Flowserve Valtek Mark 200 User Manual

USER INSTRUCTIONS

Valtek Mark 200 Globe & Angle Control Valve

FCD VLENIM0200-00 – (12/12)

Installation

Operation

Maintenance

Experience In Motion

Mark 200 Control Valve FCD VLENIM0200– 12/12

Valtek Mark 200 High Pressure Control Valve

The Mark 200 high pressure globe control valve designed to handle the most extreme severe service applications also offers high competitive ﬂ ow capacity. The Mark 200’s large galleries include longer stroke lengths which provide ﬁ ner control and result in more stages of severe service protection in smaller size valves. With a clamped-in (DIN, screwed-in) seat ring, the Mark 200 has been designed for easy maintenance and ﬂ exibility. The seat retainer/cage (DIN, seat ring) in the Mark 200 can be changed out to provide an exceptional variety of severe service options, including anti-cavitation and anti-noise.

Further sizing details are available in Performance!, Flowserve’s control valve sizing & selection software program (please contact your local Flowserve representative for further details). The plug is typically pressure-balanced to allow smaller and more economical actuators. Flow over or under the plug is available.

Figure 1: ASME Mark 200 Maximum Capacity Control Valve Figure 2: DIN Mark 200 Maximum Capacity Control Valve

ASME Contents

1 General Information 3 2 Terms Concerning Safety 3 3 ASME Valve Unpacking 4 4 ASME Valve Installation 4

4.1 ASME Valve Quick-check 4 5 ASME Valve Maintenance 5 ASME Valve Disassembly and Reassembly 7

6.1 Disassembling the Body 7

6.2 Reassembling the Body 8

6.3 ASME Valve Troubleshooting Chart 10

DIN Contents

1 General Information 3 2 Terms Concerning Safety 3 7 DIN Valve Unpacking 11 8 DIN Valve Installation 11

8.1 DIN Valve Quick-check 12 9 DIN Valve Maintenance 12 DIN Valve Disassembly and Reassembly 14

10.1 Disassembling the Body 14

10.2 Reassembling the Body 15

10.3 Special Tools 16 11 DIN Valve Troubleshooting Chart 17

Mark 200 Control Valve FCD VLENIM0200– 12/12

1 General Information

The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Flowserve Mark 200 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 adhered

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.

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

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 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.

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Mark 200 Control Valve FCD VLENIM0200– 12/12

3 ASME Valve Unpacking

1. While unpacking the valve, check the packing list against materials received. Lists describing valve and accessories are in each shipping container.

2. 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 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.

4. Should any problem arise, call your Flowserve representative.

4 ASME Valve Installation

CAUTION: The valve must be installed and commissioned by qualiﬁed staff. Qualiﬁed staff is deﬁned as personnel who are familiar with the installation, commissioning and operation of this product and possess the relevant qualiﬁcations in their ﬁeld of activity.

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. When vertical installation is not possible contact your Flowserve representative.

CAUTION: Do not insulate extension bonnets that are provided for hot or cold services.

Table 1: ASME Valve Disassembly Clearance

Valve Size

(inches)

2 5 127

3 6 152

4 8 203

6 11 279

8 12 305

10 16 406

12 17 432

14 21 533

16 22 559

NOTE: In some cases, the air supply must be limited to less than 150 psi (10.3 bar). This is indicated on a sticker or type plate 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.*

Clearance

inches mm

4.1 ASME Valve Quick-check

Prior to start-up, check the control valve by following these steps:

WARNING: Due to the risk of injury, it is prohibited to work between the yoke/columns while the valve is in operation.

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. 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.

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 ﬁlter must point down to perform properly. *

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 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.

Mark 200 Control Valve FCD VLENIM0200– 12/12

Table 2: Recommended ASME Body Bolt Torque Values

Bolt/Stud Material

Bolt Size

(inches) ft lb N m ft lb N m

1-1⁄8 520 691 380 447

1-¼ 730 990 460 624

1-3⁄8 1000 1356 630 854

1-½ 1320 1790 840 1139

1-5⁄8 1710 2318 1080 1464

1-¾ 2170 2942 1400 1898

1-7⁄8 2700 3660 1700 2305

2 3350 4542 2100 2847

2-¼ 4050 5491 2530 3430

2-½ 4850 6575 3010 4081

2-¾ 5900 8000 4400 5960

3 7273 9860 5913 8015

Carbon Steel Stainless Steel

5 ASME Valve Maintenance

At least once every six months, check for proper operation by following the preventative maintenance steps outlined below. These steps can be performed while the valve is in-line and, in some cases, without interrupting service. If an internal problem is suspected, refer to the “Valve Disassembly and Reassembly” section.

WARNING: Keep hands, hair and clothing away from all moving parts when operating the valve. Failure to do so can cause serious injury.

8. Make sure positioner linkage and stem clamp or coupling pieces are securely fastened. If the stem clamp or coupling pieces are loose, check plug thread engagement (refer to the “Reassembling the Body” section for the correct procedure on aligning the plug with the seat.) Tighten stem clamp nut or counter nut.

9. Ensure all accessories, brackets and bolting are securely fastened.

10. If possible, remove air supply and observe actuator for correct fail-safe action.*

11. Check rubber actuator bellows for splits, cuts or wear.*

12. Check tightness of the actuator. Spray a soap solution around the cylinder actuator retaining ring, adjusting screw and actuator stem guide to check for air leaks through the O-rings. *

13. Clean any dirt and other foreign material from the plug stem.

14. If an air ﬁlter is supplied, check and replace cartridge if necessary.*

* Pneumatic operated control valves

** Pneumatic operated control valves with safety function

1. Look for signs of gasket leakage through the end ﬂanges and bonnet. Retorque ﬂange and bonnet bolting (if required). See Table 2.

2. Check for ﬂuid leakage to the atmosphere through the body drain plug, if applicable.

3. Examine the valve for damage caused by corrosive fumes or process drippings.

4. Clean valve and repaint areas of severe oxidation.

5. Check packing box bolting for proper tightness. Refer to the packing installation manual for speciﬁc details on maintaining the style of packing supplied.

CAUTION: Do not overtighten packing. This can cause excessive packing wear and high stem friction that may impede stem movement.

6. If the valve is supplied with a lubricator ﬁtting, check lubricant supply

and add lubricant if necessary. See product documentation or contact the Flowserve representative.

7. If possible, stroke the valve and check for smooth, full-stroke operation.

Unsteady stem movement could indicate an internal valve problem.

NOTE: Due to excessive friction, graphite packing can cause the plug stem to move in a jerky fashion.

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Figure 3 – Exploded Drawing of an ASME Mark 200, pressure balanced with cage

Part Item Available Materials

Body 1

Seat Ring* 20 316 SS, 316 SS / Alloy 6, 410 SS HT, 416 SS HT, 420 SS HT

Plug* 50 316 SS, 316 SS / Alloy 6, 416 SS HT, 420 SS HT, CrMo/Alloy 21

Plug Stem 51 316 SS, 316 SS / Alloy 6, 416 SS HT, 17-4PH SS

Cage 30 316 SS , 416 SS HT, CrMo/Nitrided

Pressure Balanced Sleeve

Bonnet 40 Carbon Steel, 316 SS, CrMo, Duplex SS

Seat Gasket 55 PTFE, Spiral Graphite

Sleeve Gasket 56 PTFE, Spiral Graphite

Bonnet Gasket 58 PTFE, Spiral Graphite

O-Ring Seal 65 Buna, Viton®, EPDM, Perﬂouroelastomer

Back-up Ring 66 Carbon-Filled PTFE, PEEK, Vespel

PTFE Seal 65 PTFE, Glass-Loaded PTFE

Seal Types

Metal Multi-Seal 65 Rene 41

Carbon Seal 65 Carbon (Single & Triple)

Gland Flange 80 Carbon Steel

Gland Flange Bolting 109, 117 Carbon Steel

Lower Guide 83

Upper Guide 87 316 SS / GL PTFE

Packing 88

Body Bolting 108

Packing Spacers 93-99 316 SS

Carbon Steel (WCC) , 316 SS (CF8M), CrMo (WC9, C12A), Duplex SS

316 SS, 410 SS, 410 SS HT, 420 SS HT**, 316 SS / Alloy 6,

CrMo/Nitrided

, Ryton

, Inconel® X-750

, Stainless Steel2

316 SS / GL PTFE

1, 2

, 316 SS / Graphite, Bronze C93200,

Alloy 6, Ultimet

1, 2

, 316 SS / Graphite, Bronze C93200

PTFE V-Ring

1, 2

, PTFE / Glass V-Ring, Quick-Set 9001, Braided PTFE, AFPI, Graphite Rib/Braid, Safeguard, Sureguard, 1303 FEP, Chesterton 5800E, Sureguard XT, TA-Luft Double Graphite

B7-2H Zinc-coated 1, B7-2H Oxide-coated, B7M-2HM (NACE), B8-8 (304 SS) 2, B8M-8M (NACE), L7-7, L7M-7M (NACE), B16-7L, L7M-7M Uncoated (NACE)

1,2

Mark 200 Control Valve FCD VLENIM0200– 12/12

Gland Flange Bolting 109, 117

Gland Flange 80

Packing, Guides & Spacers

83-88, 93-99

Body Bolting 108

Bonnet 40

Bonnet & Sleeve Gasket

56 & 58

Pressure Balance Seals 65,66

Plug 50

Pressure Balanced Sleeve 31

Seat Ring 20

Seat Gasket 56

Body 1

* The seat ring and plug have hard facing of alloy 6 or other materials on the seating and guiding surfaces ** Internal Sleeve Only

Standard for Carbon Steel Body Construction

Standard for Stainless Steel Body Construction

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