Worcester Controls
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.
INSTALLATION
A. Standard CL94 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. The Chlorine
Institute recommends that the relief hole in the ball be upstream,
towards the pressure source. An arrow stamped on the body or
on a metal tag welded to the body indicates preferred flow
direction. The valve will seal in either direction. Note that the
maximum pressure rating is 300 psi for three-piece valves and
ANSI Class 300 one-piece valves, and 150 psi for ANSI 150 onepiece valves per the Chlorine Institute.
B. When installing CL94 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):
NOTE: Prior to welding, THOROUGHLY CLEAN ALL JOINT SURFACES
to prevent contamination.
1. Tack weld the valve in place.
2. Remove three body bolts, loosen the fourth, and swing out
the body with valve open. Close valves. Remove the ball and
one-piece seat/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 the valve to cool. Reassemble the valve.
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
Bolt. Dia. In.-Lbs. Ft.-Lbs.
¹₄" 96-120 8-10
⁵₁₆" 120-144 10-12
³₈" 216-264 18-22
⁷₁₆" 480-540 40-45
¹₂" 720-780 60-65
Stainless Steel and Alloy 20 Bolts
Bolt. Dia. In.-Lbs. Ft.-Lbs.
¹₄" 72-94 6-8
⁵₁₆" 120-144 10-12
³₈" 192-216 16-18
⁷₁₆" 336-384 28-32
¹₂" 504-552 42-46
D. CAUTION
The fluoropolymer body seal makes an excellent seal.
However, some points of caution in its use need emphasizing:
1. No fluoropolymer part (except a seat) is reusable. Upon
disassembly of the valve, they should be discarded and
replaced with new parts.
2. Care must be taken to avoid scratching or damaging the
fluoropolymer during installation. Light lubrication of these
seals can help to prevent damage.
NOTE: Only three-piece valves use a one-piece seat/body seal.
06959-G
¹₂
"–2" CL94 Three-Piece Chlorine Ball Valves
¹₂
"–4" CL94 150/300 Flanged One-Piece
Chlorine Ball Valves
Installation, Operation and Maintenance Instructions
2 06959-G
Flow Control Division
Worcester Controls
OPERATION
A. The operation consists of turning the stem (by manual or
automated means) ¹₄ turn clockwise to lose and ¹₄ turn counterclockwise 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.
C. Do not leave the ball partly open (throttling operation) without
having the 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. Torque Requirements: Operating torque requirements will vary
depending on the length of time between cycles, media in the
system, and line pressure. 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
Valve Size Torque (In.-Lbs.)
¹⁄₂"50
³⁄₄"75
1" 125
1¹⁄₂" 450
2" 600
3" 1200
4" 2000
MAINTENANCE
For maximum stem seal life, proper packing adjustment procedure
must be followed.
A. Tighten packing gland bolts to the torque values in the tables
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.
Gland Bolt Torque (In.-Lbs.)
Valve Size “T” Packing
¹⁄₂"–³⁄₄" 40-45
1" 65-70
1¹⁄₂"–2" 85-95
3"–4" 175-200
NOTE: After adjustment, packing creep will occur over several
hours. Bolt torque measured then will be lower.
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.
The valve 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. Refer to Chlorine Institute
Pamphlet 6 procedure for flushing and drying.
• All persons involved in the removal and disassembly of the valve
should wear the proper protective clothing such as face shield,
gloves, apron, etc.
• Refer to Chlorine Institute Pamphlet 6 for additional information
on precautions and cleaning.
A. A standard repair kit can be ordered for the CL94 Series valve
containing all the necessary parts for standard valve rebuilding;
seats, 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 seats, 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.
Repair Kit Ordering Examples:
1" CL RK 94 T R1 or
2" CL RK 94 RT R1
2" CL RK 94 RT TO726
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.
B. TO DISASSEMBLE ¹⁄₂"–2" THREE-PIECE CL94 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.
2. Close the valve. Remove the seats and ball.
3. Remove the handle (if any), gland bolts, Bellevilles, gland
plate and follower(s) (1 or 2 pieces) from the top of the valve.
06959-G 3
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 ¹₂"–2" FLANGED ONE-PIECE CL94 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 and seats.
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 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 3"–4" FLANGED ONE-PIECE CL94 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 and seats.
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: It is recommended that the valve be installed with the ball
relief hole upstream to ensure that cavity relief is upstream as
suggested in Chlorine Institute Pamphlet 6. An arrow pointing
downstream 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, body seal(s), split thrust bearing
and split ring or one-piece thrust bearing and stem seals with a
PTFE-based lubricant such as Fluorolube S-30 or equivalent.
TO REASSEMBLE ¹₂"–2" THREE-PIECE CL94 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 and one-piece seat/body seals. Open
the ball.
5. Place the center section between the pipe ends being careful
not to scratch any sealing surfaces. Replace the four body
bolts and nuts. Tighten finger-tight.
Flow Control Division
Worcester Controls
4 06959-G
Flow Control Division
Worcester Controls
“T” Packing Detail
¹₂" – 2" THREE-PIECE AND FLANGED
ONE-PIECE VALVES
3" – 4" FLANGED ONE-PIECE VALVES
06959-G 5
Flow Control Division
Worcester Controls
TO REASSEMBLE ¹₂"–2" FLANGED ONE-PIECE CL94 VALVES:
6. On all sizes except the ¹₂", place the far seat in the body
cavity.
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 (¹₂" valves only). With the valve in the closed
position (stem flats going across pipeline), insert the ball into
the body so that the stem slot engages the tang on the stem.
11. Install the body seal. Be certain that the body seal rests
squarely on the sealing surface in the body.
12. Insert the other seat into the cavity in the end plug.
13. Install the end plug into the body and tighten until the body
and end plug make metal-to-metal contact. The end plug may
project up to .009" beyond the surrounding serrated surface.
End plug must be fully tightened against machined step in
body. If in doubt, assemble end plug without seat and seal,
make a witness mark, then reassemble the full assembly.
TO REASSEMBLE 3"–4" FLANGED ONE-PIECE CL94 VALVES:
14. Place the thrust bearing on the stem.
15. Insert the stem and thrust bearing into the body through the
ball cavity. See instructions 21 through 26 for stem packing
and gland plate assembly.
16. Place one of the seats in the body cavity.
17. With the valve in the close position (stem groove going
across pipeline), insert the ball into the body so that the stem
slot engages the tang on the stem.
18. Install the body seal. Be certain that the body seal rests
squarely on the sealing surface in the body.
CAUTION: If the body seal is installed on the end plug, it
will be damaged.
19. Insert the other seat into the cavity in the end plug.
20. Assemble the end plug into the body as far as it will go.
Secure with end plug retaining screws tightening each one
firmly. The end plug screws only retain the end plug. Flange
bolt force is required to compress the body seal and seat the
end plug. Proper installation will allow not more than .010"
protrusion of the end plug beyond the valve body.
Upon reinstallation of the valve in the line, retighten the end
plug retaining screws after the flange bolts are fully torqued.
THE FOLLOWING INSTRUCTIONS ARE FOR ALL CL94 VALVES:
21. NOTE: Be certain that the stem seals are lubricated per
Rebuilding, section D, prior to assembly.
Install the following parts over the stem and into the packing
chamber in this order (refer to packing assembly drawing):
Filler ring, 629 seal, lantern ring-T, three Chevron packing
rings (for ¹₂"-2" three-piece and one-piece valves only, one
Chevron ring is of carbon-filled fluoropolymer material and
black in color and must be positioned as the top ring),
follower-T, follower-G or one-piece follower-T.
22. Install gland plate over stem.
23. Place three sets of two Belleville washers on each gland bolt.
Each set consists of two Bellevilles opposing each other with
their O.D.s touching.
24. Lubricate the gland bolt threads with an anti-galling agent,
such as Christo-Lube MCG-111. Install gland bolt/Bellevilles
through the gland plate and thread them into the body.
Tighten the bland bolt per Maintenance, A. Be certain that the
bolts do not bind — this can result in improper packing
loading.
CAUTION: Tightening the gland bolts can cause the stem to
be pushed into the ball cavity. The stem must either be
fixtured to prevent this, or be worked back into position
when assembling the ball and seats in to the body.
25. Tighten the body bolts per Installation Section C.6. (¹₂"–2"
three-piece valves only).
26. Add handle (if any) and tighten the handle set screws.
For 3"–4" flanged one-piece valves, add stop, spacer, and handle
assembly (if used) and tighten handle retaining bolt.
Note: The spacer is to be used only if one was removed with the
handle assembly and stop.
RECOMMENDED SPARES
When ordering parts, please provide the part name and all the valve
code information found on the nameplate on the body: valve size,
style, materials, ends, and “R” number (Revision Number).
Example: 1" CL94 4C T SE R1 Ball or
3" CL94 4C RT300 RO Stem
Valves may also be marked with additional “P”, “T”, “C’, or similar
number. These numbers designate non-standard products and must
be specified along with the valve code.
Example: 1" CL94 4C T SE P-2933 Ball or
¹₂" CL94 4C RT150 T-1340 Stem
6 06959-G
Flow Control Division
Worcester Controls
SERIES 94 (¹₂"–2" THREE-PIECE)
Qty. Per
Part No. Part Name Valve
1 Body 1
2 Pipe End 2
3 Ball 1
4 Stem 1
5 Seat/Body Seal 2
6 Split Ring 1
7 Thrust Bearing 1
8 Filler Ring 1
9 629 Seal 1
10 Lantern Ring T 1
11 Chevron Ring 3
12 Follower T 1
13 Handle 1
14 Set Screw 2
15 Gland Plate 1
16 Gland Bolt 2
17 Belleville Washer 12
18 Body Bolt 4
19 Body Nut 4
20 Nameplate 1
21 ¹₈" NPT Pipe Plug 1
Note: Handle is optional and ordered
separately from valve.
06959-G 7
Flow Control Division
Worcester Controls
SERIES 94-150 and 94-300 (¹₂"–2" FLANGED)
Qty. Per
Part No. Part Name Valve
1 Body 1
2 End Plug 1
3 Ball 1
4 Stem 1
5 Seat 2
6 Body Seal 1
7 Thrust Bearing 1
8 Filler Ring 1
9 629 Seal 1
10 Lantern Ring T 1
11 Chevron Ring 3
12 Follower T 1
13 Gland Plate 1
14 Gland Bolt 1
15 Belleville Washer 12
16 Handle 1
17 Handle Set Screw 2
18 Split Ring 1
19 Nameplate 1
20 ¹₈" NPT Pipe Plug 1
Note: Handle is optional and ordered separately
from valve.
Flow Control Division
Worcester Controls
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.
For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.
FLOWSERVE CORPORATION
FLOW CONTROL DIVISION
1978 Foreman Drive
Cookeville, Tennessee 38501 USA
Phone: 931 432 4021
Facsimile: 931 432 3105
www.flowserve.com
© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation. 06959-G 09/03 Printed in USA
(1¹₂" – 2")
SERIES 94-150 and 94-300 (3"–4" FLANGED)
Qty. Per
Part No. Part Name Valve
1 Body 1
2 End Plug 1
3 Ball 1
4 Stem 1
5 Seat 2
6 Body Seal 1
7 Thrust Bearing 1
8 Filler Ring 1
9 629 Seal 1
10 Lantern Ring T 1
11 Chevron Ring 3
12 Follower T 1
13 Gland Plate 1
14 Gland Bolt 1
15 Belleville Washer 12
16 Stop 1
17 Spacer (See Below) 1
18 Handle 1
19 Hex Head Bolt 1
20 Wrench Extension 1
21 End Plug Screw 4-8
22 Name Plate 1
23 ¹₈" NPT Pipe Plug 1
NOTE: Spacer not always present. Wrench
assembly and stop are optional and ordered
separately from valve.
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