Flowserve Noble Alloy Ball Valve IOM User Manual

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FLOWSERVE CORPORATION

NOBLE ALLOY VALVE

BALL VALVE

REPAIR INSTRUCTION

Cookeville Valve Operation

1978 Foreman Drive

Cookeville, TN 38541

PH: 800-251-6761

931-432-4021

FAX: [phone]

FLOWSERVE/NOBLE ALLOY VALVE BALL VALVE REPAIR MANUAL

CONTENTS

1. Disassembly

1.1 Retainer/Top Works

1.2 Body Split

1.3 Internal Parts

2. Inspection/Cleaning

2.1 Body

2.2 Ball, Seats

2.3 Stem

2.4 Top Works

2.5 Seals

3. Assembly

3.1 Internal Parts

3.2 Body and Seal

3.3 Top Works

3.4 Adjustments

4. Drawings/Specifications

4.1 Exploded View Drawings for Ball Valves

4.2 Torque Chart

4.3 2 Piece Seat Photo

4.4 Cavity Filler Drawings

4.5 Fugitive Emissions Parts Drawings

5. Special Applications

5.1 2 Piece Slurry Seats

5.2 Cavity Filler

5.3 PEEK Seats

August 22, 2002, Rev. 2

1.0 DISASSEMBLY

Refer to included exploded view drawings for parts identification and location

1.1 Remove the actuator from the retainer (9) if valve is automated. Mount the valve in a vice or

fixture by the flange on the Body (1) if flanged or thread a piece of pipe into the Body (1) of a
threaded end valve and clamp in a vice or suitable fixture. CAUTION: BE SURE THE VALVE

HAS BEEN FULLY DECONTAMINATED BEFORE ATTEMPTING DISASSEMBLY.

If lever operated, remove set screw (22) from the handle (21) and remove handle by lifting
straight off. The handle is not press fit to the stem.

Loosen and remove retainer hex nuts (17) and remove stop collars (19) from retainer (8). Lift
the retainer (8) off the studs (15). Remove the four emergency packing adjusting set screws
(18) from the retainer. The thrust bearing (13) may stay in the retainer or may stay on the
stem. If the thrust bearing remains in the retainer, tap the retainer on the bench to dislodge the
thrust bearing or use a pick to work it out, otherwise lift it off the stem. Remove the shear
collars (23) from the body or retainer depending where they stay when the retainer is removed.
Shear Collars are not used on valves under 1.5" conduit size. Remove the spring cap (12),
packing springs (11), and packing follower (10) from the stem. The packing will be removed
later when the body is apart. For valves with Fugitive Emissions package, refer to the drawings

for the 2 piece ball valve with dual packing and System IIÔ valves in section 4.1, and exploded
view in section 4.5 for the additional parts to be removed. These will be removed after the
retainer (8) is removed.

1.2 The next step is to disassemble the body. (In the case of 3 piece valves, the valve

incorporated 2 tailpieces and a body center section. The only difference would be the addition
of a second body seal and a second set of nuts and studs in the center section. All other repair
instructions remain the same.) Loosen and remove body nuts (16). The Tailpiece (2) can now

be removed. The body seal (7) will usually stay on the tailpiece. Remove the body seal and
discard. BODY SEALS SHOULD NEVER BE REUSED! The seat (4), if it came off with the
tailpiece, can be removed from the seat pocket. A pick may be needed, in case of a soft seat,
to get the seat from the pocket. Be careful not to scratch or damage the seat pocket. Grasp
the ball (3) and pull it out of the cavity (in the case of a 2-piece valve) using a rocking action.
The second seat can then be removed from the body seat cavity. Remove the stem (5) by
pushing it into the body cavity and then removing it from the body cavity. Remove the stem
washer (6) from the stem and discard. STEM WASHERS SHOULD NOT BE RESUSED.
NOTE: Stems on valves with 1/2" and 3/4" balls and some valves with Fugitive Emissions
packages will have a clip style stem collar. To remove this type of stem, push the stem part
way into the body cavity, remove the retainer clip and then pull the stem out the top of the
body.

Remove the packing (9). The valve is now ready for cleaning.

August 22, 2002, Rev. 2

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2.0 INSPECTION AND CLEANING

2.1 Thoroughly clean the body (1) and tailpiece (2) of all residue, scale or deposits. Be very

careful not to scratch or damage the body seal or seat pocket surfaces during cleaning or they
may not seal properly. Visually inspect the seal areas for scoring, erosion, pitting or any other
damage. Inspect the ball cavity and waterways for erosion or significant loss of material. Any
damage to the seal areas or seat pockets must be repaired before the valve can be
reassembled. Inspection the packing bore for damage or galling. NOTE: Nobleized parts
cannot be weld repaired and must be returned to the factory for repair. Inspect the end
connections for corrosion or damage. Flanged valves' composite flange cannot be removed.

If there is damage to the composite flange, it must be returned to the factory for replacement.

Most surfaces can be polished with scotch-bright without damage. Inspect the body studs and
nuts for corrosion and galling and if damaged, they must be replaced.

2.2 Thoroughly clean the ball (3) and seats (4) (if metal) of all residue, scale or deposits. Soft

seats should be discarded and not be reused. Inspect the ball for erosion on the nose and

scoring or scratches on the sealing area. If the ball has been damaged, it must be discarded.
Nobleized balls and seats cannot be repaired and must be replaced. Inspect the metal
seats, if equipped, for erosion, scoring or scratches on the seal face. Place the seat on a flat
plate. From I.D. of the seat, place a feeler gauge between the seal lip and the plate to check
for yielding. The seat must be replaced in the clearance is less than .004". If the metal seats
are to be reused, be sure the backseat surface is clean and in good condition as this is
important to sealing on this design seat.

2.3 Thoroughly clean the stem (5) of residue, scale or deposits. Inspect the stem tang (the end

that engages the ball) for corrosion, twist or bending. Inspect the packing area of the stem for
scoring, corrosion or galling. Minor galling on the stem where it comes through the body
below the packing or around the tang is acceptable and can be filed or polished smooth. If the
packing area of the stem has any damage, it must be replaced, as it will allow the packing to
leak.

2.4 Thoroughly clean the balance of the top works, including the packing follower (10), packing

springs (11), spring cap (12), thrust bearing (13), shear collars (23), retainer (8), stop collars
(19), emergency adjusting set screws (18) and studs/nuts. All parts should be free of
corrosion, scale or residue. The packing follower (10) should fit easily over the stem. The
thrust bearing (13) should fit snugly over the stem shoulder but rotate freely. It should also fit
snugly into the retainer bore but rotate freely. If not, it should be replaced. Inspect the
packing springs (11) for any signs of corrosion and replace if they have any indication of
damage or corrosion. The set screws (18) should screw in and out of the retainer easily. An
anti-seize compound should be used on these. If they are damaged or frozen in the retainer
(8) replace both the retainer and the set screws. Remember, the emergency adjusting set

screws (18) are your back up packing adjustment should the live loading of the packing
springs fail or the packing start to leak.

2.5 All seals including the packing (9), body seals (7) and soft seats (if equipped) should never be

reused and should be replaced with new factory parts.

August 22, 2002, Rev. 2

2

3.0 ASSEMBLY

3.1 Fixture the body (1) so the ball cavity is facing up. (In the case of 3 piece valves, assemble

one tailpiece to the body and then proceed with the standard assembly instructions.) Be sure
the body studs (14) are installed and equal in length. If the stem has a "c" clip retainer, install
the stem from the topside of the stem bore so it protrudes into the ball cavity, place the "c" clip
in the stem groove, and pull the stem tight into the stem bore. "C" clipped stems are only

found in valves with 1/2" or 3/4" bore balls and valves equipped with the Fugitive emission
package. Place a seat (4) into the seat pocket in the body with the conical seal face up.
Seats are not matched sets and can be installed on either side. Metal and soft seats are
interchangeable with each other. Insert the ball (3) into the body with a rocking motion so the

ball slot engages the stem tang.

3.2 Place a new body seal (7) onto the seal land on the face of the tailpiece (2). Install the second

seat into the seat pocket of the tailpiece. Carefully slide the tailpiece onto the body studs and
onto the body, making sure the seat and body seal remain in place. Once the tailpiece is in
place, install the body nuts (16) and torque to the proper specification listed on the torque
chart for that size nut. This will crush the body seal and pre-load the seats. The torque chart
is located in the specification section at the back of this manual. Check the body joint with a
feeler gauge. The joint gap must not exceed .001". If an excessive gap remains after the
body nuts have been torqued, place the valve in a hydraulic press and press until the .001"
feeler gauge cannot be insert in the joint. Re-torque the body nuts while still under pressure
on the press.

3.3 Fixture the assembled body so the stem is facing up. Slide the new packing (9) over the stem

and work into the body packing bore. In case of the fugitive package, next install the lantern
ring (25), block seal (26), FEM block (if supplied on Custom Ball valve)(27), and then the
second packing. The packing follower (10) can be used to help push the packing down.

Install the packing follower (10) onto the stem with the relief for the springs facing up, away
from the body. Place the packing springs (11) over the stem and onto the packing follower.
The dished side of the springs should face up, away from the body. Place the spring cap (12)
over the springs so it encapsulates the springs. Place the thrust bearing (13) over the stem
until it bottoms out on the land on the stem. It will sit partially in the spring cap. Install the
retainer studs (15) into the body until they bottom in the threads. Place the shear collars (23)
(if equipped) over the retainer studs and engage them into the body. Apply some anti-seize
compound to the emergency packing adjusting set screws (18) and screw them into the
retainer (8) until the ends of the screws are flush with the inside bore on the retainer. They
should not stick out into the spring cap bore. They may protrude slightly out the top of the
retainer. Install the retainer (8) over the studs and drop it into place over the stem parts.
Place the adjustable stop collars (19) over the retainer studs (15), install the retainer nuts (17)
but do not tighten fully. Install the handle (21) over the stem and place the set screw (22) into
the handle and tighten.

3.4 The only feature that requires adjustment on the Flowserve/Noble Alloy valve is the adjustable

stop collar (E) feature on the handle operated valves. Actuated valves do not have stop
collars. The packing does not require any further adjustment after the valve has been
assemble due to the live loaded design. Rotate the handle to open the valve to the full open
position and align the ball bore so that it is centered with the conduit of the valve. With the
retainer nuts (17) loosened, rotate one of the stop collars (19) until it contacts the ear on the
handle stop. Tighten the nut fully. Rotate the handle a few times to check the alignment and
readjust if necessary. Rotate the handle to close the valve, which will position the handle 90
degrees to the bore of the valve. Rotate the other stop collar (18) until it firmly touches the
handle stop and tighten the nut fully. Rotate the handle a few times open and closed and
check the alignment. Readjust if necessary. The valve is now ready for testing.

August 22, 2002, Rev. 2

3

4.0 DRAWINGS AND SPECIFICATIONS

August 22, 2002, Rev. 2

4