PlugSeal
PLUG VALVE
DVENIM0200
TABLE OF CONTENTS
HOW TO SPECIFY PLUGSEAL VALVES ......................................................................................................... 3
INTRODUCTION ..................................................................................................................................................4
SECTION I. SAFETY PRECAUTIONS......................................................................................................... 4
SECTION II. PRESSURE CONTAINING FASTENERS............................................................................... 2
SECTION III. INSTALLATION INSTRUCTION – FLANGED AND WELDED PLUGSEAL VALVES ... 2
SECTION IV. OPERATING / MAINTENCE INSTRUCTIONS ..................................................................... 7
SECTION V. VALVE DISASSEMBLY AND REPLACEMENT OF PLUG................................................. 7
SECTION VI. VALVE ASSEMBLY................................................................................................................. 8
SECTION VII. RECOMMENDED SPARE PARTS LIST ................................................................................ 9
FOREWORD
Flowserve Corporation, Flow Control Division, has established this Installation, Operating and Maintenance Manual to facilitate field installation,
operation and repair of Mach 1 Cartridge Plug Valves.
It is recommended that questions or concerns involving the process described in this manual be directed to the local Sales Representative of Flowserve
Corporation. Only Flowserve replacement repair parts and assembly tooling made or designed or approved by Flowserve Corporation should be used.
Part numbers referenced in the following sections are available from Flowserve Corporation, Flow Control Division.
2
HOW TO SPECIFY PLUGSEAL VALVES
Type Class End Style Operator Fasteners Options
Size Materials
----- --M---
Selection Code Selection Code
1 in (25 mm) 1 12 in (300 mm) 12
2 in (50 mm) 2 14 in (350 mm) 14
3 in (75 mm) 3 16 in (400 mm) 16
4 in (100 mm) 4 18 in (450 mm) 18
6 in (150 mm) 6 B840 1 B8MC1 A
8 in (200 mm) 8 B9 2 B16 B
10 in (250 mm) 10 B7 3 B8MC2 C
Selection Code
PlugSeal
Selection
Selection Code
Buttweld 3
Selection Code Operator
2-Way C
Selection Code Selection Code
CD4M 0 CK3M K
D4 1 D4L L
D20 2 D20W M
DMM 3 DINC N
DNI 4 CX2M R
DC2 5 904L T
DC3 6 CE3MN Z
D2L 9
D2 J
Selection Code Selection Code
CD4M 0 CK3M K
D4 1 D4L L
D20 2 D20W M
DMM 3 DINC N
DNI 4 CX2M R
DC2 5 904L T
DC3 6 DCI U
D2L 9
D2 J
Valve Size
Type
Class
600 6
End Connection
Plug Configuration
Body Alloy
Plug Alloy
Code
Selection Code
None W
Selection Code Selection Code
B7MT 4 I625 D
HC 6 L7M F
I718 7 I825 I
PS
B7M 9 L7M L
B7MZ 0 B7T T
Selection Code Selection Code
B840 1
B9 2 B16 B
B7 3 B8MC2 C
B7MT 4 I625 D
HC 6 L7M F
I718 7 I825 I
B7M 9 L7 L
B7MZ 0 B7T T
Selection Code
Wrench (1" - 4") 0
Gear (6" - 16") 1
Bare Stem 9
Selection Code
PFA A
Selection Code
CD4M 0
Options
Adjuster Fasteners
Top Cap Fasteners
Plug Sealing Material
Top Cap Alloy
3
INTRODUCTION
The Plugseal valve is a superior plug valve utilizing a
PFA coated plug in a machined body bore to provide
exemplary sealing capabilities in non abrasive services.
Designed for full rated class 600 service conditions with
buttweld ends, the Plugseal valve is designed to ASME
SECTION I.
SAFETY PRECAUTIONS
To avoid possible injury to personnel or damage to valve
parts, WARNING and CAUTION notes must be strictly
adhered to. Modifying this product, substituting nonfactory parts, or using maintenance procedures other
than outlined could drastically affect performance, be
hazardous to personnel and equipment, and may void
existing warranties.
1. WARNING: Standard industry safety practices
must be adhered to when working on this, or any
other, process control product. Specifically,
personal protective and lifting devices must be
used as warranted.
2. Depressurize and bleed the line on both sides of
the valve before attempting to service the valve.
3. Check nameplate before installation to ensure that
the valve is not installed in systems where service
conditions exceed those for which the valve was
designed.
B16.34 and pressures up to 1440 psi. Based on
simplicity, the design allows easy plug removal and
replacement, minimizing the number of spare parts and
inventory required.
4
IMPORTANT NOTES ABOUT YOUR WARRANTY AND SAFETY
Replacement Parts
The use of parts and components other than those
supplied by Flowserve Corporation could severely
restrict the operation and performance of this valve.
Unauthorized modifications or substitution of
components can lead to valve failure due to
corrosion and/or premature failure of the substituted
parts.
Selection, Installation, Operation and
Maintenance
Flowserve Corporation has established industry
leader-ship in the design and manufacture of its
products. When properly selected, each product is
designed to perform its intended function safely
during its useful service life. However, it is
necessary that Flowserve’s customers be fully
aware of their responsibilities when using these
products.
Each Flowserve product may be used in numerous
applications under a wide variety of industrial
service conditions. Although Flowserve can, and
often does, provide general guidelines, it is
obviously not possible to provide application
specific data and warnings for all conceivable
applications. The purchaser/end user must therefore
assume the ultimate responsibility for the proper
selection, installation, operation and maintenance of
the products. Read the appropriate IOM before
installing, operating or repairing any valve. The
purchaser/end user should train its employees
and/or contractors in the safe use of the Flowserve
products in connection with the purchaser’s
manufacturing processes.
Flowserve will continue to provide its customers
with the best possible products and service
available. We do not recommend substituting
surplus or remanufactured valves over new
Flowserve valves or those repaired in an authorized
service center. Should you have any questions about
these provisions or about Flowserve’s products in
general, please contact your local Flowserve
representative, who will be happy to help.
Paying close attention to safety is always
extremely important. However, there are often
situations that require special attention. These
situations are indicated throughout this book by
the following symbols:
DANGER – Immediate hazards which WILL
result in severe personal injury or death.
NOTE: ALWAYS COORDINATE REPAIR ACTIVITY WITH OPERATIONS PERSONNEL, AND
FOLLOW ALL PLANT SAFETY REQUIREMENTS AND OSHA REGULATIONS.
WARNING – Hazards or unsafe practices
which COULD result in severe personal injury
or death.
CAUTION – Hazards or unsafe practices which
COULD result in minor personal injury or
product or property damage.
2
SECTION II.
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 minimum yield strength of 40,000 PSI, a
minimum elongation of 12% 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 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 (latest reision) 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 (latest revision), 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.
2
Table 1
CAP SCREWS – STUDS
HHCS - Finished Heavy Hex Head Cap Screw
HCS - Finished Hex Head Cap Screw
STUD - Stud
Dimensions per ASME B18.2.1
Alloy identification stamp required on each piece.
Certification required.
Alloy Specification (40 KSI Minimum Yield Strength, 12%
Minimum Elongation)
ASTM Material Specifications
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, Teflon 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 - Chromium-Molybdenum Alloy Steel per ASTM
A320, Grade L7M, 100% hardness tested, Teflon¨
coated, Dupont SP11C, Type B - Color blue or green
N - Nickel per ASTM B160 (UNS N0220), 40 KSI Min.
Yield Strength, 12% Min. El.
N7YC - Chromium-Molybdenum Alloy Steel per A193,
Grade B7, Yellow Zinc Dichromate Plated
Table 2
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.
ASTM Material Specifications
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, Teflon¨
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
I825 - Incoloy 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
1
SECTION III.
INSTALLATION INSTRUCTION – FLANGED AND WELDED PLUGSEAL
VALVES
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 flange and then center gaskets with the valve
flanges. Fasteners or taper pins should be use to align
holes and locate gaskets. Fasteners should be
tightened to the corresponding valve and fastener size.
WELDED:
Flowserve Corporation, Flow Control Division
recommends using only qualified welding procedures
and personnel for weld installation of Plugseal valves.
The following precautions should be observed:
1. The valve should be inspected prior to welding
to assure that no foreign materials obstruct the
flow passageway and that the weld preparation
area is free of corrosion and physical damage.
2. The valve plug can be removed during welding
procedure to ensure the plug and diaphragm do
not permanently deform at elevated
temperature.
Table 3
TEMPERATURE LIMITATIONS
Material Description Maximum Service
Temperature
PFA 500°F (260°C)
3. The valve plug and diaphragm must not exceed
these temperatures during welding. This
includes preheats, interpasses or post weld heat
treatments, as applicable. Refer to Figure 1 for
locations of the plug and diaphragm in the
center valve section.
4. The temperature of the center or bowl area of
the valve must not exceed the listed temperature
of the material. Valves, two inch and smaller,
must be wrapped with water soaked fireresistant material to cool the valve bowl inlet
where the weld is to be made. Use temperature
melt crayons equal to the plug and diaphragm
rating to mark the body welding end and monitor
the temperature. Thermocouples may be
attached to the welding end or the body s urface.
Pyrometers may be used to monitor the body
bowl temperature.
5. Welding of the PlugSeal Valve without
disassembly may be accomplished with no
damage to the plug or diaphragms. Precautions
must be taken to cool the valve bowl and
monitor temperatures. CAUTION: DO NOT
ALLOW WATER FROM THE SOAKED
WRAPPING MATERIAL TO ENTER THE
WELDMENT.
2
Figure 1
19 – Handwheel
15 – Wrench
14 – Retainer Spring
13 – Top Cap Lock
12 – Locking Stop
Collar
18 – Gear
17 – Bracket
16 – Coupler
11 - Adjuster Fasteners
10 – Top Cap Fasteners
9 – Top Cap
8 – Grounding Spring
7 – Thrust Washer
6 – Metal Diaphragm
5 – PFA Diaphragm
4 - Plug
1 - Body
1” – 4” Valves 6” – 16” Valves
6
SECTION IV.
OPERATING / MAINTENCE INSTRUCTIONS
Maintenance requirements for Plugseal 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
Plugseal 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 1 for parts identification.
1. Top Cap (bonnet)
Leakage due to thermal or pressure cycling is
eliminated by snugging the top cap fasteners (Part
10) in a criss-cross pattern. 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 remain
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. It is recommended that the adjuster
fasteners be tightened evenly. The valve should be
operated between adjustments to assure that the
plug properly seats itself into the body. If leakage
persists after repeated adjustments, the plug and
diaphragm will require replacement as covered in
SECTION V.
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. It is
recommended that the fasteners be tightened
evenly. The valve should be operated during
adjustments to prevent excessive operating torque.
Should leakage persist after repeated adjustments,
the plug will require replacement as covered in
SECTION V.
SECTION V.
VALVE DISASSEMBLY AND REPLACEMENT OF PLUG
RECOMMENDED PRECAUTIONARY MEASURES:
1. Valves must be relieved of process product and
pressure prior to disassembly.
2. Personnel performing disassembly must be suitably
trained, protected and alert for emission of
hazardous process product.
DISASSEMBLY STEPS
NOTE: Refer to Figure 1 for parts identification.
REMOVAL OF TOPWORKS SIZES 1” – 4”
1. Note the orientation of the wrench relative to the
body for proper reassembly.
2. Loosen the set screw securing the wrench and
remove the wrench (Part 15) from the stem.
3. Lift retainer spring (Part 17) and top cap lock (Part
16) off of the stem.
7
REMOVAL OF TOPWORKS SIZES 6” – 16”
1. 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.
2. Remove handwheel and gear by removing fasteners
between gear and bracket.
3. Lift coupler off stem and remove bracket by
removing fasteners between bracket and valve.
VALVE DISASSEMBLY
4. Gradually loosen adjuster fasteners (Part 11) - DO
NOT REMOVE.
5. WARNING: Do not loosen or remove top cap
fasteners (Part 10) when removing an operator.
Remove the operator by unfastening it from the
bracket and removing the bracket from the valve.
6. Turn plug (Part 4) in order to raise the plug to vent
any material trapped in the valve.
7. Once the plug has been turned, the adjuster
fasteners (Part 11) can be completely removed.
8. Gradually loosen but DO NOT REMOVE all of the
top cap fasteners (Part 10). Turn the plug until it is
loose from the body bore and all pressure has been
vented. (It may be necessary to use a mechanical
means to move the plug upwards.)
9. Remove the top cap fasteners and top cap (Par t 9)
from the plug stem. Retain any identification tags for
attachment during re-assembly.
10. Remove the plug (Part 4) from the body (Part 1).
11. Remove the grounding spring (Part 8) and thrust
washer (Part 7) from the plug.
12. Remove the metal diaphragm (Part 6) and the PFA
diaphragm (Part 5) from the plug stem.
13. Inspect the plug for wear or damage, especially
scratches near the waterway on the sealing bands. If
wear or damage is excessive, the plug may require
replacement. Similarly, inspect the body bore for
wear or damage incurred by the process fluid.
Excessive scoring or erosion will reduce the valves
ability to seal.
14. Thoroughly clean all valve parts with an acceptable
cleaner.
15. 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. Plugs will
need to be replaced when leakage rates exceed
tolerable levels due to PFA erosion or wear. Bodies
must maintain an RMS 16 surface finish for proper
operation.
SECTION VI.
V ALVE ASSEMBLY
NOTE: Part number reference is shown in Figure 1.
1. Mount body (Part 1) in arbor press or table vise
holding one flange or supported in v-blocks near
the buttweld face. Ensure the body is
supported adequately to avoid movement while
assembling.
2. 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 surfa ces could result
in scratches on the lip of the diaphragm and
must be removed by polishing or replacement.
3. Place the metal diaphragm (Part 6) over the plug
stem with the raised center section up.
4. Place the thrust washer (Part 7) over the plug
stem.
5. Apply a thin film of lubricant to the plug and
place the assembled plug (complete with PFA
6. diaphragm, metal diaphragm and thrust washer),
in the open position into the body.
Table 4: Top Cap Fastener Torque
1 2 3 4 6 8 10 12 14 16
Ft-lbs 40 70 120 250 325 425 450 500 700
Table 5: Adjuster Fastener Torque
1 2 3 4 6 8 10 12 14 16
In-lbs 80 100 120
ft-lbs 20 40 50
* Torques are preproduction estimates and subject to change. Contact Factory for updated torques
7. With the top cap on a table, thread the adjuster
fasteners into the top cap until the bottoms of
the fasteners are flush with the recessed
underside of the top cap.
8. Position the top cap (Part 9) over the plug
making sure the top cap is free to move
downward (Figure V-B3).
9. Place an H shaped support over the top of the
valve, resting on the top cap. Press the top cap
downward until the top cap is firmly seated in the
counterbore of the body.
10. Using all top cap fasteners (Part 10), tighten
evenly in a criss-cross method until the top cap
bottoms on the body counter bore.
Recommended top cap fastener torques are
shown in Table 4.
11. Tighten all adjuster fasteners in a criss-cross
pattern to the recommended torque in Table 5.
8
SECTION VII.
RECOMMENDED SPARE PARTS LIST
Grounding Spring
Metal Diaphragm
PFA Diaphragm
Plug
9
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