Page 1
Valtek Valdisk 150
Control Valves
GENERAL INFORMATION
The following instructions are designed to assist in
unpacking, installing, operating and performing maintenance as required on Valdisk 150 butterfly valves.
Product users and maintenance personnel should thoroughly review this bulletin prior to working on the valve.
Separate maintenance instructions cover additional features (such as positioners, special accessories, failsafe systems,etc.)
This publication does not contain information on installing, maintaining, troubleshooting, calibrating, and operating Valtek actuators or positioners. Refer to the
appropriate Valtek Installation, Operation, Maintenance
Instructions when this information is required.
To avoid possible injury to personnel or damage
to valve parts, WARNING and CAUTION notes
must be strictly adhered to. Modifying this product, substituting nonfactory parts, or using
maintenance procedures other than outlined
could drastically affect performance, be hazardous to personnel and equipment, and may void
existing warranties.
WARNING: Standard industry safety practices must
be adhered to when working on this, or any other,
process control product. Specifically, personal
protective and lifting devices must be used as warranted.
NOTE: Selecting the proper fastener material is the
responsibility of the customer. Typically, the supplier
does not know what the valve service conditions or
environment may be. Valtek‘s standard bolting material
is B7/2H. B8 (stainless steel) is optional for applications
above 800O F and with stainless steel or alloy body
valves. The customer therefore must consider the
material’s resistance to stress corrosion cracking in
addition to general corrosion. As with any mechanical
equipment, periodic inspection and maintenance is
required. For more information about fastener materials, contact your local Valtek representative or factory.
Unpacking
1. While unpacking the valve, check the packing list
against the materials received. Lists describing the
valve and accessories are included in each shipping
container.
2. When lifting the valve from the shipping container,
position lifting straps to avoid damage to tubing and
mounted accessories. Most Valdisk 150 valves
may be lifted by the actuator lifting ring. If no lifting
ring is provided, lift the valve using lifting straps or
hook through the yoke legs and outer end of the
body.
3. In the event of shipping damage, contact your shipper immediately.
4. Should any problem arise, contact your Valtek representative.
37-1Valtek No. 35190
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Installation
TABLE I:
1. Before installing the valve, clean the line of dirt,
scale, welding chips, and other foreign material.
Clean gasket surfaces thoroughly to insure leakproof joints.
2. Check flow direction to be sure valve is installed
correctly. Fail-closed valves should be installed
with the shaft upstream only in gas service. It
is preferred that liquid service valves be installed
with the shaft downstream regardless of air failure action. However, under certain flow conditions the valve can flow shaft upstream. Consult
the factory if the valve must be mounted with the
shaft upstream in liquid service. Fail-open valves
should be installed with the shaft downstream.
3. Fully close the valve before and during the installation process.
WARNING: Keep hands, hair, clothing, etc. away
from the rotating disc and the seat when operating the valve. Failure to do so could cause serious injury.
WARNING: When valve is installed for end-ofline service, retainer ring must be supported by
the mating pipe flange.
CAUTION: Because of Valdisk 150’s self-centering seat, there is no reason to open the
valve at any time during installation. Therefore, the valve should remain closed until the
valve is fully installed.
4. Connect the air supply and instrument signal.
Throttling valves are usually equipped with valve
positioners. Two connections are marked for the
air supply and for the instrument signal. Both
cylinder and positioner are suitable for 150 psi air
supply. An air regulator is not required unless the
supply pressure exceeds 150 psi. An air filter is
recommended unless the supply air is unusually
clean and dry. All connections must be free of
leaks.
NOTE: In some rare cases, the air supply must
be limited to 80 psi rather than 150 psi. In this
case, a sticker found near the upper air port on the
cylinder will indicate this and an air regulator may
need to be installed to insure the supply pressure
does not exceed 80 psi.
5. Make sure proper clearance exists internally in
the mating piping to permit proper disc rotation.
6. Apply the recommended torque values to the line
flange bolting for proper sealing (see Table 1).
Flange Bolting Torques* (Class 150)
Valve Size
(inches)
2, 3, 4 118 160
6, 8 209 282
10, 12 337 455
* For intermediate strength bolting, per ASME/ANSI B16.5 – 1988.
Torque Values
(ft-lbs) (newton-meter)
Quick-check
Prior to start-up, check the control valve by following
these steps.
1. Check for full stroke by making the appropriate instrument signal change. Observe the disc position
indicator plate mounted on the actuator transfer
case cover plate. The disc should change position
in a smooth, rotary fashion.
2. Check all air connections for leaks. Tighten or replace any leaking lines.
3. Evenly tighten the packing nuts on the valve to finger tight plus
CAUTION: Do not overtighten packing. This can
cause excessive packing wear and high shaft
friction, which may impede shaft rotation.
After the valve has been in operation for a short time,
check the packing nuts to make sure they are just
over finger-tight (readjust if necessary). If packing
box leaking occurs, tighten the packing nuts only
enough to stop leakage.
4. To observe the valve failure mode in case of air failure, position the valve to mid-stroke and shut off the
air supply or disconnect the instrument signal. By
observing the indicator plate, the disc should either
fail open or closed. If incorrect, refer to the “Reversing the Actuator” section in the appropriate Actuator
Maintenance Instructions.
1
/2 to one full turn (Teflon only).
PREVENTIVE MAINTENANCE
At least once every six months, check for proper operation by following the preventative maintenance steps
outlined below. These steps can be performed while the
valve is in line and, in some cases, without interrupting
service. If an internal problem is suspected, refer to the
“Disassembly and Reassembly” section.
1. Look for signs of gasket leakage through the body
and line flanges. Tighten flange bolting if necessary.
2. Note if any corrosive fumes or process drippings
are damaging the valve.
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Packing Retainer
Packing
Shaft
(Item No. 88)
(Item No. 51)
(Item No. 85)
Packing Box Nut
(Item No. 117)
Gland Flange
(Item No. 80)
Packing Box Stud
(Item No. 109)
Packing Follower
(Item No. 87)
Shaft Bearing
(Item No. 83)
Thrust Washer
(Item No. 82)
Taper Pin
(Item No. 52)
Body
(Item No. 1)
Disc
(Item No. 50)
Thrust
Washer
(Item No. 82)
Shaft
Bearing
(Item No. 84)
Disc Stop
Figure 1: Body Assembly
NOTE: Item numbers correspond directly to the valve’s bill of material. Refer to it for specific part numbers.
3. Clean valve and re-paint areas of severe oxidation.
4. Check packing box bolting for proper tightness.
Packing nuts should be slightly over finger-tight;
however, tighten as necessary to prevent stem
leakage.
CAUTION: Do not overtighten packing.
5. If the valve is supplied with a lubricator, check lubricant supply and add lubricant if necessary.
6. If possible, stroke the valve and check for smooth,
full-stroke operation by observing the disc position
indicator plate mounted on the transfer case. Unsteady movement of the disc could indicate an internal valve problem (jerky motion is normal whenever
Grafoil packing is used).
7. Check positioner calibration by observing the
gauges and disc position indicator plate. Make sure
positioner is calibrated to the correct range. Refer
to positioner instructions for additional preventative
maintenance.
8. If possible, depressurize the actuator, and remove
the actuator transfer case cover plate, and make
sure the positioner linkage is securely fastened.
CAUTION: Never apply air to the actuator without the cover plate installed; otherwise, the unsupported shaft may sustain damage.
9. Be certain all accessories, brackets and bolting are
securely fastened.
10. If possible, remove the air supply and observe the
position indicator plate for correct fail-safe action.
11. Spray soap solution around the cylinder retaining
ring and the adjusting screw to check for air leaks
through the O-rings.
12. Clean any dirt or other foreign material from the
exposed portion of the shaft.
13. If an air filter is supplied, check and replace the
cartridge if necessary.
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Standard Square
Standard Single "V" Twin "V"
Twin "V" with
Lubricator
SafeGuard
(packing studs rotated 45 degrees)
SureGuard
Figure 2: Typical Packing Configuration
DISASSEMBLY AND REASSEMBLY
Removing Valve From Line
If an internal problem is suspected with the valve and
disassembly is required, remove the valve from the line
by proceeding as follows:
WARNING: Depressurize line to atmospheric pressure, drain all process fluids and decontaminate the
valve (if caustic or hazardous materials are
present). Failure to do so can cause serious injury.
1. Make sure the valve is fully closed.
CAUTION: On valves with fail-open action, the
air pressure must be supplied under the piston
to close the valve. If the valve is supplied with
a handwheel, it can be used to close the valve.
Failure to do so will damage the valve disc upon
removal from the line.
2. Attach a hoist or some means to support the valve.
3. Remove the line bolting. Do not attempt to pry the
line flanges apart by pushing or pulling on the valve
or actuator.
SafeGuard / SureGuard
Fire-safe Option
(live-loading omitted)
4. Slide the valve carefully from the line. To avoid
damage to gasket surfaces, do not twist the valve.
5. After the valve is completely removed from the line,
slowly relieve air pressure from the actuator.
CAUTION: On valves with fail-open action, the
actuator spring will cause the disc to open.
Make sure the disc will not strike any object
upon opening. Protect disc edges from damage.
Removing Actuator From Body
In most cases, both the body assembly and the actuator
are easier to disassemble with the actuator removed
from the body. To do so, proceed as follows:
1. Support the actuator assembly by the lifting ring before disconnecting it from the body sub-assembly.
2. Depressurize actuator and allow it to move to its fail
position.
3. Remove the bolts connecting the yoke to the actuator subassembly.
4. Slide the entire actuator assembly off the valve
shaft.
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Disassembling the Body
To disassemble the Valdisk 150 body, refer to Figures
1 and 3 and proceed as follows:
1. Lay the valve body on a flat surface with the seat
surface up. Carefully insert a flat screwdriver into
the groove behind the seat retainer and pry the
retainer out of the body. The seat insert will now
easily lift out of the body.
2. Turn the body over so its backside is up and mark
the location of the thin end of the taper pin on the
disc. (This mark will be used during reassembly.)
Grind off the tackweld holding the taper pin in place.
Drive the taper pin out of its slot using a punch and
hammer.
3. Place the valve body into a vise with the shaft pointing up. Use brass jaws or wood blocks to prevent
damage to the body surfaces.
4. Remove the two packing box nuts and gland flange
from off the shaft.
5. Pull the shaft out of the body, noting that the disc
may fall out of body. Use caution to prevent it from
striking any hard objects or personnel. Next, remove the packing follower, packing set and packing
retainer.
6. The disc can now be removed from the body, followed by the thrust and shaft bearings.
Reassembling the Body
To reassemble the Valdisk 150 body sub-assembly,
refer to Figures 1, 2, and 3 and proceed as follows:
1. Clean or replace all parts. The O-ring and packing
set should be replaced each time the valve is disassembled.
2. Check the disc seating surface to make sure it is
smooth and free of excessive wear, scoring and
scratches.
CAUTION: Damaged or dirty seat surfaces can
cause excessive seat wear and high torque requirements. Damaged discs should be replaced.
3. Inspect the shaft for scratches or galled surfaces.
For maximum performance, Valdisk 150 shafts are
machined to a very smooth finish. If damage exists,
replace the shaft or contact the factory representative.
NOTE: Disc and shaft are interchangeable. Replacing the disc does not require replacing the shaft
and vice versa.
4. Place the valve body in a vise with shaft bore pointing up. Brass jaws or wood blocks are recommended to prevent damage to the valve surfaces
while being held in the vise.
5. Place one shaft bearing into the lower bearing bore,
followed by a thrust bearing.
6. Place the disc into the body from the backside with
the taper pin slot on top. Do not dislodge the thrust
bearing.
7. Insert the second thrust bearing between the disc
and the valve body. Align both bearings with the disc.
8. Insert the shaft into the body with the taper pin slot
end first. Slowly insert it through the body, upper
thrust bearing, disc, lower thrust bearing and into
the shaft bearing.
9. Insert a new taper pin into the slot in the back of the
disc and in the shaft. Refer to the mark on the disc
made during disassembly and make sure the pin
does not go beyond it. Be certain the pin is flat
against the disc. Set in place with a punch and
hammer.
10. Place the remaining shaft bearings* over the shaft
and into the bearing bore. (*Refer to the valve’s bill
of materials for the number of shaft bearings required.) Next, place the packing retainer, followed
by the packing set into the packing bore. (See Figure 2. Teflon packing chevrons point away from the
disc.) Be careful to not damage the packing rings
while inserting them over the shaft.
11. The packing follower is next inserted into the packing bore with machined lip end up.
12. If the packing box studs were removed, re-install
them using anti-seize lubricant. Tighten until they
bottom out. Place a washer over each stud and secure in place with a jam nut tightened until snug
(valve sizes 1 thru 6-inch).
13. Place the gland flange over the shaft and onto the
studs being certain the rocker knob is facing toward
the disc. Place the packing box nuts onto the packing box studs and tighten finger tight plus 1/2 to one
full turn with Teflon packing. (Rope packing should
be torqued to 14 foot-pounds or 19 newton-meters.)
14. Install the seat assembly into the valve body by first
inserting seat gasket into outer seat retainer groove.
Next, remove the body from the vise and lay it on a
flat surface with the seat side up. Proceed as follows.
Soft or metal seat design - Lay the seat insert into
the valve body. Next, insert the seat retainer into the
body seat counter bore. Use a rubber mallet or
press to press the seat retainer into the body.
Fire-safe seat design - Place one Grafoil gasket
into the retainer ring groove. Place two additional
Grafoil gaskets on either side of the seat insert.
Place the metal seat on top of the seat/gasket assembly and then place the entire assembly into the
retainer ring in the body. Next, insert the seat retainer into the body seat counter bore. Use a rubber
mallet or press to press the seat retainer into the
body.
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84
83
117
80
87
82
88
109
82
50
52
85
114*
113*
51
1
Figure 4: Exploded Body Sub-assembly
26
21
27
26
26
25
22
Item No. Description
1 body
21 seat insert
22 seat retainer
25 retainer O-ring
26 fire-safe gasket**
27 fire-safe seal**
50 disc
51 shaft
52 taper pin
80 gland flange
82 thrust washer
83 shaft bearing
84 shaft bearing
85 packing retainer
15. Rotate disc several times to allow seat to self-center in the body. Again, check packing box nuts to be
certain they are tight, per step number 13. Do not
overtighten.
CAUTION: Do not over tighten packing box
nuts. This can cause excessive packing wear
and high shaft friction, which may impede shaft
rotation.
16. After the valve is fully assembled and seat leak
tested, use a compatible welding rod to tackweld
the taper pin to the disc at its thickest end. Later,
this will allow the taper pin to be removed after the
weld has been ground off.
Remounting Valve to Actuator
Before mounting a Valdisk 150 valve to a Valtek actuator, verify that the disc rotation matches the actuator
rotation and complies with the air failure requirements.
87 packing follower
88 packing
109 packing box stud
113 jam nut*
114 washer*
117 packing box nut
* 1 thru 6-inch only
** Fire-safe designs only
Procedures for mounting the actuator are as follows.
1. Slide the entire actuator assembly onto the shaft.
To ensure full rotation of the disc, marks provided
on the end of the valve shaft and on the actuator
lever arm should be aligned.
2. Bolt the actuator yoke to the valve body. Be certain
the stroke indicator plate is positioned properly to
accurately indicate the valve’s rotation.
3. Adjust the actuator stroke stop bolts until the disc is
parallel to the seat surface.
CAUTION: Actuator stroke stop bolts must be
properly adjusted to prevent the valve disc from
overstroking. If incorrectly adjusted the valve
shaft may be twisted or sheared off.
4. Install the valve in line as outlined in the “Installation” section.
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Troubleshooting Valdisk 150 Valves
Failure Probable Cause Corrective Action
Valve moves to failure 1. Failure of actuator O-ring 1. Replace actuator stem O-ring
position, excessive air 2. Failure of sliding seal assembly 2. Repair or replace sliding seal assembly
bleeding from transfer case
Jerky shaft rotation 1. Overtightened packing 1. Retighten packing box nuts to slightly over
finger-tight for V-ring packing, 14 ft-lbs for
braided packing
2. Improper adjustment of lever arm on 2. Readjust lever arm (see step 1 in the
shaft causing arm to contact transfer case “Remounting Actuator” section)
3. Cylinder wall not lubricated 3. Lubricate cylinder wall with silicone lubricant
4. Worn piston O-ring allowing piston to 4. Replace O-ring; if galling has occurred
gall on cylinder wall replace all damaged parts
5. Worn actuator stem O-ring causing 5. Replace O-ring; if actuator stem is galled
actuator stem to gall on stem collar replace it
6. Worn (or damaged) thrust bearings, shaft 6. Disassemble and inspect parts; replace
bearings or packing followers any worn or damaged parts
Excessive leakage 1. Improper adjustment of external stroke 1. See “Remounting Valve to Actuator”
stops section
2. Worn or damaged seat 2. Replace seat
3. Damaged disc seating surface 3. Replace disc
4. Improper handwheel adjustment acting 4. Adjust handwheel until disc seats properly
as limitstop
Leakage through line 1. Dirty line gasket surfaces 1.Clean gasket surfaces and reinstall valve
2. Improper sealing of line flanges 2.Tighten line flanges evenly and
completely (see Table 1 for proper torque)
3. Flange or pipe misalignment 3. Clean body bore and stem, replace packing
Leakage through 1. Loose packing box nuts 1. Tighten packing box nuts to slightly over
packing box finger-tight for V-ring packing, 14 ft-lbs for
braided packing
2. Worn or damaged packing 2. Replace packing
3. Dirty or corroded packing 3.Clean body bore and stem, replace packing
Disc interferes with body 1. Disc installed upside down 1. Reinstall disc
2. Worn thrust bearings 2.Replace thrust bearings
Disc interferes with line 1.Cement lining or heavy schedule pipe 1. Modify line to allow proper disc clearance
Valve slams, won’t open, 1. Improper valve installation 1.See step 2 in “Installation” section and
or causes severe water correct flow direction
hammer
Shaft rotates, disc remains 1. Missing or broken taper pin 1. Replace taper pin
open or closed 2.Broken shaft 2. Replace shaft, make sure disc does not
overstroke and contact disc stop
Actuator operates, shaft 1. Broken internal actuator parts 1. Refer to appropriate actuator Maintenance
does not rotate Instructions
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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 presented 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 of its worldwide operations or offices.
For more information, contact:
Flowserve and Valtek are registered trademarks of Flowserve Corporation.
contact www.flowserve.com or call USA 972 443 6500
Regional Headquarters
1350 N. Mt. Springs Prkwy.
Springville, UT 84663
Phone 801 489 8611
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FCD VLAIM037-00 © 2000 Flowserve Corporation. Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
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