Flowserve Valtek Mark 100 User Manual
F C D F C A I M 0 1 0 0 - 0 2
Mark 100
Installation, Operation and Maintenance Instructions
1 General Information
The following instructions are designed to assist in unpacking,
installing and performing maintenance as required on Flowserve
Mark 100 control valves. Product users and maintenance personnel should thoroughly review this bulletin prior to installing,
operating or performing any maintenance on the valve. Separate
Installation, Operation, and Maintenance instructions cover additional features (such as special trim, actuators, handwheels,
packing and positioners.)
To avoid possible injury to personnel or damage to valve parts,
WARNING and CAUTION notes must be strictly followed. Modifying
this product, substituting non-factory parts or using maintenance
procedures other than outlined could drastically affect performance
and be hazardous to personnel and equipment and may void existing
warranties.
WARNING: Standard industry safety practices must be ad-
c
hered to when working on this or any other process control
product. Specifically, personal protective and lifting devices
must be used as warranted.
NOTE ON FASTENERS: Selecting the proper fastener material is
the responsibility of the customer. Typically, the supplier does not
know what the valve service conditions or environment may be.
Flowserve’s standard body bolting material is B7/2H. B8 (stainless
steel) is optional for applications more than 800°F / 425°C and with
stainless steel or alloy-body valves. The customer therefore must
consider the material’s resistance to stress corrosion cracking in
addition to general corrosion. As with any mechanical equipment,
periodic inspection and maintenance is required. For more information about fastener materials, contact your Flowserve representative.
Flow Control Division
Mark 100
WARNING: indicates that death, severe personal injury and/
c
or substantial property damage can occur if proper precautions are not taken.
CAUTION: indicates that minor personal injury and/or prop-
a
erty damage can occur if proper precautions are not taken.
NOTE: indicates and provides additional technical information, which
may not be very obvious even to qualified personnel.
Compliance with other, not particularly emphasized notes, with
regard to transport, assembly, operation and maintenance and with
regard to technical documentation (e.g., in the operating instructions, 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.
3 Unpacking
1. While unpacking the valve, check the packing list against materials received. Lists describing valve and accessories are in each
shipping container.
2. When lifting the valve from shipping container, use the lifting
lugs attached to the bonnet bolting. Take care to position lifting
straps to avoid damage to the tubing and mounted accessories.
WARNING: When lifting a valve using the lifting lugs, be
c
aware that the center of gravity may be above the lifting
point. Therefore, support must be given to prevent the
actuator from rotating. Failure to do so can cause serious injury to personnel, damage to the valve or nearby
equipment.
3. Contact your shipper immediately if there is shipping damage.
2 Terms Concerning Safety
The safety terms DANGER, WARNING, CAUTION and NOTE are used
in these instructions to highlight particular dangers and/or to provide
additional information on aspects that may not be readily apparent.
DANGER: indicates that death, severe personal injury and/or
b
substantial property damage will occur if proper precautions
are not taken.
FCD FCAIM0100-02 Mark 100 Installation, Operation and Maintenance Instructions 3
4. Should any problem arise, call your Flowserve representative.
Flow Control Division
Mark 100
4 Installation
1. Before installing the valve, clean the line of dirt, welding chips,
scale or other foreign material.
2. Whenever possible, the valve should be installed in an upright
position. Vertical installation permits easier valve maintenance.
CAUTION: Do not insulate extension bonnets that are
a
provided for hot or cold services.
3. Be sure to provide proper overhead clearance for the actuator to
allow for disassembly of the plug from the valve body. Refer to
Table 1 for the necessary clearance needed for valve disassembly.
Table 1: Valve Disassembly Clearance
Valve Size
(inches)
6 10 254
8 13 330
10 14 356
12 16 406
14 18 457
16 20 508
18 23 584
20 25 635
24 31 787
30 37 940
inches mm
Clearance
4.1 Quick-check
Prior to start-up, check the control valve by following these steps:
1. Stroke the valve and observe the plug position indicator on the
stem clamp compared to the stroke indicator plate. The plug
should change position in a smooth, linear fashion.
NOTE: Due to excessive friction, graphite packing can cause the
plug stem to move in a jerky fashion.
2. Check for full stroke by making appropriate instrument signal
change.
3. Check all air connections for leaks.
4. Check packing box bolting for the correct adjustment. Refer to
the packing installation manual for specific details on maintaining the style of packing supplied.
CAUTION: Do not overtighten packing. This can cause
a
excessive packing wear and high stem friction that may
impede plug movement.
5. Make sure the valve fails in the correct direction in case of air
failure. This is done by turning off the air supply and observing
the failure direction.
6. After a temperature excursion has occurred, bonnet flange bolting should be retorqued to ensure bonnet gaskets do not leak.
See Table 2.
4. Double-check flow direction to be sure the valve is installed
correctly. Flow direction is indicated by the arrow attached to the
body.
5. If welding the valve into the line, use extreme care to avoid
excess heat buildup in the valve.
6. Connect the air supply and instrument signal lines. Throttling
control valves are equipped with a valve positioner. Refer to the
appropriate positioner bulletin for connections, maximum air
supplies, and maintenance instructions.
CAUTION: On valves equipped with air filters, the air
a
filter must point down to perform properly.
NOTE: In some rare cases, the air supply must be limited to
less than 150 psi (10.3 bar). This is indicated on a sticker found
near the upper air port on the actuator cylinder. An air regulator should be installed to ensure the supply pressure does not
exceed the line pressure indicated on the sticker.
Table 2: Recommended Body Bolt Torque Values
Bolt Size
(inches) ft-lb N m ft-lb N m
7
⁄8 230 312 150 203
1 350 474 220 298
1
⁄8 510 691 330 447
1
1¼ 730 990 460 624
3
⁄8 1000 1356 630 854
1
1½ 1320 1790 840 1139
5
⁄8 1710 2318 1080 1464
1
3
⁄4 2170 2942 1400 1898
1
7
⁄8 2700 3660 1700 2305
1
2 3350 4542 2100 2847
1
⁄4 4050 5491 2530 3430
2
1
⁄2 4850 6575 3010 4081
2
Carbon Steel Stainless Steel
Bolt/Stud Material
4 Mark 100 Installation, Operation and Maintenance Instructions FCD FCAIM0100-02
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