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
TypeMaterial 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)
Tefzel300°F (149°C)
VMPE200°F (93°C)
Max Service
Temperature
2
®
4
7
17
20
19
18
STOP!
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
®
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.
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
SECTION IV
PRESSURE CONTAINING FASTENERS
MATERIAL SELECTION
Selecting the proper fastener material is the ultimate responsibility of
the customer because the supplier does not typically know in what
service the valves will be used or what elements may be present in
the environment. Flowserve normally supplies B7 (carbon steel) for
ductile cast iron and carbon steel valves. For stainless steel and high
alloy valves, B8, Class 2B (stainless steel) fasteners are supplied as
standard. All fasteners used must have a minimum yield strength of
65,000 PSI, a minimum elongation of 25% and be compatible with
the process fluid. Determining compatibility to the process fluid goes
beyond a material being resistant to general corrosion
because the more important consideration is a material’s resistance
to stress corrosion cracking. Depending on the service, it may make
sense to use B7 fasteners on high alloy valves. One such service
would be marine environments because of stainless steel’s susceptibility to stress corrosion cracking in chloride environments.
Another key aspect of fasteners is frequent visual inspection.
Because of the common practice of using steel fasteners rather than
stainless steel to avoid chloride stress corrosion cracking, visual
inspection is recommended
to monitor the general corrosion of these fasteners. If jacketing or
insulation is used on a valve, it must be periodically removed
TABLE I
CAP SCREWS - STUDS
HHCS - Finished Heavy Hex Head Cap Screw Alloy identification stamp required on each piece.
HCS - Finished Hex Head Cap Screw Certification required.
STUD - Stud Alloy Specification (40 KSI Minimum Yield Strength, 12% Minimum Elongation)
Dimensions per ASME B18.2.1
for visual inspection of the fasteners. If you wish assistance in
determining the proper fasteners to use, please refer to the
attached chart.
DESIGN & TYPE
Flowserve’s valve design standards adopt ASME B18.2.1 (1996,
Addenda 1999) as the standard for fastener type and design. This
national standards requires that finished hex ‘head’ cap screws
be used when the head of the fastener is turned. A finished hex
‘head’ cap screw and a heavy hex cap screw have a bearing
surface under the head to minimize frictional resistance during
tightening. They also comply to qualified body diameters and
fully formed head dimensions. Cookeville Valve Operation’s policy is to use finished hex ‘head’ and heavy hex ‘head’ cap screws
for all pressure retaining fasteners. This includes top caps, packing adjusters, plug adjusters, bottom caps, body halves or other
pressure retaining components. Compliance is made with
ANSI B18.2.2 (1987, reaffirmed 1993), Square and Hex Nuts,
when studs and heavy hex nuts are required. Additional information on these items may be obtained from the Flowserve
Corporation, Cookeville Valve Operation, Cookeville,
Tennessee.
B9 -Stainless Steel per ASTM A193, Class 2B, Grade B8 (AISI type 304)
B16 - **Stainless Steel per ASTM A193, 100% hardness tested
B7 - **Chromium - Molybdenum Alloy Steel per ASTM A193, Grade B7
B7M - Chromium - Molybdenum Alloy Steel per ASTM A193, Grade B7M, 100% hardness tested
B7MT - Chromium - Molybdenum Alloy Steel per ASTM A193, Grade B7M, 100% hardness tested, PTFE coated, Dupont SP11C,
Type B - Color blue or green
B8M - 316 Stainless Steel per ASTM A193, Grade B8M, Class 1, 40 KSI Min. Yield Strength, 12% Min. El.
B8C2 - 304 Stainless Steel per ASTM A193, Grade B8, Class 2
C20 - *Carpenter C20, CB-3 (UNS NO8020), ASTM B473, 40 KSI Min. Yield Strength, 12% Min. El
HC - *Hastelloy C276 (UNS N10276), ASTM B574
I625 - * Inconel 625 (UNS N006625), ASTM B446
I825 - *Incoloy 825 (UNS N08825), ASTM B425, 40 KSI Min. Yield Strength, 12% Min. El.
IN - *Inconel 600 (UNS N0660), ASTM B166, 40 KSI Min. Yield Strength, 12% Min. El.
M - *Monel (UNS N04400), ASTM B164, Class A or B, 40 KSI Min. Yield Strength, 12% Min. El.
HB - Hastelloy B (UNS 10665), ASTM B335
I718 - **Incoloy 718, AMS 5595B
MKH - *Monel K-500, Cold drawn and aged hardened, QQN-286 and ASTM F468
L7 - **Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7
L7M - Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7M, 100% hardness tested
L7T - **Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7, Teflon® coated, Dupont SP11C, Type B - Color blue or green
L7MT N-200 - *Nickel per ASTM B160 (UNS N0220), 40 KSI Min. Yield Strength, 12% Min. El.
B7YC - **Chromium-Molybdenum Alloy Steel per A193, Grade B7, Yellow Zinc Dichromate Plated
* These options should be limited to glass ISO valves.
** CL 600 valves are limited to these alloys.
Chromium-Molybdenum Alloy Steel per ASTM A320, Grade L7M, 100% hardness tested, Teflon® coated, Dupont SP11C, Type B - Color blue or green
5
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
SECTION IV
TABLE II
NUTS
HN - Finished Heavy Hex Nut
XN - Finished Hex Nut
HXN - Regular Heavy Hex Nut
Dimension per ANSI B18.2.2
Alloy identification stamp is required on each piece.
Certification required.
8 -304 Stainless Steel per ASTM A194, Grade 8
8M - 316 Stainless Steel per ASTM A194, Grade 8M
2H - ASTM A194, Grade 2H
2HM - ASTM A194, Grade 2HM
7M - ASTM A194, Grade 7M, 100% hardness tested
7MT - ASTM A194, Grade 7M, 100% hardness tested, PTFE coated, Dupont SP11C, Type B - Color blue or green
M - Monel (UNS N04400), ASTM B164, Class A or B, QQN-281, Class B
HB - Hastelloy B (UNS 10665), ASTM B335
HC - Hastelloy C276 (UNS N10276), ASTM B574
I625 - Inconel 625 (UNS N06625), ASTM B446
I718 -Incoloy 718, AMS 5596B
I825Incoloy 825 (UNS N08825), ASTM B425
L7 - Chromium-Molybdenum Alloy Steel per ASTM A194, Grade 7
L7M - Chromium-Molybdenum Alloy Steel per ASTM A194, Grade 7M, 235 BHN Max, ASTM A320, Section 9
MKH - Monel K-500, Cold drawn and aged hardened, QQN-286 and ASTM F467
8F - 303 Stainless Steel per ASTM A194, Grade 8F
2HYC - ASTM A194, Grade 2H, Yellow Zinc Dichromate Plated
SECTION V
A. VALVE ASSEMBLY 1"-6" MACH 1 WITH PORT SEALS
NOTE: Part number reference is shown in Figure II-1, page 3.
1. Mount body (Part 1) on arbor press or table vise holding
one flange.
2. Place port seals (Part 2) in position in body. Align port seal
ports with body ports. (See Figure V-A1)
FIGURE V-A1
3. Place the plug (Part 4) into the port seals in the closed
position.
4. Push the plug (still in the closed position) downward, using
the arbor press or other suitable means, until the top of the
plug taper is 1/16" above the top port seal surface. Allow the
plug to remain in this position for the time listed in Table
V-A-I, Port Seal Sizing Times.
TABLE V-A-I
PORT SEAL SIZING TIMES
Valve sizes
Time (min)
5. Remove the plug.
6. Assemble the PFA diaphragm (Part 5) over the plug stem
(Part 4) with the aid of a diaphragm guide, Part series
BY77543A (Figure V-A2). The plug stem and diaphragm
guide should be checked for nicks before installing the
diaphragm. Nicks on these surfaces could result in
scratches on the lip of the diaphragm and must be
removed by polishing.
1" - 3"4" - 6"
58
6
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
SECTION V
FIGURE V-A2
7. Place the metal diaphragm (Part 6) over the plug stem with the
raised center section up.
8. Place the thrust gland (Part 7) over the plug stem.
9. Apply a thin film of lubricant to the plug and place the assem-
bled plug (complete with PFA diaphragm, metal diaphragm and
thrust gland), in the open position into the body. (Figure V-A3).
11. Turn the top cap to the right side up position and place the
top cap (with grounding spring in place) over the plug
stem. Orient the top cap anti-rotation lugs with the antirotation lugs on the body (Figure V-A5).
FIGURE V-A5
FIGURE V-A3
10. Lay the top cap (Part 9) upside down (the bonnet gasket flange
upward). Hold the grounding spring (Part 8) so the tabs on the
spring ID point downward. Insert the grounding spring into the
top cap and push the grounding spring to the bottom of the
center cavity in the top cap. (Figure V-A4).
FIGURE V-A4
12. Coat the top cap fastener threads (Part 10) with Loctite
®
242. Replace the tags removed in step 7 of Section III,
Valve Disassembly. Install the top cap fasteners in the top
cap.
13. Use an arbor press to push the top of the plug downward
until the bottom of the plug port aligns with the bottom of
the body port.
14. Maintain the top cap position relative to the body anti-
rotation lugs (Figure V-A5), and using all top cap fasteners
(Part 10), tighten evenly in a cross-cross method until the
top cap bottoms on the body counterbore. (Figure V-A5).
Tighten top cap fasteners to the value per valve size and
pressure class as listed in Tables V-A-II, V-A-III and V-A-IV.
15. Remove the valve from the arbor press. Operate the plug
several times. Torque will be high, but will reduce and the
plug will turn freely.
16. Install adjuster fasteners (Part 11) (Figure V-A6) and hand
tighten evenly to the values listed in Table V-A-V or until
the bottom of the plug port is 1/16" to 1/8" above the bottom of the body port.
FIGURE V-A6
7
SECTION V
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
17. Place the locking stop (Part 12) on the top cap as shown in
Figure V-A7 and tighten the locking stop fasteners (Part 13) to
a reasonable torque. Check their orientation based on the location marks made during disassembly (Section III, step 1).
FIGURE V-A7
18. Place the stop collar (Part 14) and retainer (Part 15) on the
plug stem as shown in Figure V-A8. The stop collar should
point in the direction of the flow. Check the orientation based
on the location marks made during disassembly (Section III,
step 1).
TABLE IV-A-II
FIGURE V-A8
19. The valve should turn clockwise to close. The valve is now
ready for test and use.
20. LEAK TESTING: Anytime a valve has been modified in any
manner, including fastener changes, it must be re-tested.
Normal testing, using gas, should be at 80 PSI for Class
150 through Class 600. Refer to API or MSS for test procedures complying with these specifications.
*Apply Loctite® 242 to fastener threads, top cap only.
TORQUE REQUIRED ON TOP CAP FASTENERS OF CLASS 150 MACH 1 VALVES
Valve sizes
1"1.5"2"3"4"6"
Max. Torque (ft-lbs)101015284080
TABLE V-A-III
*Apply Loctite® 242 to fastener threads, top cap only.
TORQUE REQUIRED ON TOP CAP FASTENERS OF CLASS 300 MACH 1 VALVES
Valve sizes
1"1.5"2"3"4"6"
Max. Torque (ft-lbs)1212223562115
TABLE V-A-IV
*Apply Loctite® 242 to fastener threads, top cap only.
TORQUE REQUIRED ON TOP CAP FASTENERS OF CLASS 600 MACH 1 VALVES
Valve sizes
1"1.5"2"3"4"6"
Max. Torque (ft-lbs)142035454270
TABLE V-A-V
TORQUE ON PLUG ADJUSTER OF MACH 1 VALVES, 150#, 300# AND 600#
Valve sizes
Max. Torque (ft-lbs)
1"1.5"2"3"4"6"
3535355075150
8
SECTION V
STOP!
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
B. VALVE ASSEMBLY 1"-6" MACH 1 WITH SLEEVE
1. Mount body (Part 1) on arbor press or table vise holding
one flange.
2. Place the sleeve (Part 3) into the bowl of the body.
WARNING: Sleeve port must be aligned with body port.
(See Figure V-B1)
FIGURE V-B1
FIGURE V-B3
6. Check that the top seal of the sleeve is seated into the body
counterbore. (See Figure V-B4) Remove the top cap fasteners and top cap.
FIGURE V-B4
3. Apply a thin film of lubricant on the plug (Part 4).
4. Place the plug in the closed position into the sleeve which
is in the body. (See Figure V-B2)
FIGURE V-B2
5. Position the top cap (Part 9) over the plug with the anti-
rotation lugs aligned with the body lugs, making sure the
top cap is free to move downward (Figure V-B3). Using all
top cap fasteners (Part 10), tighten evenly in a cross-cross
method until the top cap bottoms on the body counterbore.
7. Push the plug downward, while still in the closed position,
until the top of the plug taper is 1/16" above the top of the
sleeve surface. Allow the plug to remain in this position for
the time listed in Table V-B-I.
TABLE V-B-I
SLEEVE SIZING TIMES
Valve sizes
Time (min)
1" - 3"4" - 6"
58
8. Remove the plug.
9. Continue with assembly as in V-A, Valve Assembly of 1"-6"
MACH 1 with port seals, starting at number 6, assembling
diaphragms on plug stem.
9
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
NOTE: Part number reference is shown in Figure VI-1.
1. Normal procedures for field replacement of port seals or
sleeves are to be followed. Refer to V-A, steps 1-5, and V-B,
steps 1-8.
2. The fireseal top seal assembly differs from the standard Mach
1 top seal and is completed per the following instructions.
FIGURE VI-1
TYPICAL ASSEMBLY OF FIRESEAL MACH 1
16
15
14
13
12
11
10
9
8
7
3.The PFA diaphragm (Part 19) is to be flared on a tapered
bar just enough to slip over the plug stem (Fig. VI-2)
FIGURE VI-2
4. The PFA diaphragm is placed over the plug stem with the lip down using the diaphragm guide (Figure VI-3). The
plug stem should be checked for nicks before installing
the PFA diaphragm. Nicks on this surface could result in
scratches on the lip of the diaphragm.
FIGURE VI-3
17
20
19
5. The metal diaphragm (Part 20) is placed over the plug
18
3
4
2
1
10
stem just far enough to enlarge the ID to conform to the
plug stem and then removed (Figure VI-4).
FIGURE VI-4
SECTION VI
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
6. The metal diaphragm is removed from and replaced on the plug
stem with the ID lip down. (Figure VI-5)
FIGURE VI-5
7. The Grafoil packing ring (Part 17) is placed over the stem
(Figure VI-6).
FIGURE VI-7
9. The entire assembly is turned over and the Grafoil gasket
(Part 18) placed on the metal diaphragm (Figure VI-8). A
small amount of rubber cement is placed on the Grafoil in
several places to cause it to adhere to the metal diaphragm.
FIGURE VI-8
FIGURE VI-6
8. The thrust gland (Part 7) is then assembled over the plug and
driven into place using the thrust gland guide, part series
BY90431 and arbor press. (Figure VI-7)
10. Continue to assemble the valve per Section V-A, beginning
at step 6.
11
®
User Instructions Mach 1 High Performance Plug Valve - DVENIM0300-01 - 03.13
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.