Flowserve CPT Metal Characterized Seat Control Valve User Manual
Worcester Controls
CAUTION: Flowserve recommends that all products 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. Valve is designed for flow in either direction. Use care to exclude
pipe sealants from valve cavity.
2. When installing CPT 44 or CPT 51/52 flanged valves, use
standard gaskets suitable for the specific service and tighten the
flange bolts or studs evenly. On CPT 44 wafer valves it is
recommended to leave the ball in the open position while
installing, to eliminate possibility of damaging ball finish.
3. CPT 44 Weld End Valves (SW, BW):
NOTES: Prior to welding, THOROUGHLY CLEAN ALL JOINT
SURFACES to prevent contamination.
Valves with “AG”, “GG”, “PG”, “RG”, and “XG” 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. These valves will have a red
welding tag attached. 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 valve 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:
a. Tack weld the valve in place.
b. Remove actuator and all four body nuts and bolts and place
the valve in the open position.
c. Remove center section from between pipe ends by separating
the pipe ends from the body by at least !?8" to allow locating
diameter on the back of the metal characterized seat (inserted
into oversized pipe end bore) to clear pipe end flange.
d. With valve in closed position, remove seats, seat back seal(s),
body seals and ball. Return the body to its original position
and temporarily secure it with two bolts diagonally opposite
each other.
e. Weld valve in line. If gas welding is used, do not play flame on
valve body.
f. Allow valve to cool. Remove body and, with stem in the closed
position, replace ball, seats and install new seat back seal(s),
which are shipped separately from valve. Do not reuse old seat
back seal(s). The characterized seat has a “V” or “Slot” cut in it
for improved flow control, and must be properly oriented to
function. A locating pin is provided in the body, and a groove
in the seat, to assure that proper alignment is accomplished.
The seat must fit properly and not jam on the pin. The opposite
seat has a standard round port in it.
g. Open the valve and replace body seals, or add new body seals, if
they were shipped separately from the valve. Temporary Buna
body seals, if found in the valve as received, are not to be reused.
(If coated stainless steel “S” gasket body seals are used [Code M
or G], install them with wide flange facing the body [see view A-A
on page 6]). Before putting the center section between the pipe
ends, make sure that the seat back seal is centered on the back of
the seat. If it is not, it could be damaged or cause the valve to leak.
h. Place center section between pipe ends by separating the pipe
ends from the body by at least A?k" to allow locating diameter
on the back of the metal characterized seat (for insertion into
oversized pipe end bore) to clear pipe end flange. Replace
actuator and body bolts and nuts. Tighten and torque the body
bolts evenly and diagonally opposite each other, alternating in
a criss-cross pattern to the following torque figures:
17812-N
Metal Characterized-seated Control Valve
1
/4" – 4" CPT 44 and 1/2" – 4" CPT 51/52
Installation, Operation and Maintenance Instructions
Carbon Steel Stainless Steel and
Bolts Alloy 20 Bolts
Bolt Bolt
Diameter in-lb ft-lb Diameter in-lb ft-lb
!?4" 96-120 8-10 !?4" 72-94 6-8
%?16" 156-204 13-17 %?16" 120-144 10-12
#?8" 216-264 18-22 #?8" 192-216 16-18
/?16" 480-540 40-45 /?16" 336-384 28-32
!?2" 720-780 60-65 !?2" 504-552 42-46
2 Metal Characterized-Seated Control Valve !?4"–4" CPT 44 and !?2"–4" CPT 51/52 Installation, Operation and Maintenance 17812-N
Flow Control Division
Worcester Controls
NOTE: Stainless steel bolts and nuts are used in all three-piece valves
with stainless steel bodies and also valves with “GG” seats and body
seals.
4. CAUTION:
a. The seat back seals, fluoropolymer body seals (T), and the
coated stainless steel gasket body seals (M and G) are not
reusable. Upon disassembly of the valve these seals must
be replaced. Also ensure that the fluoropolymer seals, or
the coating of the stainless steel gaskets is not scratched or
damaged during installation. Light lubrication of these seals
can help to prevent damage.
b. Care must also be taken when handling graphite thrust bear-
ings, stem seals or 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.
c. The ball used in CPT valves is round to special tolerances
to ensure proper contact with the seat. Do not drop, dent or
scratch the ball during handling. The ball also has a
special anti-galling coating; DO NOT use an uncoated ball
in CPT valves.
B. OPERATION
1. The operation consists of turning the stem A?f turn clockwise to
close and !?4 turn counter-clockwise to open. When stem flats
(!?4" – 2") or stem groove (3", 4") are in line with the pipeline, the
valve is open. This valve is designed to be automated.
2. CPT valves meet the leakage rates of ANSI B16.104 Class VI.
3. As shipped from the factory, valves contain a silicone-based
lubricant. This is for break-in purposes. Lubricant may be
removed with a solvent, such as lacquer thinner, if found to be
objectionable for a particular application, and replaced with a
non-silicone based lubricant. CPT valves should not be operated
without a break-in lubricant.
4. Media which can solidify, crystallize or polymerize should not be
allowed to stand in valve cavities.
5. 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. All figures in the
following table are based in laboratory tests with water as the
media. They are measured at WOG rated pressure, 70°F, with clean
tap water, after 24 hours. For a more detailed analysis of valve
torque requirements, see Worcester’s Actuator Sizing Manual.
C. MAINTENANCE
1. For 3"– 4" CPT 44/51/52 Revision RO-R2 valves, if seepage is noted
at stem, tighten retaining nut 1/6 turn at a time until seepage stops.
2. Tighten stem seal retaining nut (!?2"– 2" CPT 44 Revision RO valves)
or self-locking stem nut (!?4"– 2" CPT 44 & !?2"– 2" CPT 51/52
Revision R1-R4 valves) if seepage is noted at stem.
CAUTION: For maximum stem seal life, proper stem adjustment
procedures must be followed. Excessive tightening causes higher
torque and shorter stem seal life.
Revision RO Valves:
a. Loosen top retaining nut.
b. While holding the stem to prevent turning, tighten bottom-
retaining nut until Belleville washers are flat (the nut will bottom).
c. Back off bottom retaining nut !?6 turn.
d. Tighten the top retaining nut securely to lock the bottom
retaining nut in place with the lockwasher in between. Hold the
bottom nut securely with wrench while tightening the top nut to
lock the two nuts in place.
Revision R1 -R4 Valves:
e. Tighten self-locking stem nut until Bellevilles washers are flat,
then back off nut !?3 turn.
CAUTION: The self-locking stem nut is difficult to tighten, and
must fully flatten Bellevilles before backing off.
D. REBUILDING
a WARNING: - BALL VALVES CAN TRAP PRESSURIZED FLUIDS IN
THE BALL CAVITY WHEN CLOSED.
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.
1. A standard repair kit can be ordered for these valves consisting
of seats, control seat or control seat insert (3"– 6" valves only),
body seal(s), seat seal(s), Belleville washers, stem seal(s), thrust
bearing(s), and a self-locking stem nut (!?4"– 2" Revision R1-R4
valves only). Specify the valve size and series, the material of the
seat and body seal, the characterized seat configuration (if
needed), and the “R” number (Revision Number) of the valve or
for non-standard valve, the “P” number, “T” number, “C”
number, or similar, as found on either the mounting bracket
nameplate or the valve nameplate.
Maximum Expected
Valve Size Breakaway Torque
!?4", !?2" 150 in-lb
#?4" 175 in-lb
1" 250 in-lb
1!?2" 400 in-lb
2" 700 in-lb
3" 1900 in-lb
4" 3300 in-lb
17812-N Metal Characterized-Seated Control Valve !?4"–4" CPT 44 and !?2"–4" CPT 51/52 Installation, Operation and Maintenance 3
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. To Disassemble !?4"– 2" CPT 44 Valves (All Revisions):
a. Remove actuator and all four body nuts and bolts, and place the
valve in the open position.
b. Remove center section from between pipe ends by separating
the pipe ends from the body by at least !?8" to allow locating
diameter on the back of the metal characterized seat (inserted
into oversized pipe end bore) to clear pipe end flange.
c. With valve in closed position, remove old seats, seat back
seal(s), body seals and ball.
d. Revision RO Valves: Using a wrench to prevent stem from
turning, remove top retaining nut, lockwasher, bottom retaining
nut, and (2) Belleville washers from stem.
Revision R1-R4 Valves: Using a wrench to prevent stem from
turning, remove self-locking stem nut, and (4) Belleville washers
from stem.
e. Remove the follower, stem, stem seal(s), stem seal protector (if
any), thrust bearing, and thrust bearing protector (if any), which
may be on the stem or in the body cavity. Retain the follower.
To Disassemble !?2"– 2" CPT 51/52 Valves (All Revisions):
f. Remove actuator from valve. 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 body and discard. Also remove the
near seat and seat back seal, if applicable. Place valve in closed
position and remove the ball, the far seat and seat seal.
NOTE: If required, end plug removal tools are available from your
supplier or from your Worcester representative.
g. Using a wrench to prevent stem from turning, remove self-
locking stem nut, and (4) Belleville washers from stem.
NOTE: On the !?2" valve, the far seat must be removed before pushing
stem into cavity.
h. Remove the follower, stem, stem seal(s), stem seal protector
(if any), and thrust bearing, and thrust bearing protector (if
any), which may be on the stem or in the body cavity. Retain
the follower.
To Disassemble 3"– 4" CPT 44/51/52 Valves (All Revisions):
i. Remove actuator from valve. Unscrew all flange bolts and nuts
and remove valve from line. Remove all end plug retaining set
screws from the valve body. Remove end plug. If necessary, drive
end plug from the valve using a wooden drift applied to the ball.
If the body seal was not removed with the end plug, remove it
from the body and discard. Also remove the near seat and seat
back seal (if any). Place valve in closed position and remove the
ball, the far seat, seat insert (if used), and seat back seal.
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, and may include a stem
seal protector.
j. Prevent the stem from turning by holding inside body. (The ball
can be inserted and prevented from rotating with a non-metallic
rod such as a screwdriver handle.) This will hold the stem
stationary without damaging the ball. Remove retaining nut and
stem spacer (if used).
k. Remove Belleville washers (if any). Remove and retain the
follower and push stem into ball cavity and remove. Discard old
stem seal protector (if any), stem seal(s) and thrust bearing,
which may be stuck on the stem or in the body cavity. Remove
stem-centering washer(s) and retain.
3. Visual Inspection:
a. As noted in part A.4.c, the ball is round to special tolerances and
should be visually checked for defects. Light marring from the
action of the ball against the seats is normal and will not affect
the operation of the valve. Visible tracking is normal. Tracking
which can be felt is a potential problem.
b. The stem and body surfaces that the thrust bearing and stem
seal contact should be clean, undamaged, and free of pit marks
and scratches.
4. Reassembly:
NOTE: For all valves, lightly lubricate the ball, seats, seat back seal(s),
body seal(s), stem seal(s), and thrust bearing(s) with a lubricant
compatible with the media and temperature being handled. White
petroleum jelly is a good general-purpose lubricant.
When a repair kit is purchased, the seats will be lubricated at the
factory. If they are not, they should be lubricated as noted in
Paragraph D.4. and B.3. DO NOT operate a newly rebuilt valve
without break-in lubricant. The seat back seals will be preassembled to the seat backs.
If graphite parts are used, handle them gently on the flat surfaces
rather than the O.D. These parts can be easily damaged by
squeezing the O.D. These parts will not work if they are cracked or
broken. Light flaking of the material is acceptable.
For stem area rebuilding of all CPT valves, refer to exploded views,
stem build illustrations, and stem component color chart on the
following pages that pertain to the particular valve being rebuilt.
Please note that PEEK thrust bearing and stem seal protectors are
placed outside of seals and bearings. The seals and bearings must
contact the body.
Flow Control Division
Worcester Controls
Repair Kit Order Example
1" CPT RK 44 GG G60 R1 or TO914
(Size) (Valve Series) (Repair Kit) (Valve Type) (Seat, Seal) (Characterized Seat Configuration) (Revision # or P, T, C, etc., #)
Not Used with A?s"– 2" CPT
44 Revision RO Valves
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