Flowserve CPT Metal Characterized Seat Control Valves User Manual

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.

I. INSTALLATION

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

installed for flow in either direction. Use care to exclude pipe sealants from the valve cavity.

B. When installing CPT 94 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 inline. 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 valve must be open to prevent adhesion of weld spatter to the ball. Use STICK or MIG welding, 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 all four body nuts and bolts, and place the valve in

the open position. Remove center section from between pipe ends by separating the pipe ends from the body by at least

to allow locating diameter on the back of the metal characterized seat (inserted into oversized pipe end bore) to clear pipe end flange. With valve in closed position, remove seats, seat back seal(s), body seals and ball.

3. Return the body to its original position and temporarily secure it with two bolts diagonally opposite each other.

4. Weld valve inline. If gas welding is used, do not play flame on valve body.

5. 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.

6. 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 7). 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.

7. Place center section 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 (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 figures on the following page.

D. CAUTION

The fluoropolymer body seals (code T) and the coated 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.

09015-G

Metal Characterized Seated Control Valve

2"-2" CPT 94, Three-Piece Ball Valves,

2"-4" CPT 94 150/300,

1"-2" CPT 94 600 Flanged One-Piece Ball Valves

Installation, Operation and Maintenance Instructions

2. Avoid scratching or damaging the fluoropolymer seals or the coating of the stainless steel 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 6).

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 CPT 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 CPT valves.

II. OPERATION

A. The operation of the valve consists of turning the stem 1/

4 turn

clockwise to close and

4 turn counter-clockwise to open. When

the stem flats (

2"-2") or groove (3" and 4") are in line with the

pipeline, the valve is open. These valves are designed to be automated.

B. CPT 94 Series valves meet the leakage rates of ANSI B16.104

Class VI.

C. As shipped from the factory, valves 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. Replace with a non-silicone based lubricant. CPT valves should not be operated without a break-in lubricant.

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

allowed to stand in ball valve cavities.

E. 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 the Worcester Actuator Sizing Manual.

Valve Size -1/

"1" 1

"2"3" 4"

Maximum Expected - 240 265 360 550 850 2100 3500 Breakaway (In.-Lbs.)

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.

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.

NOTE: 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.

CARBON STEEL BOLTS STAINLESS STEEL & ALLOY 20 BOLTS

2 Metal Characterized Seated Control Valves Installation, Operation and Maintenance Instructions 09015-G

Flow Control Division

Worcester Controls

Bolt Diameter

16"

In.-Lbs.

96-120

155-204

216-262

480-540

720-780

Ft.-Lbs.

8-10

13-17

18-22

40-45

60-65

Bolt Diameter

16"

In.-Lbs.

72-94

120-144

192-216

336-384

504-552

Ft.-Lbs.

6-8

10-12

16-18

28-32

42-46

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.

09015-G Metal Characterized Seated Control Valves Installation, Operation and Maintenance Instructions 3

• 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 CPT 94 Series valve

containing all the necessary parts for standard valve rebuilding; seats, seat back seal(s) (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 seats and body seals, the characterized seat configuration, 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" CPT RK94 PM A06 R0 1" CPT RK94 GG G30 R0 3" CPT RK94 PT G60 R0 3" CPT RK94 RZ A30 R0 2" CPT RK94 AG G60 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 VALVES:

1. Remove actuator and place valve in open position. Remove all

four body bolts and nuts and remove center section from between the 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.

2. Close the valve. Remove the seats, seat back seal(s), ball and

body seals.

3. Remove the gland bolts, Bellevilles, gland plate and follower

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

2"-2" FLANGED ONE-PIECE VALVES:

5. Place valve in closed position, remove actuator from valve and remove valve from line.

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 seal(s).

8. Remove the gland bolts, Belleville washers, gland plate and follower 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.

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.

Flow Control Division

Worcester Controls

VALVE SIZE GLAND BOLT TORQUE (In.-Lbs.) GLAND BOLT TORQUE (In.-Lbs.)

“T” PACKING “G” PACKING

3"-4"

40-45

65-70

85-95

175-200

90-110

120-140

210-230

270-295

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

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Flowserve CPT Metal Characterized Seat Control Valves User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual