Flowserve 94 User Manual

Worcester Controls

06957-L

2"–2" Series 94 and FZ94 Three-Piece Ball Valves,

2"–6" Series 94 and FZ94 150/300,

1"–2" Series 94 600, and 4"–6" Series AF94 150/300 Flanged One-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 120°F or below 40°F may occur. Do not store within 50 feet of any source of ozone.

I. INSTALLATION

A. Standard 94 Series three-piece and flanged one-piece valves may

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

B. When installing 94, AF94 or FZ94 flanged one-piece valves, use

standard gaskets suitable for the specific service. Tighten flange bolts or studs evenly. Follow ANSI standards for flange bolt torque.

C. For Weld End Valves (SW, BW):

NOTES: Prior to welding, THOROUGHLY CLEAN ALL JOINT SURFACES to prevent contamination.

Valves with “PG”, “RG”, “XG”, “AG” and “GG” seat/body seal combinations and V67 option code are compatible with welding temperatures. Therefore, these valves are weld-as-is and do not have to be disassembled to be welded in line. A red welding tag will be attached to the valve. If these valves are disassembled, the

graphite-coated stainless steel gasket body seals (code “G”) and the seat back seals (used with “A” or “G” seats only) must be replaced. When welding these valves, the ball must be open to prevent adhesion of weld spatter to the ball. Use STICK or MIG welding and allow valve and joint to cool to the touch between passes.

For All Other Weld End Valves:

1. Tack weld the valve in place.

2. Remove three body bolts, loosen the fourth and swing out the body with valve open. Close the valve and remove the seats, ball and body seals.

NOTE: FZ94 valves can not be swung out. Remove fourth bolt and spread pipe ends to clear centering ring (Revision R3 FZ94 valves with “G” seats, and all Revision R4 and later FZ94 valves do not have centering rings). Close valve, remove ball, seats, body seals.

3. Swing body in and secure it with one additional body bolt diagonally from first.

4. Weld pipe ends. When gas welding, DO NOT play flame on the valve body.

5. Allow valve to cool. Reassemble valve. Install new body seals, or coated stainless steel “S” gaskets (code M or G), if they were shipped separately from the valve, discarding the temporary Buna body seals found in the valve as received. See I.D.3.

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6. Tighten and torque the body bolts of the valve evenly and diagonally opposite each other, alternating in a criss-cross pattern. Use the torque figures shown:

Carbon Steel Bolts Stainless Steel & Alloy 20 Bolts

Bolt. Dia. In.-Lbs. Ft.-Lbs. Bolt Dia. In-Lbs. Ft.-Lbs.

4" 96-120 8-10

4" 72-94 6-8

16" 156-204 13-17

16" 120-144 10-12

" 216-264 18-22

" 192-216 16-18

16" 480-540 40-45

16" 336-384 28-32

2" 720-780 60-65

2" 504-552 42-46

NOTE: Stainless steel bolts and nuts are used in all threepiece valves with stainless steel bodies and also valves with “GG” seats and body seals.

D. CAUTION: The fluoropolymer body seals (code T) and the

coated stainless steel stainless steel gaskets (codes M & G) make excellent seals. However, some points of caution in their use need emphasizing:

1. No coated stainless steel gasket body seal, graphite seat back seal or fluoropolymer part (except a seat) is reusable. Upon disassembly of the valve, they should be discarded and replaced with new parts.

2. Avoid scratching or damaging the fluoropolymer seals or the coating of the “S” gaskets during installation. Light lubrication of these seals can help to prevent damage.

3. “S” gaskets are installed with the wide flange against the valve body (see View A-A on page 7).

4. Care must also be taken when handling graphite seat back seals, stem seals, thrust bearings, and body seals. These parts can be easily damaged by squeezing the O.D. Parts should 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.

5. The ball used in “A” or “G” (filled metal) seated valves is round to special tolerances. To ensure proper contact with the seat, do not drop, dent or scratch the ball during handling. These balls also have an anti-galling coating; DO NOT use uncoated balls with filled metal seats.

II.OPERATION

A. The operation of the valve consists of turning the stem (by

manual or automated means)

4 turn clockwise to close and

turn counter-clockwise to open. When the handle (if used) and/or stem flats or groove are in-line with the pipeline, the valve is open.

B. 94 Series valves will provide bubble-tight shutoff when used in

accordance with Worcester’s published pressure/temperature chart, with the exception of “G” seated valves. Valves with “G” seats meet the leakage rates of ANSI B16.104 Class VI.

C. Do not leave the ball partly open (throttling operation) without

having first determined whether the pressure drop and/or flow rate are detrimental to the valve seats. These conditions should be checked with Worcester’s Control Valve Manual or the factory.

D. As shipped from the factory, valves (except oxygen prepared

(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.

E. Media that can solidify, crystallize or polymerize should not be

allowed to stand in ball valve cavities.

F. Torque Requirements: Operating torque requirements will vary

depending on the length of time between cycles, media in the system, line pressure and type of valve seats. The figures in the following table are based on laboratory tests with clean tap water as the media. They are measured at WOG rated pressure, 70°F, after 24 hours. For a more detailed analysis of valve torque requirements, see Worcester’s Actuator Sizing Manual.

Maximum Expected Breakaway Torque (In.-Lbs.)

All Seats

Valve Size Except A, G, X A, G, X Seats Only

" 125 225

4" 150 275

1" 250 360

11/

" 400 550

11/

2" 600 750

2" 750 850 3" 1800 2100 4" 2500 3600 6" 6500 7500

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

III. MAINTENANCE

For maximum stem seal life, proper packing adjustment procedure must be followed.

A. Tighten packing gland bolts to the torque values in the table

below. Alternate between the two gland bolts when tightening to maintain the alignment of the gland plate with the top of the valve body. Some rocking of the gland plate can be tolerated; however, excessive misalignment may cause premature failure of the stem packing.

Flow Control Division

Worcester Controls

06957-L 3

Gland Bolt Torque (In.-Lbs.)

Valve Size “T” Packing “G” Packing

" 40-45 90-110

1"-11/

4" 65-70 120-140

11/

2"-2" 85-95 210-230

3"-4" 175-200 270-295

6" 240-265 340-365

NOTE: After adjustments, packing creep will occur over several hours. Bolt torque measured then will be less.

IV. REBUILDING

This manual contains exploded views of the valves covered by the text. They have been included to aid in the rebuilding of the valves. Please refer to them when following the written instructions.

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

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

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

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

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

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

A. A standard repair kit can be ordered for the 94 Series valve

containing all the necessary parts for standard valve rebuilding; seats, seat back seals (used with “A” and “G” filled metal seats only), body seals, split thrust bearing, split ring, all non-metallic stem packing parts, and Belleville washers. To order, specify the valve size and series, the material of the ball, seats and body seals, and the “R” number (Revision Number) or for non-standard valve, the “P” number, “T” number, “C” number, or similar number. This information is found on the nameplate on the valve body. If valve body is stainless steel, place a “6” after valve size in repair kit ordering code.

Repair Kit Ordering Examples:

1" RK94 6PM R0 3" RK94 PT R0 2" 6 RK94 6PM R1

1" FZRK94 PM R1 3" FZRK94 RZ R0 2" RK94 AG T0726

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

B. TO DISASSEMBLE

2"-2" THREE-PIECE 94 VALVES:

1. Place valve in open position. Remove three body bolts and nuts and loosen fourth to swing the center section out from between the pipe ends, or remove all four bolts to remove the valve from the line; whichever is more convenient. FZ94 valves require spreading the pipe ends to clear the centering rings (Note: Revision R3 FZ94 valves with “G” seats, and all Revision R4 and later FZ94 valves do not have centering rings).

2. Close the valve. Remove the seats, seat back seals (if any), ball and body seals.

3. Remove the handle (if any), gland bolts, Bellevilles, gland plate and follower(s) (1 or 2 pcs.) from the top of the valve.

4. Remove the stem and packing from the valve:

a. Push the stem down into the body cavity.

b. Remove the split ring and split thrust bearing from the

recessed diameter above the stem tang.

c. Remove the stem from the top of the body. This may

require considerable force. The flats on the stem can be clamped in a vise or other fixture to aid in removal. Avoid damaging the stem flats. The packing will be removed with the stem by the shoulder on the end of the stem.

CAUTION: Use care to avoid scratching the surface of the stem and packing chamber.

d. Remove the packing from the stem.

TO DISASSEMBLE 1/

2"-2" FLANGED ONE-PIECE VALVES:

5. Place valve in closed position.

6. Unscrew end plug and remove. If required, end plug disassembly tools are available from your supplier or from Flowserve Corporation.

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

8. Remove the handle (if any), gland bolts, Belleville washers, gland plate and follower(s) (1 or 2 pieces) from the top of the valve.

9. Remove the stem and packing from the valve:

a. Push the stem down into the body cavity.

b. Remove the split ring and split thrust bearing from the

recessed diameter above the stem tang.

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4 06957-L

c. Remove the stem from the top of the body. This may

CAUTION: Use care to avoid scratching the surface of the stem and packing chamber.

d. Remove the packing from the stem.

TO DISASSEMBLE 3"-6" FLANGED ONE-PIECE VALVES:

10. Place valve in closed position. Remove end plug retaining screws.

11. Remove end plug. If necessary, drive end plug from valve, using wooden drift applied to face of ball. Be certain the ball is fully closed.

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

13. Remove the handle assembly, spacer, and stop (if any), gland bolts, Belleville washers, gland plate and follower(s) (1 or 2 pieces) from the top of the valve.

14. Push the stem down into the body cavity and remove.

15. Remove the thrust bearing and stem packing from the body.

CAUTION: Use care to avoid scratching the surface of the stem and packing chamber.

C. VISUAL INSPECTION

1. The ball and 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 that can be seen, but barely detected with fingertips, are acceptable.

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

D. REASSEMBLY

NOTE: Valves with a pressure relief hole in the ball (V3) must be assembled with the hole upstream when valve is closed. Any valve with this V3 option will have an arrow indicating downstream. This arrow is stamped on the body or on a metal tag welded to the body.

Clean all sealing surfaces of the valve including the ball.

Lightly lubricate the ball, seats, seat back seals (if used), body seal(s), split thrust bearing and split ring or one-piece thrust bearing, and stem seals with a lubricant compatible with the media being handled (except for valves with V38 option, which are assembled dry) as the parts are used. White petroleum jelly is a good general purpose lubricant. For oxygen prepared valves (prefix code “X”), use a PTFE-based lubricant such as Fluorolube

S-30 or eqiuvalent. Filled metal seats will be lubricated at the factory. If they are not, they should be lubricated as previously stated. The seat back seals will be preassembled to the seat backs. Do not operate a newly rebuilt valve with filled metal seats without lubricant.

If graphite parts are used, they should be handled on the flat surfaces rather than the O.D. These parts can be damaged by squeezing the O.D. and will not work if they are cracked or broken. Light flaking of the material is acceptable.

TO REASSEMBLE

2"-2" THREE-PIECE VALVES:

1. Insert the stem down through the bonnet and into the body.

2. Place the split thrust bearing in the recessed diameter above the stem tang. Place the split ring in the same recessed diameter, under the split thrust bearing (refer to exploded view).

3. Pull the stem up so that the split thrust bearing and split ring are drawn into the stem hole recess in the ball cavity. See instructions 21 through 26 for stem packing and gland plate assembly.

4. With the valve in the closed position (stem flats going across pipeline), replace the ball, seats and seat back seals (with “A” or “G” seats only). Open the ball and add the body seals. For “S” gaskets, see cautions I.D.1 - I.D.5. If seat back seals are used, be certain that they are correctly located on the seat back face before putting the center section between the pipe ends. Damage may occur and leaks or high operating torque may result if the seat back seals are not located correctly.

5. Place the center section between the pipe ends and replace the four body bolts and nuts. Tighten finger-tight. For FZ94 valves, insert the centering rings (if any) into the pipe ends before installing the center section of the valve.

TO REASSEMBLE

2"-2" FLANGED ONE-PIECE VALVES:

6. On all sizes except the

", place the far seat and seat back seal (used with “A” or “G” seats only) in the body cavity. If seat back seals are used, be certain that they are correctly located on the seat back face before installing the ball and end plug. Damage may occur and leaks or high operating torque may result if the seat back seals are not located correctly.

7. Insert the stem down through the bonnet and into the body.

8. Place the split thrust bearing in the recessed diameter above the stem tang. Place the split ring in the same recessed diameter, under the split thrust bearing (refer to exploded view).

9. Pull the stem up so that the split thrust bearing and split ring are drawn into the stem hole recess in the ball cavity. See instructions 21 through 26 for stem packing and gland plate assembly.

10. Install far seat (

2" valves only). With the valve in closed

position (stem flats going across pipeline), insert the ball into the body so that the stem slot engages the tang on the stem.

Flow Control Division

Worcester Controls

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