column and the fluid velocity prior to closure
initiation. If the application involves a long upstream line, a long downstream line, high velocity, and/or
rapid closure, singly or in any combination, the possibility of an unacceptable pressure surge should be
investigated.

Also to be considered are condensation-induced pressure surges which occur when a fluid velocity
change is caused by rapid condensation or when a slug of water is accelerated by contact with steam.
An example would be when condensate collects on one side of a closed valve that has steam on the
other side. Opening the valve causes collapsing steam voids, sharp pressure surges and acceleration
of condensate slugs. Condensation-induced pressure waves can result in pressure pulses that are
significantly higher than those produced by a sudden valve closure. In such events, non-shock rated
gray iron valves installed in steel piping systems are particularly vulnerable to catastrophic failure. Traps
are required to prevent condensate accumulation and “blow off’ valves, located at the low point in the
system, are needed to ensure condensate drainage. Operation and maintenance personnel must be
aware of the function of these devices in relationship to the “shutoff’ valve operation and the necessity
for them to function properly.

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Throttling Service

Valves used to control the rate of fluid flow may be subject to severe fluid turbulence that can have the
effect of creating a high-energy conversion within the valve and piping system. This energy conversion
is usually indicated by high noise levels, either from cavitation of liquids or shock waves from gases.
(The noise in a water faucet is an example of a low-level cavitation noise.)

The possibility exists for mechanical damage to the valve and piping system when throttling of liquid
flow results in severe and continuous cavitation conditions. Likewise, with gas flow under severe throt­tling conditions, shock waves can possibly result in damage to the system.

Flowserve Nordstrom Valves should be consulted on proper valve selection for throttling applications.

Temperature Changes

Valve structural materials expand with rising temperatures and contract with falling temperatures.
Generally, increasing temperature causes a decrease of mechanical strength that is regained on return
to a lower temperature. A condition of non-uniform temperature in a structure may impose significant
thermal stresses or distortion with possible adverse effect on valve performance.

The possibility of thermal stress fatigue should be considered in applications involving frequent
temperature cycling. This possibility is increased by any one or a combination of the following:
increasing temperature range, increasing temperature level, increasing rate of temperature change,
increasing thermal conductivity of the fluid, increasing thickness of metal sections or increasing the
number of cycles. In some cases, thermal cycling may also increase the tendency for stem seal leakage.

Over-pressurization

Dynamic Balanced iron plug valves are not provided with a pressure relief device. It is the user’s
responsibility to provide a relief device as part of the system in which the valve will be used.

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Trapped Pressure

When a closed valve containing liquid is heated (e.g., from process condition, radiation or solar heating)
the cavity pressure will increase due to volumetric expansion or vaporization of the liquid. Conversely,
cooling an undrained cavity below the freezing point may also result in volumetric expansion of the
media. These expansions can result in extremely high pressures occurring in the valve.

The purchaser should consider the necessity of providing positive means for prevention of such over­pressurization where these conditions can be anticipated.

Material Compatibility

It is important that valve structural materials and lubricants be chemically compatible with the other
piping system components, line fluids and the environment. Guidance should be obtained from
informed sources such as NAI or the system engineers whenever there appears to be reason for such
concern.

Operating Effort

Manually operated valves are usually designed to require a reasonable amount of physical effort applied
to a handwheels or handle to open or close at rated working pressure. However, typical use of a valve
may involve a lower working pressure thereby substantially reducing the differential pressure across
a valve closure element and a resulting reduced operating effort. Lower operating effort can also be
achieved by opening a bypass valve in some cases.

In all cases, the purchaser should determine that the manually operated valves selected will be capable
of being operated under the anticipated operating conditions by the personnel required to perform such
operation. Oversize handwheels and gear operators will require specific operator training to prevent
applying damaging overloads. NAI should be consulted for specific instruction on operating torques.

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Shipping and Storage

2

Introduction

Flowserve recognizes the importance of maintaining the as-built condition of valves, and has prepared
this section to call attention to important considerations in the handling of valves prior to installation.

Industrial valves as manufactured, tested, and ready for delivery to users, are typically well-designed
products that are property fabricated and inspected and capable of giving satisfactory service. Valves
enjoy a degree of inherent protection against degradation by impact, impingement or invasion of
harmful materials after installation. However, the intervening period between the production test and the
installation in line may involve substantial exposure to such degradation that can adversely affect the
subsequent service performance of the valves.

Observance of the recommendations and cautions offered herein should provide increased assurance of
satisfactory valve performance.

Handling

Appropriate care in handling valves should be complementary to the degree of protection provided in
preparation for transport. A basic consideration in handling valves should be to avoid damaging the
protection provided for shipment. An obvious general rule is that valves should never to thrown or
dropped. Valves whose size requires handling by crane or lift truck should be “slung” or “rigged” care­fully to avoid damage to exposed valve parts. Handwheels and stems, in particular, should not be used
as lifting or rigging points for large valves.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Storage

The problems to be considered in regard to storage are generally the same as those previously
discussed relative to preparation for transport. The time element is important as conditions that would
not be seriously harmful for a period of a few days could result in need for costly reconditioning if
extended over weeks or months.

Valve end protectors should not be removed unless necessary for inspection and installation.

Protection against weather should be provided. Ideally, valves should be kept indoors with actual valve
temperatures always higher than the dew point.

Valves should be supported off the ground and/or pavement and protected by a watertight cover if
outdoor storage is unavoidable.

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Installation

3

Introduction

A most critical point in time in the life of an industrial valve is the moment of installation. The possibili­ties for degradation of the valve are numerous. Conversely, the exercise of proper care in this process
will assure increased probability of trouble-free valve service.

The valve industry has prepared this Section in order to provide useful information, warnings and
reminders, in a format that will be helpful to all concerned. A judicious selection of these pages,
delivered to the installation site with the valve itself, will provide the opportunity for the person having
the greatest need to know to be informed or reminded of what is most important at the time such
information can be the most useful.

Inspection

The testing and inspection required by applicable standards and specifications make it generally reason­able to assume that a new valve, about to be installed in a piping system, has been properly designed
and manufactured. Nevertheless, it is important to recognize that in the transport, handling and storage
of a valve between the time of manufacture and the time of installation, there are numerous possibilities
for accident or error that could adversely affect valve performance.

It is therefore important to determine that the valve is in satisfactory condition before installation. The
following points are generally applicable and may be helpful in avoiding subsequent valve problems.

a) Carefully unpack the valve.

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b) Make a point of noting any special warning tags or plates attached to or accompanying the valve

and take any appropriate action.

c) Check the valve for any marking indicating flow direction. Make sure that the valve is installed in the

proper flow orientation when a flow direction is indicated on the valve.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

d) Inspect the valve interior to the extent practical through the end ports. Make sure it is reasonably

clean, free from foreign matter and harmful corrosion. Remove any special packing materials.

e) If practical, actuate the valve through an open-close-open or close-open-close cycle. Inspect

any significant functional features such as guides or seat faces that are made accessible by such
actuation.

CAUTION: Avoid contact with the valve closure element during cycling. It is usually desir-

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able to leave the valve closure member in the position in which it was shipped following
such inspection.

f) Check the piping to which the valve is to be fastened for proper alignment, cleanliness and freedom

from foreign materials immediately prior to valve installation.

Flanged Joint Assembly

Flanged joints depend on compressive deformation of the gasket material between the facing flange
surfaces for tight sealing. The bolting must provide the mechanical force necessary to maintain the
compressive stresses on the gasket, as well as resist the normal pressure forces tending to separate
the joint. It should be recognized that with “brute force” alignment of misaligned flanges, sufficient
bolting force may not be available to sustain the required gasket loading and to resist the load caused
by the pressure separating force, resulting in a joint leakage problem. The following practices should be
observed for satisfactory flange joint make-up.

a) Check the mating flange facings. Do not attempt to assemble the flanges if a condition is found

which might cause leakage (e.g., a deep radial groove cut by a retracting cutting tool or a dent
across the face caused by mishandling), until the condition is corrected

b) Check the gasket materials. See ASME B16.5 for additional requirements for flange joints using low

strength bolting, (e.g., gray iron flanges or Class 150 steel flanges). Metal gaskets (flat, grooved,
jacketed, corrugated, or spiral wound), should not be used with these flanges.

Types of Gaskets

There are two basic styles of gaskets used: full-face gaskets and flat ring gaskets. Full-face gaskets
cover the face of the flange and the bolting goes through them. Flat ring gaskets extend only to the
bolting.

What the Codes and Standards say about flanges and gaskets
ASME B16.1

tion about these flanges is shown in the Flowserve Nordstrom Iron Plug Valves brochure under
Drilling Templates, Flange Dimensions, and Bolting Data.

ASME B16.1, Section 5.2

installing items that have cast iron flanges. A footnote to this section reads as follows:

For Class 25 and Class 125 flanges note: The carbon steel bolts prescribed for the flanges in this
standard are based upon using a flat “ring” gasket that extends to the bolts.

Where cast iron-to-cast iron flanges or cast iron to steel flanges are used with full-face gaskets,
higher strength bolts may properly be used.

Where cast iron flanges are bolted to steel flanges and flat ring gaskets are used, carbon steel bolts
prescribed in this standard shall be employed.

covers Class 125, 250, and 800 Cast Iron Flanges and Flanged Fittings. Informa-

recommends the use of bolting conforming to ASTM A307 Grade B for

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

MSS SP-92 in part, reads as follows:

Section 3.4c

ductile materials. The use of lower strength bolting is recommended to reduce the possibility of
overstressing the flanges by excessive flange bolt preload. Full-face gaskets on flat flanges provide
desirable protection against flange breakage by over-torquing of flange bolts. A flat-face flange
should not be installed against a raised face flange.

Good preassembly alignment is especially important in cast iron flange joints in order to assure that
adequate gasket compression can be achieved without excessive bolting loads.

Section 3.4d

provided for iron flanges (see Section 3.4c above) or Class 150 steel, metal gaskets (flat, grooved,
jacketed, corrugated, or spiral wound), should not be used. See ASME B16.5 for additional require­ments.

In summary, all of this means that the following is to be considered:

1. Either full-face or flat ring gaskets may be used in conformance with recognized standards.

2. The use of flat ring gaskets requires the use of low-strength ASTM A307 Grade B bolting.

3. The use of full-face gaskets should minimize flange breakage.

4. Cast iron flange breakage is always a possibility if the mating flanges are not properly aligned.

c) Check the gaskets for freedom from injurious defects or damage.

d) Use care to provide good alignment of the flanges being assembled. Use suitable lubricants on the

bolt threads. Sequence the bolt tightening to make the initial contact of the flanges and gaskets as
flat and parallel as possible. Tighten the bolts gradually and uniformly to avoid the tendency to twist
one flange relative to the other. Use of a torque wrench is helpful to ensure correct and uniform final
tightening of the flange bolting. Parallel alignment of flanges is especially important when assem­bling a valve into an existing system. It should be recognized that if the flanges are not parallel,
then it would be necessary to bend something to make the flange joint tight. Simply forcing the
flanges together with the bolting may bend the pipe or it may bend the valve. This is particularly true
in large diameter piping. Such conditions should always be brought to the attention of someone
capable of evaluating the bending condition and the corrective measures that need to be taken. The
assembly of certain “short pattern” valves between mating flanges requires that the installation be
checked for any possibility of interference between the moving parts of the valve and the adjacent
pipe, fitting, or valve.

Cast iron flanges are less “forgiving” of improper installation than flanges of

Check gasket material. For flange joints using low-strength bolting, such as may be

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CAUTION: Torque wrenches should always be used to assure proper tightening of the flange

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bolting. If, in the tightening process, the torque on a given bolt has been increasing with each
part turn and then is observed to remain unchanged or increase a much lesser amount with an
additional part turn, that bolt is yielding. That bolt should be replaced and discarded since it is
no longer capable of maintaining the proper preload.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Testing and Adjustment

It is reasonable to assume that a valve that has been properly inspected and installed will be in good
condition and ready to operate. However, the actual operability of a valve can only be proved by test.

A first observation can be made by actuating the valve through an open-close-open or close-open-close
cycle. If no obvious problems are observed, an actual test at pressure may then be applied while tight­ness and operability are checked.

It is common practice after the installation of a piping system to clean the system by blowing through
the system with a gas or steam or flushing with a liquid to remove debris and/or internal protective films
and coatings. It should be recognized that valve cavities may form a natural trap in a piping system and
material not dissolved or carried out by the flushing fluid may settle in such cavities and adversely affect
valve operation.

CAUTION: If the system is being cleaned with a cleaning material (gas or liquid) different from

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the line media, the effect of the cleaning material upon the valve sealant must be evaluated prior
to use.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Operation and Maintenance

4

Introduction

An industrial valve, reasonably matched to a particular service application and properly installed in a
piping system, can be expected to have a long service life with a minimum of attention. Unlike totally
passive components such as pipe fittings, vessels, etc., valves are a special kind of “machinery”
having moving and wearing parts. The satisfactory performance of these working parts depends on the
long-term preservation of various highly finished surfaces. Therefore, it is important to give adequate
attention to the specific requirements for proper operation and reasonable maintenance of all valves
throughout their service life.

Operation, Manual Valves

Most valves are actuated manually with rotational movement of a handwheel, wrench, handle, etc.
Care is required to assure that such movement is in the correct direction, is not too fast or too slow
and is applied through the proper distance. The terminal positions, open and/or closed, have important
functional significance.

Plug valves do not rely on stem actuating force to provide tight shutoff. However, the correct position of
the closure element in these types of valves is very important. In some cases the effort required to move
the closure element might increase substantially during final approach to the closed position, giving
a false impression of having reached the required position. Failure to get to and stop at the full closed
position can result in leakage and consequent damage to the sealing elements.

Plug valves require correct positioning of the closure element to seal properly. Closing travel should not
stop until a positive stop is reached or a position indicator reaches the “closed” position.

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Purchase specifications requiring restrictive maximum forces to be applied on levers or handwheel rims
may also lead to damaging forces being applied to valves or actuators in actual practice as larger forces
are some-times applied in the field. Users should consider this fact in training of operating personnel.
Be sure to consult the gearing manufacturers maintenance manual for more detailed information.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Operation, Power Actuated Valves

Functionally, closure performance characteristics and backseating considerations are associated with all
valve types regardless of the means of operation. Satisfactory valve performance with power actua­tion requires appropriate programming of the various requirements and constraints into the actuator
controls. Therefore, the actuator should be adjusted to deliver an adequate opening, running and closing
force to suit the anticipated service conditions. For position-sensitive valve types, the closing opera­tion should be position controlled by external stops or limit switches. Be sure to consult the actuator
manufacturer’s operation manual for more detailed information.

Data required for selection and adjustment of power actuators should be delineated clearly in purchase
specifications for actuated valves. This data shall include but not necessarily be limited to:

a) Upstream pressure and differential pressure conditions at which both opening and closing shall

be required. Specify direction if applicable. Additionally, specify if valve operation is required under
high-flow “blow down” conditions.

b) Speed of operation required or the maximum time for opening and/or closing. Also, specify a

minimum time if required due to fluid dynamics.

c) Electrical power supply available (AC or DC voltage, phase, frequency) for electrical power actuators

or controls. Operating conditions for reduced voltages should also be considered.

d) Pneumatic pressure available for pneumatic actuators (cylinders or diaphragms). Also, specify

fail-open, fail-closed, fail-as-is, or any special requirements.

e) Requirements for position indication signals.

Actuator selection and adjustments should normally be made by NAI based on published literature
and/or technical advice of actuator manufacturer. NAI should be consulted when a manually operated
valve must be retrofitted with a power actuator.

CAUTION: Some valve actuators, when sized to provide specified loading, may have much

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higher output at maximum switch or control settings and therefore be capable of damaging
valves if misadjusted. Valve and actuator manufacturer instructions should be followed closely
to prevent overloading valve stems, backseats and other structural parts. Successful operation
of power operated valves requires a diligent coordination of the skills and efforts of the valve
specifier, NAI and the actuator manufacturer. Most applications are problem-free, but miscom­munication can lead to unreliable operation at one extreme and possible valve or actuator
damage at the other extreme.

Fluid Dynamics of Shutoff Valve Operation

A flowing fluid in a piping system has mass and velocity. Anything that causes a moving mass to
change its velocity will experience a reacting inertia force in proportion to the magnitude of the mass
and the rate of the imposed velocity change.

However, in the flow of gases the reacting inertia forces are inherently moderated by the compressibility
of the fluid that permits the instantaneous velocity change to be effectively limited to the mass of fluid
in the immediate vicinity. This, in addition to the self-cushioning capacity of the fluid column in the
upstream pipe, effectively precludes any significant problem of pressure surge in rapidly closed valves
in gaseous fluid piping.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

In contrast, the inertia of the fluid column in a liquid pipeline is not so easily overcome. Its relative
incompressibility provides no such cushion or proximity-limiting mechanism. The entire upstream fluid
mass is required to be decelerated at once by the closing valve and the resulting pressure surge may be
of sufficient magnitude to cause structural damage.

An additional potential problem can occur downstream from the closing valve. This may be described as
fluid column rupture and involves the inertia of the fluid column carrying it away from the closed valve
with the proximate space being occupied by a bubble of the fluid vapor or, simply, a substantial vacuum.
If there is sufficient backpressure in the line, the fluid column will reverse its velocity and close the void
created by the fluid column rupture and causes another pressure surge when it reaches the valve.

It should be recognized that pressure surge intensity is roughly proportional to the length and velocity of
the fluid column upstream of the closing valve and inversely proportional to the time taken to close the
valve. Fluid column rupture and return surge intensity is proportional to the same condition on the other
side of the valve in addition to the back pressure in that section of piping. Therefore, a slow closing is
helpful in limiting the magnitude of the pressure surge phenomena.

In large long distance liquid pipelines it is critically important to evaluate pressure surge possibilities
and to establish limits on the speed of closure of the flow shutoff valves. In operating such valves or
setting the speed of operation of power actuated valves, design limits on speed of closure should be
conscientiously observed.

Rapid closure of a valve in any flowing liquid pipeline can cause a substantial pressure surge that may
manifest itself in a sharp “bang” or possibly a series of “bangs”. This is frequently referred to as water
hammer. This phenomenon can occur in any flowing liquid line and is not limited to waterlines. Rapid
closing of a shutoff valve in a flowing liquid line should be avoided especially during the last part of the
stem travel.

Noise

There are many different valve-operating conditions that can result in noise. Such noise may be
“normal” considering the nature of the fluid and the pressure, temperature and velocity of flow. There
may be a “wind” noise in a flowing gas line. There may be clear or hoarse whistling sounds resulting
from the shape of the flow passage, including the flow path through a valve. Cavitating conditions in a
liquid line can cause a “white noise” that ranges from a whisper to a sound like rocks and gravel to a
deafening roar. There may also be mechanical noises as a result of movement of internal parts acted on
by the flowing fluid. Some of these noises may be relatively harmless insofar as system integrity and
performance are concerned. Mechanical damage in lines with compressible fluid is generally limited to
points of sonic or supersonic velocity, or where a vortex resonance with an internal component causes
movement and wear or breakage.

Vortex resonance with an internal component may also cause problems in liquid service. In addition,
noise may be evidence of cavitation which has the potential for causing mechanical, damage, including
massive erosion of the metal walls of a valve or pipe walls and/or other internal components.

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A full technical discussion of all of the sound-generating mechanisms is beyond the scope of this docu­ment. Nevertheless, it is recommended that an evaluation be made of any condition of remarkable noise
in a piping system at least to the point of understanding its cause. If a valve is involved, a determination
should be made as to whether the valve is the source or just happens to be the location of the noise.
Usually, if the valve is the source, the noise can be “tuned” by slightly “throttling” the valve.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Mechanical or high intensity fluid noise in the vicinity of a valve may be a warning of potentially serious
trouble. Expert assistance should be obtained from system engineers or the valve manufacturer to
determine the cause and evaluate possible need for action.

Noise emitted from a closed valve is a special case that may indicate seat leakage requiring repair. A
whistling sound may indicate sever erosion of seating surfaces while “gurgling” or “popping” sounds
may signify less severe leakage.

Maintenance

Valves are properly considered to be a hybrid structure, a combination of a pressure vessel and oper­ating machinery. Maintenance procedures therefore, must reflect the requirements of the occasional
opening or closing of the “machinery” and the predominant operating condition of the valve where
pressure is continuously applied and nothing is moving. The important performance parameters are
pressure boundary integrity, actuating effort required and internal leak tightness. Maintenance should
logically address the importance of preserving these performance parameters.

Valves that remain in one position for long periods of time may be hard to operate and/or not function
as well as when originally installed. This reduction of operability can result from either a loss of effective
lubricants, aging of packing, surface corrosion of moving parts, or an accumulation of deleterious
solids. In some applications it may be desirable to schedule periodic partial or full cycle exercising of
such valves.

Pressure boundary integrity requires basically sound pressure-containing parts, a pressure-tight static
seal at assembly joints and in most cases, an effective working seal between a moving stem and the
valve body. Maintenance of pressure boundary parts and the static seal of assembly joints are not
usually considered to be a problem. However, continuous monitoring is recommended to confirm that
problems do not occur. The need for paint protection against corrosion of exposed piping should be
obvious from normal observations of the system.

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Dynamic Balance Iron

5

Notice

This manual is intended as a maintenance guide for Flowserve Nordstrom Dynamic Balance Iron Valves.
Before working on any Nordstrom valve or related product, the reader should review and fully comply
with this manual and its warnings as well as the reader’s company safety procedures.

If anything in this manual is unclear, contact the Flowserve Nordstrom Valves Customer Service Depart­ment for assistance.

Flowserve and its employees are in no way responsible for damage to property or for personal injury or
death that may result through the use or misuse of any Flowserve Nordstrom Valves product, publica­tion, audio or visual aid.

Economics of Valve Repair

The instructions listed in this maintenance manual are intended to serve as a basic guide for recondi­tioning or repairing all Dynamic Balance Plug Iron Valves.

Plug Valve Maintenance

18

Whether a used valve justifies repair is an individual matter and should be decided by comparing the
probable cost of repair with the cost of purchasing a new valve for replacement. Naturally, the cost of
repair will depend upon the amount of work involved and the cost of parts, if any are required.

The reclamation of Dynamic Balance iron valves of all sizes and figure numbers is usually worthwhile
when the condition of the valve is such as to require only cleaning, inspection, and reassembly with new
packing, diaphragms, and gaskets.

In severe cases, the valve body may require boring and fitting an oversize plug. Repairs of this extent
are economically justified for a great many sizes and figure numbers of Dynamic Balance valves. Only
general indications can be given since repair costs will vary due to differences in labor and overhead
rates in various shops.

Before any repair is started, it is suggested that the cost of non-guaranteed repair valve performance
be considered. Many times valves repaired by other than the original equipment manufacturer can cost

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

more in faulty performance and short life than is necessary. In order to maintain the high standards of
performance expected of Flowserve Nordstrom Valves, we offer the service of valve remanufacturing
that provides a three-year warranty at a percentage of new valve cost!

Many Nordstrom valve users find it more economical to have Nordstrom remanufacture their valves
than to repair them themselves because of the following features and benefits:

1. Repair work guaranteed under a three-year warranty.

2. Valve is tested to new valve standards.

3. A like-new valve at a percentage of a new valve cost.

Customer Service

If at any time you require assistance from Nordstrom in the maintaining of your Dynamic Balance valve,
feel free to call your Customer Service Representative, at the appropriate number listed on the back
cover of this manual.

Or write us at:

Flowserve Sulphur Springs Operations
1511 Jefferson Street
Sulphur Springs, Texas 75482
USA

Or FAX us at: [phone]

Field Service

Our Sales Representatives are the best in the business. They can provide you with technical informa­tion about your Dynamic Balance Plug Valve, and are available to visit your facility to conduct general
maintenance seminars.

In addition, Nordstrom maintains a highly skilled staff of Service Representatives who provide mainte­nance assistance over the telephone, or visit your facility to conduct maintenance seminars or to assist
you in the maintenance and repair of your Dynamic Balance iron valve.

DVDs

It is often difficult to assemble the appropriate people for training. Nordstrom has produced a series of
DVDs that allow training at your convenience. For your Dynamic Balance iron plug valves, we suggest:

• Operation and Maintenance of Nordstrom 400-D Handgun and Hypregun-Plus

To obtain copies of this training video, contact your Flowserve Sales Representative or Customer
Service Representative.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

When You Call or Write...

Be sure you provide the correct information and/or part numbers for your Dynamic Balance plug valve.
Over the years there have been design changes due to our continuing effort make a great valve even
better. It is very important that we are provided the information necessary to correctly identify your
valve.

The following information, located on the valve Nameplate, is required to ensure the correct information
and/or parts are provided for your valve:

1. The valve Size and Figure Number (including any prefixes or suffixes).

2. The Bill of Material Number.

Introduction

The maintenance procedures outlined in this manual are designed to help you reestablish quick and
easy operation, drop-tight shutoff, and a long service life of your Dynamic Balance plug valves.

Some procedures listed in this manual can be performed with the valve in-line and under pressure while
others require that the valve be removed from line pressure. Those procedures that require the valve to
be removed from line pressure will be so noted.

Pressure can become trapped in the valve body cavity even after line pressure has been removed.

Before removing pressure-retaining parts, be sure to:

• Cycle the valve once line pressure has been removed, and

• Stand away from the valve when removing the Gland and Cover.

A number of procedures in this manual may cause flying debris that may cause eye injuries. Safety
glasses should be worn at all times while repairing and maintaining Dynamic Balance valves.

The procedures described in this manual are intended only for Dynamic Balance Plug Valves. Do not
follow these procedures for any other brand or type of valve.

Basic Construction Principles

So that you may develop a plan of proper maintenance, it is best to understand the basic principles
involved in Dynamic Balance iron plug valves.

The lubricated plug valve was invented by Sven Nordstrom in 1914, and basically represented an
application of Pascal’s Law of Hydraulics to the dry plug cock. Mr. Nordstrom created a valve sealant
system to prevent taper lock in plug valves and enable the valve closure member to be operated easily.
Over the years, as valve services became more severe and as technology improved, several design

20

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

improvements were made. However, the basic principle of the use of Pascal’s Law has not changed and
continues to be used in the sealant systems of lubricated plug valves today.

All Nordstrom Lubricated Plug Valves use the same basic principles of design. In the Dynamic Balance
Plug Valve, these principles consist of a body, plug and stem, cover, adjustment member, and sealant.
The function of each of these items is as follows:

1. The

Body connects the valve to the pipeline. The body also mates with the Plug to form a pressure

vessel, capable of operation under various pressures and temperatures.

2. The

Plug, rotated by operation of the Stem, has a tapered surface designed to mate with the body

taper bore to provide tight shutoff.

3. The

Cover prevents external leakage and is designed to allow a finite floating of the plug.

4. The Adjustment Member

the Body.

5.

Sealant is an integral part of all lubricated plug valves and has three functions:

• To ensure bubble-tight shutoff on hard-to-hold line media by acting as a secondary seal against
seat leakage.

• Provides a flexible and renewable seat, eliminating the need to force fit or replace sealing parts to
obtain a seal.

• Applies Pascal’s Law by providing the hydraulic means necessary to push the plug from its
tapered seat in the body.

is provided so the position of the Plug can be set in the proper relation to

Sealant System

Flowserve Nordstrom Valve Sealant functions as an integral part of the lubricated plug valve. Sealant is
the basic improvement over the dry plug cock. In order for sealant to be effective, the valve requires a
system of internal channels - the Nordstrom Sealdport Grooving System.

The Nordstrom Sealdport Grooving System provides complete shutoff of line media regardless of the
flow direction of material through the valve. Nordstrom valves can be lubricated with the plug in any
position while the valve is subjected to line pressure. With the plug in the closed position, the down­stream port is completely surrounded by a film of Sealant between the body and plug seating surfaces.
When rotating the plug between the open and closed positions, the grooves exposed to the valve flow
passages are disconnected from the sealant system.

By maintaining a periodic sealant injection schedule, the Sealdport grooving system will sustain a pres­surized sealant system regardless of whether the valve is in the open, closed or throttled position.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Design Features

To better understand the Dynamic Balance plug valve, listed are the principal design features. Refer to
pages 34–37 for illustrations.

1.

Stem Wrench operated stems have wrench flats which align the wrench handle with the flow
passage of the Plug, thus becoming an easily visible position indicator.

2. Stem Seals O-rings are used for stem sealing.

3. Plug Balancing Spring Designed to preload the plug to prevent vibration and thermal cycling

from wedging the plug into the body taper even when the valve is installed upside down.

4. Bottom Balancing Hole An integral part of the Dynamic Balance System. The balancing hole

maintains pressure equalization between the plug port and the bottom of the plug.

5. Balance Hole with Ball Check (not shown) Ensures that pressure above the plug is the same as

or greater than in the plug port.

6. Sealant Injection Fitting Permits restoration of damaged seats for drop-tight shutoff.

7. Stem Weather Seal

stem-to-body joint from hostile environments that can lead to corrosion.

8. Tapered Plug

sealant grooves in the plug match the sealant grooves in the body to form the Sealdport groove
system.

9. Plug Adjustment Screw

valve assembly. A hex-head bolt (or three-bolt cover plate) is provided to reduce the chance of
accidental turning of the Plug Adjustment Screw.

(Wrench operated only) Specially shaped and constructed to protect the

individually matched to each body and lapped to achieve the best possible fit. The

provides a means of properly positioning the plug into the body after

Valve Front Identification

This manual will periodically refer to the valve front. For clarification, the front of the valve will have
these things in common:

• Sealant Injection Fitting

• Handwheel (gear operated only)

Note:

Refer to the Technical Data section for a parts list and exploded view of a “typical” wrench oper-

ated Dynamic Balance Plug Valve.

22

Gearing

Simple or single reduction worm gearing is used on Dynamic Balance iron plug valves.

All gear mechanisms are enclosed in weatherproof housings and packed with gear grease.

A Position Indicator, mounted on the upper end of the gear segment, aligns with the plug port to provide
a visible means of plug port positioning in relation to the flow line of the valve.

During operation, all parts of the gearing have free movement.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Sealants

Valve sealant is a viscous material that resists chemical attack and the dissolving characteristics of line
media. Sealant performs four specific functions in a lubricated plug valve.

1. Drop-Tight Seal

between the body and plug. This seal is formed by sealant transmitted in a system of grooves
around each port. With proper selection of sealant for your particular service, this tight seal can be
retained over a wide range of temperatures and pressures.

2. Lubrication

of the valve by filming over bearing surface irregularities. The film of sealant permits the plug and
body of a plug valve to glide smoothly over each other allowing the valve to operate easily.

3. Renewable Seat

seat. There is no need to disassemble the valve or remove it from the line to repair the seats. Injec­tion of sealant is all that is required.

4. Plug-Jacking

application of Pascal’s Law. Sealant, under pressure developed by the injection of sealant, supplies
the hydraulic means for lifting the plug from its tapered seat in the valve body thus allowing the plug
to float freely in the body and allow easy operation.

A regularly scheduled sealant injection program will allow your Dynamic Balance plug valves to operate
more easily and will extend the service life of your valves. For more information on sealant injection,
refer to Installation, Operation, and General Maintenance Manual for Nordstrom and Dynamic Balance
Plug Valves.

Flowserve Nordstrom Valves supplies many different types of sealant for use in plug valves. When
selecting Sealant for your specific services, please refer to the Nordstrom Valve Sealants brochure, or
consult your Flowserve Nordstrom Customer Service Representative

To secure an absolutely tight seal, the film of sealant works to form a seal

A protective film of sealant prevents metal-to-metal contact of the bearing surfaces

Sealant is a structural part of the valve that provides a flexible and renewable

The fundamental operating principal of the traditional plug valve design lies in the

VXX Valve Purge

VXX Valve Purge, a non-hazardous formulation, was developed for cleaning valves in-line, returning
them to service without disassembly, and eliminating down time. Periodic injection of sealant into a
valve flushes debris from the sealant system and allows sealant to flow more freely. See procedures in
the Troubleshooting section.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Sealant Injection Equipment

So that Sealant injection can be performed easily, Nordstrom offers five designs of heavy-duty valve
sealant injection equipment.

1. 400-D Hydraulic Hand Gun – uses “J” stick sealant and Gun Pak sealant

2. Hypregun-Plus 5Q – uses a five-quart can of sealant

3. Hypregun-Plus 5G – uses a five-gallon pail of sealant

4. 400-A Screw Prime Hand Gun – uses “K” stick sealant and cartridge sealant

5. 400-B five-Gallon Bucket Pump – uses the contents of a five-gallon pail of sealant

For additional information about Nordstrom Sealant Injection Equipment, refer to the appropriate
Nordstrom Sealant Injection Equipment brochure.

Valve Maintenance

NOTE: The procedures described in this manual are intended for use on valves that are in-line.

Proper valve performance depends on:

• A periodic program of Sealant injection to maintain adequate sealant pressure in the valve to ensure
positive shutoff and smooth operation.

• Selecting the correct Nordstrom Valve Sealant for the valve service conditions. Because of variations
in the product temperature, line pressure, and frequency of valve operation, proper sealant selection is
essential. An “all purpose” valve sealant or lubricant does not exist. Only the correct Nordstrom Valve
Sealant can assure proper valve performance.

• The proper application of the correct sealant. Knowing how to correctly inject sealant will keep your
Dynamic Balance plug valve in proper working order without removing it from the line.

Be sure to remember:

1. Sealant injection may be performed with the valve in-line and under pressure.

2. Never attempt to attach or detach the 400-D Hand Gun or Hypregun-Plus while the gun hose is

pressurized.

Basic Sealant Injection

NOTE: High pressures are generated during sealant injection. It is recommended that safety glasses and
thick leather gloves be worn during sealant injection.

1. Before injecting sealant into the valve, determine if the valve is fully open or closed. While the

Dynamic Balance plug valve can be lubricated with the plug in any position, either the full open
or full close position allows the Sealdport groove system to completely distribute the pressurized
sealant to the valve seating surfaces.

24

2. Locate the Sealant Injection Fitting on the side of the valve. Remove any debris from the face of

the sealant fitting and attach your sealant injection device to the fitting. Be careful not to damage
the fitting in any way. A smooth contact surface is necessary to ensure an adequate seal is formed
between the button head coupler and the Sealant Fitting.

3. Inject sealant following the operating instructions for the injection equipment that you are using.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

4. There are four gauge scenarios that will help you determine valve seat leakage problems. Once you
have identified the applicable gauge scenario, you can apply the appropriate maintenance proce­dures, found in the specific valve maintenance manual, to ensure your valves are operating at their
peak.

• Gauge Scenario One:

required to inject sealant into the valve. Assuming your injection equipment is operating correctly,
there are two possible problems: a) the sealant system is not full, or b) the seat is leaking.
Leakage may be caused by too loose an adjustment or damage to the valve’s seating areas.

• Gauge Scenario Two:

until an initial plateau is reached, then at some point the pressure increases to a higher plateau
and abruptly falls back to a lower level. This scenario indicates that the valve is receiving sealant
properly, the valve sealant system has filled, and the plug has moved off the seat. Even though
this scenario shows the plug has moved off the seat, it is still possible that the valve may be
difficult to operate. Operation difficulties may be caused by a) too tight an adjustment, b) stem
corrosion, or c) gearing problems on gear operated valves.

The gauge does not indicate a pressure increase above the initial pressure

As sealant is injected, the gauge indicates a gradual increase in pressure

• Gauge Scenario Three: This scenario is much like Scenario Two except the sealant pressure

gauge reaches a plateau and remains at that point as the injection equipment is operated, even
after you have injected more than enough sealant to fill the valve. This scenario signals one of
two quite different conditions. If the plug is not locked in the body taper, then the plug may be
unseated and additional sealant is simply bypassing the plug. This is normal and indicative of a
properly maintained and well pressurized valve. However, if the plug is locked in the taper and
cannot be operated, this indicates that the plug or valve body may be damaged and sealant is
bypassing the sealing surfaces. In Scenario Three it is also possible for the valve to be difficult to
operate. The likely causes are the same as with Scenario Two: a) too tight an adjustment, b) stem
corrosion, or 3) gearing problems on gear operated valves.

• Gauge Scenario Four:

never indicates a pressure decrease. This scenario indicates three possible problems: a) the valve
sealant fitting is faulty, b) the sealant system is blocked, or c) the plug has seized in the body
taper.

5. Open and close the valve several times while continuing to inject sealant. If conditions do not allow
you to fully open or close the valve, rotate the plug back and forth (approximately 20 degrees)
several times.

6. After you have completed the injection of sealant, relieve the pressure within the injection equip
ment and remove it from the Sealant Fitting.

The gauge indicates a continual rise in pressure as sealant is injected, but

-

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Valve Maintenance: Troubleshooting

This section lists common problems you may encounter with the Dynamic Balance plug valve, the
probable causes, and solutions that should remedy the situations. The listed procedures are intended to
serve as guides to remedy conditions you may encounter when performing maintenance on your valve.
The procedures, as well as information shown in the Tables of this manual are based on factory valve
assembly procedures. Precise estimates of field conditions are not feasible. Judgement and experience
must be applied when working on valves in actual field site conditions.

It is highly recommended that sealant be injected into the valve prior to proceeding with valve adjust­ment or repair. Gauge scenarios, as detailed earlier, will help you focus on specific solutions to remedy
your valve problem. Your sealant injection equipment should be operating properly prior to diagnosing
valve problems.

CAUTION: If a non-compressible fluid is trapped in the center cavity of the plug, when the valve

a

is in the closed position, injecting sealant at high pressures or high volumes can cause the plug
to lock in place. This can also cause the Cover Bolts to yield, thus producing Cover leakage.

Problem: Valve seat leakage

Cause 1: Insufficient sealant in the valve
Solution: The lack of sufficient sealant to adequately fill and pressurize the sealant system is the most

common problem associated with seat leakage. Inject the correct amount of sealant into the valve and
again check for seat leakage.

Cause 2:
Solution: Loose plug adjustment may also be recognized by the valve operating torque being lower than

normal. If possible, operate the valve a number of times prior to adjusting the Plug Adjustment Screw
and make adjustments using the following procedures:

1. Remove the hex head cap screw or thin metal plate located on the Bottom Cover of the valve to

2. Insert the proper size hex head wrench into the hexagonal shaped hole in the Plug Adjustment

3. Operate the valve back and forth through its 90° operating range, and simultaneously tighten the

Plug adjustment is too loose

expose the Plug Adjustment Screw. After the valve is assembled at the factory, the Plug Adjusting
Screw and valve cover is marked by chisel point to locate the position of factory adjustment. Check
the Plug Adjustment Screw for tampering. If the Adjusting Screw has been moved in counter-clock­wise direction, you should retighten to the factory adjustment mark.

Screw.

Note:

During factory assembly, thread-locking compound is applied to the Plug Adjustment Screw.

The screw may be initially difficult to turn.

Plug Adjusting Screw. This action will help disperse previously injected valve sealant. If operating
conditions prevent rotating the plug completely through its 90° operating range, you can rotate
the plug through a 20° arc to disperse the sealant. Continue to tighten the Adjusting Screw until a
noticeable torque increase makes the plug harder to turn. This will indicate you have metal-to-metal
contact between the body and plug.

26

CAUTION: Over-adjustment of the Plug Adjusting Screw will lock the plug into the body

a

taper.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

4. Loosen the adjustment screw 1⁄8 turn. If possible, the valve should be in the full open position for final
plug adjustment.

5. Inject sealant (see pages 24 & 25.) You should receive a higher pressure reading on the gauge. If
you still do not get a pressure increase on the gauge, repeat Steps 3 and 4. If a second attempt at
plug adjustment is unsuccessful, it is likely there is a damaged area on the plug or body-seating
surface. Refer to Cause 3.

6. Replace the Plug Adjusting Screw cover.

Cause 3:
Solution: A simple way to determine if the plug is damaged is to rotate the plug 180 degrees to place

the upstream seat into the downstream position. The following procedure is a temporary solution to the
seat leakage problem and the valve should be identified for remanufacture or replacement.

For a Wrench Operated Valve:

a) Loosen the Plug Adjusting Screw ½ turn.

b) With the valve in the full open or full closed position, remove the Retaining Ring and the Stop Collar.

c) Rotate the valve Stem 180 degrees.

d) Replace the Stop Collar and the Retaining Ring.

e) Adjust the Plug as described in Valve Sealant Leakage, Cause 2, Steps 3 through 6.

f) Inject sealant – see pages 24 and 25.

For a Gear Operated Valve:

a) Loosen the Plug Adjusting Screw ½ turn.

b) With the valve in the full open position, remove the Gear Housing Bolting.

c) Turn the Gearing Handwheel clockwise. The Gear Housing will move counterclockwise (be careful

Damaged plug

not to damage the Gear Housing Gasket while rotating the gearing). Turn the Handwheel until the
Gear Housing bolt holes align with the next hole in the Gear Flange.

d) Replace two of the housing bolts to hold the Gearing firm.

e) Turn the Handwheel counterclockwise until the Gear Segment contacts the valve stop.

f) Repeat steps c) and d) until the Gear Housing has been rotated 180 degrees.

g) Replace the Gear Housing bolting.

h) Inject sealant – see pages 24 and 25.

i) Adjust the Plug as described in Valve Seat Leakage; Cause 2 Steps 3 through 6.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Problem: Operation difficulties

Cause 1: Insufficient sealant in the valve
Solution: The lack of sufficient sealant to adequately fill and pressurize the sealant system is the most

common problem associated with a valve being hard to operate. Inject the correct amount of sealant
into the valve and again check the operating torque of the valve.

Cause 2:
Solution: Loosen the plug adjustment.

1. Loosen the Plug Adjusting Screw

2. Inject sealant into the valve.

3. The valve should now be operable.

Cause 3:
Solution: Lubricate the Stem-to-Gland joint.

1. Remove the Retaining Ring and Stop Collar.

2. Remove the Weatherseal and inspect it for signs of damage. If the Weatherseal is damaged, replace

3. If corrosion exists, dam the area around the Stem-to-Gland joint with a heavy grease or Nordstrom

4. Introduce penetrating oil into the Stem-to-Gland joint. Allow the penetrating oil to saturate for a

5. If the valve becomes operable, clean the Stem-to-Gland joint of excess penetrating oil.

6. If penetrating oil does not free the valve, clean the Stem and inside surface of the Gland as

Too tight of a plug adjustment

1

⁄8 turn.

Minor Stem corrosion (wrench operated valves)

it. Check for corrosion on the stem or internal surface of the gland.

stick grade sealant.

minimum of 24 hours. Periodically operate the valve.

described in Operation Difficulties, Cause 4.

28

7. Coat the area under the Weatherseal with lithium base grease.

8. Replace the Weatherseal, Stop Collar, and Retaining Ring.

Cause 4:
Solution: Remove corrosion from the Stem and interior surface of the Gland or Gland Retainer (gear

operated valves).

1. Remove the Retaining Ring and Stop Collar.

2. Remove the Weatherseal and inspect it for signs of damage. If the Weatherseal is damaged, replace

3. If corrosion exists, attempt to lubricate the Stem-to-Gland joint as described in Operation Difficul

4. Remove the Gland and Gland Bolts.

5. Remove internal corrosion from the Gland by scraping and/or #120 emery cloth.

6. Remove Stem corrosion by scraping and/or #120 emery cloth.

Severe Stem corrosion (wrench operated valves)

it. Check for corrosion on the Stem or internal surface of the Gland.

-

ties, Cause 3. If this does not work, continue with Step 4.

Remove line pressure from the valve before performing the following procedures.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

7. Remove the liquid gasket from the Gland contact area of the Body.

8. Clean debris from the top of the Packing and from the Gland bolt holes.

9. Fill the relief area of the Gland with valve sealant.

10. Apply liquid gasket to the Gland-to-Body mating surface.

11. Replace the Gland.

12. Apply an anti-seize compound to the Gland Cap Screws and install. Use the bolting torque guide
lines as referenced in the Technical Data: Procedure for Tightening Cap Screws.

13. Apply lithium base grease to the bottom of the Weatherseal and replace.

14. Replace the Stop Collar and Retaining Ring.

Cause 5:
Solution: Check to see if the valve gearing is causing operational problems.

1. Remove the Indicator.

2. Completely remove the Gearing.

3. Remove the Gear Segment Key.

4. Replace the Gearing less the Segment Key.

5. Rotate the Handwheel to operate the Gearing. If the Gearing is difficult to operate, the problem is in

6. Inspect the Gear Segment and the Worm Gear for excessive wear or damage or lack of lubrication.

7. Rotate the Worm Shaft to determine if the Bearings are binding.

8. Replace any parts as necessary and ensure the Gearing operates properly before reassembling to

Gearing problems

the Gearing. If the gearing is easy to operate, the problem is within the valve.

the valve.

-

Problem: Blockage of sealant system

Cause 1: Sealant groove blockage
Solution: Some sealant can harden in the valve sealant system if not properly maintained. Hardened

sealant can prevent or reduce the flow of sealant injected into a valve. To clear the valve sealant
system of hardened sealant, inject VXX Valve Purge.

1. Inject VXX Valve Purge liberally into the valve using sealant injection equipment. If possible, the
valve should be operated several times during application.

2. Allow the VXX Valve Purge to remain in the valve for an extended period of time with periodic valve
operation.

3. Repeat Steps 1 and 2.

4. Inject an excess amount of the appropriate valve sealant into the valve.

5. If valve operation is improved by this procedure but the valve is still not operating properly, repeti
tion of this procedure may be required.

6. Under conditions of severe sealant deterioration, VXX Valve Purge may not be capable of dislodging
sealant residues and valve disassembly and physical cleaning may be required.

-

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Cause 2: Sealant Fitting blockage
Solution: In the event no sealant is being injected into the valve even though the sealant equipment is

pressurized, the Sealant Fitting may be blocked and should be replaced.

CAUTION: The following procedures should be performed with extreme caution. Make sure the

a

sealant fitting is pointed away from your body before attempting. Heavy leather gloves should
be worn during these procedures.

1. Check for sealant pressure behind the Sealant Fitting by pressing the center button of the fitting
with a small punch or screwdriver. If a small amount of fresh sealant is released through the Sealant
Fitting center button, the fitting is accepting sealant and operating properly.

If the center button of the Sealant Fitting cannot be depressed the Sealant Fitting is faulty or clogged
with debris and/or hardened sealant and should be cleaned or replaced. Proceed to Step 2.

If a steady stream of sealant or line fluid is ejected from the Sealant Fitting, the Check Valve is not
operating properly and should be flushed or replaced. See Blockage of Sealant System, Cause 3.

Before replacing a faulty Sealant Fitting, remove the valve from line pressure.

2. First, test for trapped pressure below the Sealant Fitting by carefully unscrewing it while attempting
to move the fitting back and forth. If pressure is present, continue to move the fitting back and forth
until the pressure is relieved. Do not remove the fitting until all pressure is relieved.

3. Once the fitting is removed, attach the sealant injection equipment to the fitting and inject sealant.
If sealant does not flow from the fitting, the fitting is faulty and must be replaced. If sealant can be
pumped through the fitting, the problem may be with the Check Valve or valve sealant-grooving
system.

4. Replace the Sealant Fitting, if necessary.

Cause 3:
Solution: Check Valve blockage may be the result of debris or hardened sealant not allowing the Check

Valve ball to move off of its seat. Remove the sealant fitting as described in Cause 2, Step 2. Inject
sealant and/or VXX Valve Purge before continuing with this procedure. Flush or replace the Check Valve
if the solution to Sealant System Blockage, Cause 1 and 2 are unsuccessful.

Before replacing a faulty Check Valve, the valve must be removed from the line.

1. Remove the Sealant Fitting as described in Cause 2.

2. Using a .188" square tool or an Allen wrench, remove the Check Valve.

3. Once the Check Valve has been removed, clean the removal area of all debris and check for

4. Lubricate the new Check Valve threads with light machine oil.

5. Install a new Check Valve.

Check Valve blockage

thread damage. Failure to do so may allow contaminates to enter the valve sealant system and
damage the sealing surface of the Plug and/or Body.

30

6. Replace the Sealant Fitting.

7. Inject sealant into the valve.

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Cause 4: Plug seized in the Body taper
Solution: Adjust the Plug.

1. If the plug cannot be unseated by sealant injection, remove the Plug Adjusting Screw cover.

2. Turn the Plug Adjusting Screw counterclockwise 1/8 turn.

3. Inject sealant into the valve and move the Plug Adjusting Screw back and forth, until the Plug lifts
off of the Body taper.

4. Once the Plug has lifted off of the body taper, retighten the Plug Adjusting Screw until the valve
becomes difficult to operate.

5. Loosen the Plug Adjusting Screw 1/8 turn.

6. Inject sealant into the valve.

Problem: Cover leakage

Cause 1: Damaged Gasket
Solution: Replace the Gasket. It is recommended that the old Gasket be replaced with new parts

whenever the Cover is removed from the valve.

The valve must be removed from line pressure before removing the Cover.

1. Be sure there is no pressure trapped in internal cavities of the valve (refer to the Introduction).
Operate the valve one complete quarter-turn cycle, and then put the valve in the full open position. If
your valve is equipped with a Relief Fitting, loosen the fitting as a final release for pressure, and then
tighten it.

2. Remove the hex head cap screw, or thin, bolted plate, located on the bottom Cover of the valve. This
exposes the Plug Adjustment Screw, the threads of which have been treated with a thread-locking
compound at the Nordstrom factory.

3. Loosen the Plug Adjustment Screw until there is no mechanical load on it.

4. If the valve is installed vertically, support may be required for the Cover so that the internal parts,
which are secured by the Cover, will not fall out when the Cover Bolts are removed.

5. Loosen and remove the Cover Bolts. Remove the support piece and carefully remove the Cover,
Ball, and Ball Seat.

6. Carefully remove the Gasket and all traces of it from the valve Body.

7. Apply a film of sealant on the entire surface of the large end of the plug.

8. Place the new Gasket onto the Body.

9. Place the Ball on the Plug.

10. Place the Ball Seat and O-rings into the Cover.

11. Place the Cover on the valve.

12. Lubricate the Cover Bolts with a quality thread lubricant.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

13. Insert the Cover Bolts, but do not screw the bolts all the way down.

14. Tighten the Cover Bolts, using the appropriate torque values from Table 1 and the procedure for
Tightening Cap Screws and Nuts.

15. Remove the Plug Adjusting Screw and apply a thread-locking compound.

16. Insert the Plug Adjustment Screw into the Cover until the screw is “even” with the inside of the
Cover.

17. Adjust the Plug as follows:

• Tighten the Plug Adjustment Screw to a “snug” condition.

• Loosen the Plug Adjustment Screw

1

⁄16" to 1⁄8" of radial movement.

18. Inject sealant.

Cause 2:

Non-compressible fluid trapped in port of plug while in the closed position.

Solution: Allow pressure to self-relieve over a period of time. If Cover leakage continues, follow
procedures as described in Cause 3.

Cause 3:

Loose bolting.

Solution: Tighten the cover bolting to the torque and order as listed in the section Tightening Cap
Screws and Nuts.

1. Loosen the Plug Adjustment Screw approximately ½ turn.

2. Tighten the Cover cap screws to the torque shown in Table I, Torque Values for Pressure Retaining
Bolting.

3. Tighten the Plug Adjustment Screw until the Plug is tight in the Body, and then loosen the Adjust

-

ment Screw approximately ¼ turn. The valve should be in the full open position if possible.

4. Inject Sealant.

5. If leakage continues, then it is probable that the Cover Gasket or O-rings on the Ball Seat have been
damaged. These can be replaced only when the valve is out of service. Procedures for replacing the
Gasket and O-rings are described in Cover Leakage Cause 1.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Problem: Leakage at the Stem

Cause 1: Line pressure is bypassing Stem O-rings.
Solution: Replace Stem O-rings.

Line pressure must be removed from valve before changing Stem O-rings.

1. Make sure there is no internal pressure trapped inside the valve. Operate the valve one complete
quarter-turn cycle, and then place the valve in the full open position.

2. For wrench operated valves – Remove the Retaining Ring and Stop Collar.

3. For gear operated valves – Remove the Position Indicator and Gearing. Remove the Gear Segment
and Segment Key from the Stem.

4. For wrench operated valves – Remove the Gland Bolts and the Gland with Weatherseal.

5. For gear operated valves – Remove the Gland Bolts and the Gland.

6. Remove the existing O-rings and thoroughly clean the Gland.

7. Install the new Stem O-rings.

8. Prepare the Gland for installation.

a) For wrench operated valves – Examine the Stem Weatherseal and replace it if necessary.

b) For wrench and gear operated valves – Apply sealant to the inside diameter of the Gland.

9. Install the Gland.

Apply a thin film of good quality gasket compound to the mating surface of the Body or Gland and
install the Gland. On wrench operated valves the stop lug is to the left when facing the front of the
valve.

10. Lubricate the Gland Bolts with a good quality thread lubricant and install.

11. Tighten the Gland Bolts as described in the section Tightening Cap Screws and Nuts.

12. Install the Stop Collar (remember to position it so the valve will turn clockwise to close and
counterclockwise to open) and the Retaining Ring.

13. Inject sealant.

Problem: Sealant Fitting leakage

Cause: Line pressure bypassing Check Valve.
Solution: Leakage at the Sealant Fitting indicates there is leakage around or through the Check Valve

(located behind the Sealant Fitting). Follow the Steps as listed in Cause 3 of Sealant System Blockage.

Problem: Check Valve leakage

Cause 1: The Check Valve ball is not seating properly.
Solution: Clean or replace the Check Valve. Follow the Steps as listed in Cause 3 of Sealant System

Blockage.

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

17

22

20

11

12

13

14

15

16

18

19

23

21

Detail Sketch: Stem End Detail –
Wrench Operated Valve

No. Item Description

11 Balance Ball

12 Spring

34

13 Check Valve

14 Sealant Fitting

15 O-Ring

16 O-Ring

17 Plug Stem

18 Gland

19 Cap Screw

20 Stop Collar

21 Ball Retaining Washer

22 Retainer

23 Weather Seal

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

2423

11

12

13

14

15

16

17

18

19

20

21

22

25

ADAPTER PLATE
SIZE 20 ONLY

Detail Sketch: Stem End Detail –
Gear Operated Valve

No. Item Description

11 Balance Ball

12 Spring

13 Check Valve

14 Sealant Fitting

15 O-Ring

16 O-Ring

17 Plug Stem

18 O-Ring Gland

19 Cap Screw

20 Key

21 Ball Retaining Washer

22 Gearing

23 Lock Washer

24 Cap Screw

25 Adapter Plate (size 20 only)

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

1

2

3

4

5

6

7

8

9

10

Detail Sketch: Cover End Detail –
Ball Seat Arrangement

No. Item Description

1 Body

2 Plug

3 Cover

4 Cover Cap Screw

5 Thrust Ball

6 Ring Gasket

7 O-Ring

8 Adjusting Screw

9 Adjusting Screw Cap

10 Ball Seat

36

Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

Technical Data: Procedure
for Tightening Cap Screws

Note: This procedure is intended only as a guide. It is impossible for Flowserve Sulphur Springs Opera­tions to know actual field-site conditions, so your judgement and experience must be exercised.

1. Inspect applicable parts to be sure that:

a) Tapped holes are clean, dry, and free of foreign matter.

b) Threads are free of nicks, grit, and burrs.

2. Apply a quality thread lubricant on the threads of the Cap Screws/Nuts, or the tapped holes, and the
contact face of the Cap Screws/Nuts.

3. Install all Cap Screws/Nuts by hand. Engage the threads at least ½ of the diameter before using a
wrench.

4. Hand-tighten the first four Cap Screws/Nuts in the sequence shown in Diagram 1. This is to avoid
cocking the parts.

5. Tighten the Cap Screws in a crisscross pattern. Tighten them first to the 10% torque value, then in a
crisscross pattern to the 75% torque value.

6. Repeat Step 5, tightening the Cap Screws to the full torque value as shown in the table below.

7. Recheck the torque on all Cap Screws. If the torque is less than the minimum shown, tighten them
to the full torque.

Valve Size

4 14 104 127 150

6 22 167 205 240

8 34 257 315 370

10 22 167 205 340

12 34 257 315 370

14 34 257 315 370

16 54 407 500 585

18 70 521 640 750

20 70 521 640 750

Intermediate

10% 75% Min. Max.

Final

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

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Nordstrom Figure 50165 and 50169 Dynamic Balance Iron Plug Valve FCD NVENIM2006-00 – 09/05

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flowserve.com

39

FCD NVENIM2006-00 Printed in USA. (Replaces IOM-50169)

To find your local Flowserve representative:

For more information about Flowserve Corporation, visit
www.flowserve.com or call USA 1 800 225 6989

United States

Flowserve Corporation
Flow Control
Nordstrom
1511 Jefferson Street
Sulphur Springs, TX 75482
Phone: [phone]

903-885-4691

Fax: [phone]

Latin America

Telephone: [phone]
Fax: [phone]

Other Countries

Telephone: [phone]
Fax: [phone]

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.

© 2005 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.

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