Flowserve Mach 1 User Manual
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User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
USER INSTRUCTIONS
Mach 1
™
High Performance Plug Valve
FCD DVENIM0300-01 03/13
Installation
Operation
Maintenance Instructions
Quality
System
Certificate
1
®
STOP!
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
TABLE OF CONTENTS
SECTION TITLE PAGE
I INSTALLATION ................................................................................. 2
II OPERATING/MAINTENANCE INSTRUCTIONS FOR MACH 1 .............................................. 3
III VALVE DISASSEMBLY - MACH 1
RECOMMENDED PRECAUTIONARY MEASURES ....................................................... 4
DISASSEMBLY STEPS ........................................................................... 4
IV PRESSURE CONTAINING FASTENERS .............................................................. 5
V A. VALVE ASSEMBLY 1"-6" MACH 1 WITH PORT SEALS ................................................ 6
B. VALVE ASSEMBLY 1"-6" MACH 1 WITH SLEEVE ..................................................... 9
VI ASSEMBLY SPECIFICATIONS - FIRESEAL VALVES 1"-6" MACH 1 ......................................... 10
DANGER: indicates that death, severe personal injury
and/or substantial property damage will occur if proper
precautions are not taken.
WARNING: indicates that death, severe personal injury
and/or substantial property damage can occur if proper
precautions are not taken.
CAUTION: indicates that minor personal injury and/or
property damage can occur if proper precautions are
not taken.
NOTE: indicates and provides additional technical infor-
mation, which may not be very obvious even to qualified personnel. Compliance with other, not particularly
emphasised notes, with regard to transport, assembly,
operation and maintenance and with regard to technical
documentation (e.g. in the operating instruction, product documentation or on the product itself) is essential, in order to avoid faults, which in themselves might
directly or indirectly cause severe personal injury or
property damage.
SECTION I
INSTALLATION INSTRUCTIONS - FLANGED MACH 1, CLASS 150, 300 AND 600
FLANGED:
Installation of Flowserve flanged valves is best accomplished by
locating valves in pipeline flanges, assuring all corrosion and foreign
materials are removed from pipe flanges and then center gaskets
with the valve flanges. Fasteners or taper pins should be used to
align holes and locate gaskets. Fasteners should be tightened to the
corresponding valve and fastener size.
TABLE I
Temperature Limitations
Type Material Description
R Seat (full, no insert) 400°F (204°C)
PFA
S Seat (full, insert) 525°F (274°C)
P Seat (partial, insert) 525°F (274°C)
Tefzel 300°F (149°C)
VMPE 200°F (93°C)
Max Service
Temperature
2
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4
7
17
20
19
18
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User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
SECTION II
OPERATING/MAINTENANCE INSTRUCTIONS FOR MACH 1
Maintenance requirements for Mach 1 valves may vary due to
operating conditions of the process. Factors such as operating
temperature, pressure, solids content, and frequency of
cycling
can influence valve performance and maintenance
requirements.
Seal wear is compensated by adjusting appropriate parts. For
Mach 1 valves, there are three possible leak paths:
1. Top Cap (bonnet)
2. Stem
3. Line (through)
Corresponding adjustments for each leak path are as follows.
NOTE: Refer to Figure II-1 or Figure VI-1 for parts identification
1. Top Cap (bonnet)
Leakage due to thermal or pressure cycling is eliminated by
tightening the top cap fasteners (Part 10) in a “criss-cross”
pattern to the torque values given in the tables. This adjustment is most effective when the valve is not pressurized. It is
important that the top cap fasteners not be tightened excessively and that torque values applied be within industry standard for fasteners.
2. Stem
Leakage due to wear of the diaphragm, and/or wear to the
sleeve (primary seal) is eliminated by tightening the adjuster
fasteners (Part 11) in 1/4 turn increments. The adjuster fasteners must be tightened evenly for maximum adjustment. The
valve should be operated between adjustments to assure that
the plug properly seats itself into the sleeve. If leakage persists
after repeated adjustments, the sleeve and diaphragm will
require replacement as covered in Section V and Section VI.
FIGURE II-1
Typical Assembly of Mach 1
16
15
14
13
12
11
10
9
8
7
6
5
3. Line (through)
Through leakage due to wear of the primary seal can be elimi-
nated by tightening the adjuster fasteners (Part 11) in 1/4 turn
increments. The fasteners must be tightened evenly for maximum adjustment. The valve should be operated during adjustments to prevent excessive operating torque. Should leakage
persist after repeated adjustments, the port seals or sleeve will
require replacement as covered in Section V and Section VI.
WARNING:
To avoid personal injury and prevent damage to
equipment, do not operate or repair this valve without observing the following procedures outlined in this manual.
3
4
2
1
3
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STOP!
SECTION III
VALVE DISASSEMBLY - MACH 1
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
RECOMMENDED PRECAUTIONARY MEASURES
1. Valves must be relieved of process fluid and pressure prior
to disassembly.
2. Personnel performing disassembly must be suitably pro-
tected and alert for emission of hazardous process fluid.
DISASSEMBLY STEPS
NOTE: Refer to Figure II-1 or VI-1 for parts identification.
If an actuator or gearbox operates the valve, alignment
marks should be noted to assure correct orientation when
reassembled. This may best be accomplished by making
matching marks on the plug stem and operator housing
with no burrs made on the plug stem.
1. Remove the wrench (Part 16), if so equipped. Remove the
stop collar retainer (Part 15), stop collar (Part 14) and
locking stop (Part 12) after marking their orientation.
2. Gradually loosen adjuster fasteners (Part 11) - DO NOT
REMOVE.
3. WARNING: Do not loosen or remove top cap fasteners
(Part 10) when removing an operator. Remove the operator by unfastening it from the bracket.
4. Turn plug (Part 4) in order to raise the plug to vent any
material trapped in the valve (see note below).
NOTE: If there is no upward movement of the plug, it will
be necessary to devise a method of lifting the plug upward.
This may require removal of the valve operator (Step 3).
This operation should be undertaken noting the above
precautionary measures. Methods of plug removal must
include protective measures on plug stem and plug end.
11. Inspect the valve port seals or sleeve for wear or damage,
especially scratches near the top, bottom, and port areas. If
wear or damage is excessive, the port seals/sleeve should
be replaced.
12. Remove port seals or sleeve as follows:
NOTE: Care must be taken not to damage the machined
internal body bore.
a. Lift port seals out of body bowl.
b. To remove the sleeve, use a wooden dowel and pry the
sleeve upward by engaging the dowel in the sleeve at the
top of the port. A sharp blow may be necessary to dislodge
the sleeve. Both sides of the sleeve may need to be pried
upward for removal. (See Figure III-1)
APPLY FORCE APPLY FORCE
Figure III-1
5. Once the plug has lifted, the adjuster fasteners (Part 11)
can be completely removed.
6. Gradually loosen but DO NOT REMOVE all of the top cap
fasteners (Part 10). Turn the plug until it is loose from the
port seal (Part 2) or sleeve (Part 3) and all pressure has
been vented. (Again, it may be necessary to use a mechanical means to move the plug upwards.)
7. Remove the top cap fasteners and top cap (Part 9) from
the plug stem. Retain the tags for attachment during
re-assembly.
8. Remove the plug (Part 4) from the body (Part 1).
9. Remove the grounding spring (Part 8) and thrust gland
(Part 7).
10. Remove the metal diaphragm (Part 6) and the PFA dia-
phragm (Part 5) from the plug stem.
4
13. Thoroughly clean all valve parts with an acceptable cleaner.
14. Inspect parts for damage. Look for marred, scratched, or
rough sealing surfaces on the valve plug or machined
body bore.
NOTE: Reinstallation of damaged or unclean parts will ruin
any replacement seals installed into the valve.
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