Flowserve 82 User Manual

Worcester Controls

18510-P

82/83 Series 150# and 3003 Flanged

2" - 1

2" One-Piece and 2" - 10 "

Two-Piece Ball Valves

Installation, Operation and Maintenance Instructions

CAUTION: Flowserve 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 1200°F or below 400°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 the valve cavity.

2. When installing, use standard gaskets suitable for the specific service. Tighten flange bolts or studs evenly. Follow ANSI standards for flange bolt torques.

B. OPERATION

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

4 turn

clockwise to close, and

turn counter-clockwise to open. When

handle and/or stem flats (

2"-1

2"), or stop plate pointer and/or

stem groove (2"-10") are 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 Flowserve's published Pressure-Temperature Chart.

3. It is not good practice to leave a ball valve partly open (throttling operation) without knowledge of the pressure drop and flow at that position. These conditions should be checked with the Worcester Control Valve Brochure.

4. As shipped from the factory, valves (except oxygen prepared (V20, V33 or prefix code “X”) and valves with V38 or V46 option) contain a silicone based lubricant. This is for break-in purposes and may be removed if it is objectionable for a particular application by disassembling and solvent washing. Lacquer thinner will remove the lubricant.

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

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

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

CAUTION:

7. The fluoropolymer body seal (T), the fluoropolymer coated stainless steel “S” gasket (M), the graphite body seal (Z), and the Grafoil laminated gasket (G) make excellent seals. However, some points of caution in their use need emphasizing.

a. No teflon part (except seats) is reusable. Coated stainless steel

“S” gaskets and graphite body seals, and Grafoil laminated gaskets are also not 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 the

coating of the stainless steel “S” gasket during installation. Light lubrication of these seals and gaskets can help to prevent damage.

2 18510-P

Flow Control Division

Worcester Controls

C. MAINTENANCE

Tighten retaining nut if seepage is noted at stem.

CAUTION: For maximum stem seal life, proper stem adjustment procedure must be followed. Excessive tightening causes higher torque and shorter stem seal life.

For

2"-1

2" 82/83 Valves

FOR VALVES WITH TWO STEM NUTS AND A LOCKWASHER:

1. Tighten retaining nut (lower nut) until Belleville washers are flat, the nut will “bottom”.

2. Back off retaining nut

turn.

3. Tighten handle nut securely to lock retaining nut in place. (On some automated valves, two retaining nuts are used with a lockwasher in between. Hold the bottom nut securely with a wrench while tightening the top nut to lock the two nuts in place.)

FOR VALVES WITH SELF-LOCKING STEM NUT:

1. Tighten self-locking stem nut until Belleville washers are flat, the nut will “bottom”.

Back off nut

3 turn.

CAUTION: The self-locking stem nut is difficult to tighten, and must fully flatten Belleville washers before backing off.

For 2"-10" 82/83 Valves

1. Tighten retaining nut

turn at a time until seepage stops.

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 be taken for safe removal and disassembly:

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

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

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

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

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 valves, the “P” number, “T” number, “C” number, or similar number, as found on the nameplate. Some series, such as AF & V51 option have their own repair kits, which are ordered by the prefix or adding V51 suffix. If valve body is stainless steel, place a “6” after valve size in repair kit ordering code. (Use Series 82 designation for both 82 and 83.)

NOTE: V51 high cycle stem packing option is used on 2"-6" sizes only and is not used with AF Series valves.

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

3. To Disassemble

"-1

" One-Piece Valves:

a. Remove valve from line. Unscrew end plug and set aside. If

the body seal was not removed with the end plug, remove it from the valve and discard. Remove and discard the near seat. Place valve in closed position and remove the ball.

NOTE: If required, end plug disassembly tools are available from your distributor or from Flowserve.

b. Remove handle nut, lockwasher, also separate handle and

stop or one-piece handle/stop (if manual valve). (This step is not applicable to valves with self-locking stem nut.)

c. Remove retaining or self-locking stem nut. Prevent stem from

turning with wrench.

d. Remove and discard Belleville washers. Push stem into ball

cavity and remove. On the

" size, the far seat must be

removed before pushing stem into cavity.

e. Remove and discard stem seal(s), stem seal protector (if

any), thrust bearing, and thrust bearing protector (if any),

Example Repair Kit Orders

Valve Size Prefix RK Series Material Revision # or P, T, C, etc., Number

(if required)

3" AF RK 82 TZ R1 —-

2" RK 82 T R1 V51 —-

4" RK 82 RT —— T0914

18510-P 3

which may be on the stem or in the body stem cavity. Remove and discard the far seat. Retain the follower.

To Disassemble 2"-10" Two-Piece Valves:

f. Valve should be placed with the end connector (smaller body

section) uppermost and on a clean surface, the valve preferably clamped or bolted down. To disassemble end connector from body, remove body stud nuts from midflange.

g. Strike end connector with mallet and close the valve. The

mid-flange connection should break open. Repeat if not successful at first try. The end connector should now be lifted vertically from the body and placed on the clean surface with mid-flange end uppermost.

With the valve still in the closed position the ball may now be lifted from the body cavity, and the seats and body seal are now exposed in either body or end connector. These should now be removed. Care must be taken to avoid scratching the machined faces on which they make contact with valve body and end connector.

General Note: Depending on whether a standard or AF Series valve is being disassembled, stem seals may be three-piece or one-piece. Also, the 2

"-10" 82/83 Series valves have one

metal stem washer, and the 2

2"-10" AF82/83 Series valves

have two metal stem washers under the stem seal(s).

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

j. Remove retaining nut. Prevent stem from rotating by holding

stem with wrench.

k. Remove stop or valve stem spacer (2"-6" actuated valves).

Remove and discard Belleville washer(s) (if present). Remove and retain the follower.

l. Push stem into body cavity and remove. Remove and discard

stem seal(s) and thrust bearing. Remove and retain stem washer(s) (if any).

4. Visual Inspection:

a. The ball and the surfaces against which the seats 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 fingertips are acceptable.

b. The stem and body surfaces that the thrust bearing(s) and

stem seal(s) contact, must be undamaged, clean and free of pit marks and scratches.

5. Reassembly:

Refer to exploded views and also stem build illustrations on the following pages for proper reassembly.

NOTE: Care must be used when handling graphite stem seals, thrust bearings, and body 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. If metal stem washer(s), 2

"-10" sizes only, and/or Belleville washer(s) were

furnished on valve, they must be reused.

Valves with a pressure relief hole in the ball (V3) must be reassembled and installed with the hole upstream (end connector side) to ensure that cavity relief is upstream when valve is closed. Any valve with the V3 option will have an arrow on the body pointing downstream. This arrow is stamped on the body or on a metal tag welded to the body.

For all valves, except for valves with V20, V33 or V38 options, which are assembled dry, lightly lubricate the ball, seats, body seal, stem seal(s), and thrust bearing(s), with a lubricant compatible with the media being handled. White petroleum jelly is a good general purpose lubricant. For oxygen prepared valves (prefix “X”) use a PTFE-based lubricant such as Fluorolube S-30 or equivalent.

2"-1

2" One-Piece Valves:

a. On all except the

2" size, install the far seat in the body cavity.

b. Place new thrust bearing(s) on stem and insert assembly

through body cavity. Place new stem seal(s), stem seal protector (if any), and the follower in position. Thrust bearing and stem seal protectors are placed outside of seals and bearings. The seals/bearings must contact the body.

Stem seals, stem seal protectors and thrust bearings that are the same size and color are generally interchangeable.

NOTE: Anti-static fire-rated valves (AF82 & AF83) use a graphite stem seal which is metallic silver gray in color. Also a black, carbon-filled fluoropolymer or a gray graphite thrust bearing must be used for proper grounding of the stem to body.

c. Place two new Belleville washers in position with the larger

diameter sides touching each other.

For those valves with single self-locking stem nut, place four new Belleville washers in position (two pairs of washers with larger diameter sides touching each other).

Place retaining or self-locking stem nut on stem and using handle or a wrench to prevent rotation, tighten nut to make snug and firm. Follow Section C - Maintenance - for proper stem adjustment.

d. Replace separate stop and handle or one-piece handle and stop

(if manual valve), lockwasher and handle nut on stem. (This step is not applicable to valves with self-locking stem nut.)

e. Install far seat (

2" valves only), ball, body seal, second seat

and end plug. When end plug and body are metal-to-metal, end plug raised face may project up to .009" beyond flange surface. End plug must be fully tightened against machined

Flow Control Division

Worcester Controls

+ 5 hidden pages