Flowserve Marathon-Mach 1 User Manual
Installation, Operation and Maintenance
Marathon-Mach 1
HIGH PERFORMANCE
PLUG VALVE
™
Breaking The Barriers
Quality
System
Certificate
Bulletin
DVENIM0333
Flow Control Division
Section 1.0
PRESSURE CONTAINING FASTENERS (continued)
TABLE OF CONTENTS
SECTION TITLE PAGE
I INSTALLATION ................................................................................2
II OPERATING/MAINTENANCE INSTRUCTIONS FOR MARATHON-MACH 1 .................................... 3
III VALVE DISASSEMBLY - MARATHON-MACH 1
RECOMMENDED PRECAUTIONARY MEASURES .......................................................4
DISASSEMBLY STEPS ...........................................................................4
IV PRESSURE CONTAINING FASTENERS ..............................................................5
V A. VALVE ASSEMBLY 1"- 6" MARATHON-MACH 1 WITH PORT SEALS ......................................6
B. VALVE ASSEMBLY 1"- 6" MARATHON-MACH 1 WITH SLEEVE .......................................... 9
VI ASSEMBLY SPECIFICATIONS - FIRESEAL VALVES 1"- 6" MARATHON-MACH 1 .............................. 10
SECTION I
INSTALLATION INSTRUCTIONS - FLANGED MARATHON-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.
2
TABLE I-1
Temperature Limitations
Type
PFA
P-Seat (port seal, insert) 525°F (274°C)
UMPE 200°F (93°C)
Tefzel 300°F (149°C)
Material
Description
R-Seat (full, no insert) 400°F (274°C)
S-Seat (full, insert) 525°F (204°C)
Maximum Service
Temperature
SECTION II
OPERATING/MAINTENANCE INSTRUCTIONS FOR MARATHON-MACH 1
Flow Control Division
Section 1.0
Maintenance requirements for Marathon-Mach 1 valves may
vary due to operating conditions of the process. Factors such
as operating temperature, pressure, solids content, and
frequency of cycling
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 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.
can influence valve performance and
FIGURE II-1
Typical Assembly of Marathon-Mach 1 Valve
3. Line (through)
Through leakage due to wear of the primary seal can be
eliminated 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.
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
SECTION III
VALVE DISASSEMBLY - MARATHON-MACH 1
Flow Control Division
Section 1.0
RECOMMENDED PRECAUTIONARY MEASURES
1. Valves must be relieved of process fluid and pressure
prior to disassembly.
2. Personnel performing disassembly must be suitably
protected and alert for emission of hazardous
process fluid.
DISASSEMBLY STEPS
NOTE: Refer to Figure II-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.
10. For Marathon valves, be sure to remove the o-rings and
backup rings first and then the PFA diaphram.
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)
FIGURE III-1
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.
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).
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.
4
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