Flowserve 51 User Manual

Worcester Controls

12230-N

3" - 10" 51/52, 3" - 6" 4, 151/301
Flanged and Wafer One-Piece Ball Valves
(Including D, PT, CL, AF and FZ Series Valves)

Installation, Operation and Maintenance Instructions

CAUTION: Worcester recommends that all product which must be
stored prior to installation be stored indoors, in an environment
suitable for human occupancy. Do not store product in areas where
exposure to: relative humidity above 85%, acid or alkali fumes,
radiation above normal background, ultraviolet light, or
temperatures above 120°F or below 40°F may occur. Do not store
within 50 feet of any source of ozone.

A. INSTALLATION

1. Standard valves may be installed for flow or vacuum in either
direction. Valves with upstream relief hole in ball (V3 option) are
one-way valves. Use care to exclude pipe sealants from valve
cavity.

Diverter valves (D51) may be installed using the bottom port as
the inlet port. The flow can then be diverted to either one of the
two side outlet ports.

For chlorine valves, the maximum pressure rating is 300 psi. The
Chlorine Institute Pamphlet #6 recommends that the relief hole in
the ball be upstream when valve is closed, toward the pressure
source.

2. When installing, use standard gaskets suitable for the specific
service. Tighten flange bolts or studs evenly.

3. On 151 and 301 wafer valves, it is recommended to leave the ball
in the open position while installing, to eliminate possibility of
damaging ball finish.

B. OPERATION

1. The operation consists of turning the handle and/or stem 1/

4 turn

clockwise to close, and

1

/

4

turn counterclockwise to open. When
stop plate pointer and/or stem groove is in line with the pipeline,
the valve is open. These valves may also be automated.

2. These valves will provide bubble-tight shutoff when used in
accordance with Worcester’s published pressure/temperature
chart. Valves with “G” seats meet the leakage rates of ANSI
B16.104 Class VI.

3. The diverter valve will allow no leakage through the closed output
port when used as described with the bottom port as the inlet.

The porting one (V1) style valve is operated by turning the handle
one quarter-turn to change selection of sources. With this style of
valve the flow is never shut off and some mixing of the media is
possible. This valve is easily automated with a pneumatic or
electric actuator.

The porting two (V2) valve is operated by turning the handle one­half turn to direct the flow from one side to the other. With this
style valve, the flow is shut off in the 90° position. (There is no
stop in this position.) This valve may be automated with an electric
actuator only.

4. It is not good practice to leave a ball valve partially open (throttling
operation) without knowledge of the pressure drop and flow at that
position. These conditions should be checked with Flowserve.

5. As shipped from the factory, all valves (except chlorine, oxygen
prepared (V20, V33 or prefix code “X”) and valves with V38 or V46
options) contain a silicone-based lubricant. This is for break-in
purposes and may be removed, if it is objectionable for a particular
application, by disassembling and solvent washing. Lacquer
thinner will remove the lubricant. “A” or “G” (filled metal) seated
valves should not be operated without a break-in lubricant.

6. Media which can solidify, crystallize or polymerize should not be
allowed to stand in ball valve cavities.

7. Torque Requirements: Operating torque requirements will vary
depending on the length of time between cycles, line pressure,
type of valve seats and the media in the system. For a detailed
analysis of valve torque requirements, see Worcester’s Actuator
Sizing Manual.

NOTE: Media which contain fine powders (25 microns or less)
will significantly raise ball valve torque requirements.

CAUTION

8. The fluoropolymer (T) and UHMWPE (U) body seals, the graphite
body seals (Z) and the seat back seals (used with “A” or “G”
seated (filled metal) valves) make excellent seals. However, some
points of caution in their use need emphasizing.

a. No seat back seal, graphite body seal, fluoropolymer or

UHMWPE part (except a seat) is reusable. Upon disassembly of
the valve, they should be discarded and replaced with new
parts.

b. Care must be taken to avoid scratching the fluoropolymer or

UHMWPE seal during installation. Light lubrication of these
seals can help to prevent damage. Care must also be taken
when handling a graphite thrust bearing, stem seal, body seal
or seat back seal. These parts are easily damaged and should
be handled on the flat surface rather than the O.D.

c. The ball used in “A” or “G” (filled metal) seated valves has a

special anti-galling coating. DO NOT use an uncoated ball with
filled metal seats. To ensure proper contact with the seat, do
not drop, dent or scratch the ball during handling.

C. MAINTENANCE

If seepage is noted at stem, tighten retaining nut 1/

6 turn at a time until

seepage stops.

CAUTIONS: Excessive tightening causes higher torque and shorter
stem seal life.

For chlorine valves only, immediately after the first frost is
detected around the stem, tighten the retaining nut to adjust the
compression of the stem seals.

D. REBUILDING

a WARNING: BALL VALVES CAN TRAP PRESSURIZED FLUIDS IN
BALL CAVITY WHEN CLOSED.

If the valve has been used to control hazardous media, it must be
decontaminated before disassembly. It is recommended that the
following steps are taken for safe removal and disassembly:

- Relieve the line pressure. Operate the valve prior to attempting
removal from line.

- Place valve in half-open position and flush the line to remove any
hazardous material from valve body.

- All persons involved in the removal and disassembly of the valve
should wear the proper protective clothing such as face shield,
gloves, apron, etc.

- For chlorine valves, refer to Chlorine Institute Pamphlet #6 for
flushing and drying procedure, and for additional information or
precautions and cleaning.

1. A standard repair kit may be ordered for the valve. Specify the
size, series, material of seats and body seal and R# (revision
number) of valve or for non-standard valve, the “P” number, “T”
number, “C” Number, or similar number, as found on nameplate.
Some series, such as CL, PT, FZ, AF, and V51 option have their
own repair kits, which are ordered by the prefix or adding V51
suffix. If valve body is stainless steel, place a “6” after the valve
size in repair kit ordering code.

Examples:

P, T, C

or

Valve Prefix similar

Size (if required) RK Series Material Rev. # #

3” AF RK 51 PT R3 —

3” RK 51 RT R5 V51 —

4” RK 51 T — T0914

NOTES: For Series 4 (151/301) and 52 valves, repair kits can be
ordered as RK51. V51 high-cycle stem packing option cannot be
used with CL, FZ, AF series, or oxygen service valves or valves
with “G” seats.

CAUTION: If the seats and seals installed differ from those
removed, the valve nameplate must be replaced or remarked to
indicate the altered materials and ratings or valve tagged to so
indicate.

2. This covers rebuilding of both flanged and wafer valves.

Special handling and cleaning procedures are necessary for
oxygen and vacuum service valves. Refer to industry practices
when overhauling these units.

NOTE: Series 51 and 52 Revision OF valves do not have retaining
screws. Consult your distributor or Flowserve for end plug
removal tools to facilitate removal of screwed ring insert retainer.

a. Disassembly of Valve:

1) Place valve in open position. Unscrew all flange bolts or
studs and nuts and remove valve from line.

2 12230-N

Flow Control Division

Worcester Controls

12230-N 3

2) With valve in closed position, remove end plug retaining
screws.

3) Remove end plug. If necessary, drive end plug from valve
using wooden drift applied to ball.

4) Remove body seal, ball, seats and seat back seals (if
any).

b. Removing Stem Assembly:

GENERAL NOTE: Due to different valve series and body styles,
one or two metal stem centering washers may be used and
the stem seal may be one-piece or three-piece.

1) Remove handle assembly (if any) by loosening handle
screw.

2) Remove retaining nut. Prevent stem from rotating by
holding stem with wrench.

3) Remove stop or valve stem spacer (actuated valves).
Remove and discard Belleville washer(s) (if any). Remove
and retain the follower.

4) Push stem into body cavity and remove. Remove stem
seal(s), stem seal protector (if any) and thrust bearing.
Remove and retain stem centering washer(s).

c. Visual Inspection:

1) The ball and the surfaces against which the seats and
seals are installed should be undamaged, clean and free
of pit marks and scratches. Light marring from the action
of the ball against the seats is normal and will not affect
the operation of the valve. Flaws which can be seen but
barely detected with finger tips are acceptable.

2) The stem and body surfaces that the thrust bearing and
stem seals contact, must be undamaged, clean and free
of pit marks and scratches.

d. Reassembly:

NOTE: Except for valves with graphite stem seals or V51
option, it is not necessary to replace Belleville washers.

CAUTION: Care must be used when handling graphite stem
seals, thrust bearing, body seals and seat back seals.
These parts can be easily damaged by squeezing the O.D.
of the seal. Parts are to be handled on the flat surfaces
rather than the O.D. These parts will not work if they are
cracked or broken. Light flaking of the material is
acceptable. If resistance is encountered when installing
stem seals over the stem, use follower to gently push the
stem seal down.

1) Lightly lubricate the ball, seats, seat back seals (if used),
body seal, stem seal(s), stem seal protector (if any) and
thrust bearing with a lubricant compatible with media
being handled, except for valves with V20, V33 or V38
options, which are assembled dry. White petroleum jelly
is a good general purpose lubricant.

For valve repair kits with “A” or “G” seats, the filled metal
seats will be lubricated at the factory. If they are not, they
should be lubricated as noted in Para. B.5 and also as
stated above. DO NOT operate a newly rebuilt valve using
filled metal seats without break-in lubricant. The seat back
seals will be pre-assembled to the seat backs.

For chlorine and oxygen prepared (prefix code “X”) valves
only, lightly lubricate the ball, seats, body seal, stem
seals, stem seal protector (if any), and thrust bearing with
a PTFE (fluoropolymer) lubricant, such as Fluorlube S-30
or equivalent.

2) To reassemble stem, reinstall stem centering washer(s)
into the recesses in the body. When only one washer is
used, it goes inside recess on top of the body and under
the stem seal(s). Place new thrust bearing onto stem and
insert through body cavity. The thrust bearing can be
distinguished from the stem seals by the darker color of
the 25% filled fluoropolymer used in the thrust bearing.
UHMWPE thrust bearings and stem seals are opaque
white in color and the same size, and are interchangeable.
Assemble new stem seal(s) over the top of the stem and
down into the recess in the top of the body. The follower
is installed on top of the stem seal(s). For valves with
graphite stem seal(s), the stem seal is metallic silver gray
and thicker than the thrust bearing. A Belleville washer is
also added, concave side up over follower (3” - 8” sizes
only). Place stop (or spacer) onto valve stem.

For valves with V51 high cycle stem packing option, the
thrust bearing and stem seals are the same size and color,
and they are interchangeable. A stem seal protector of
PEEK material and tan in color is also used and installed
over the stem seals.

NOTE: FOR ACTUATED VALVES HAVING A GRAPHITE
STEM SEAL OR V51 OPTION, TWO BELLEVILLE
WASHERS ARE USED. THE BELLEVILLES SHOULD BE
INSTALLED WITH THE LARGER DIAMETER SIDES
TOUCHING EACH OTHER. THE STEM SPACER IS
DELETED AND NOT USED.

ON ANTI-STATIC FIRE-RATED VALVES (AF51, AF52, FZ51
& FZ52) A BLACK, CARBON-FILLED FLUOROPOLYMER
THRUSTBEARING MUST BE USED FOR PROPER
GROUNDING OF STEM TO BODY.

3) When stem assembly is complete, place retaining nut
onto stem. Using handle or wrench to prevent rotation,
tighten retaining nut to fully compress packing or fully
flatten Belleville(s), if used, then backed off

1

/

6 turn.

Excessive tightening causes higher torque and shorter
stem seal life.

Flow Control Division

Worcester Controls