Experience In Motion
USER INSTRUCTIONS
Installation
Operation
Maintenance
Flowserve Valtek Control Products
Mark One and Mark Two Control Valves
FCD VLENIM0001-02-A4 – 08/15
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
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Contents
1 General Information 3
2 Unpacking 4
3 Installation 5
4 Quick Check 5
5 Valve Maintenance 6
6 Disassembly and Inspection 7
7 Assembly and Installation 9
8 Severe Service Trim Options 12
8.1 CavControl 12
8.2 ChannelStream 12
8.3 Diamondback 13
8.4 MegaStream 14
8.5 Stealth 14
8.6 TigerTooth 14
Figures
Figure 1 – Mark One Control Valve Body Assembly
(optional angle body) 4
Figure 2 – Pressure Balanced Mark One Control
Valve Body Assembly 6
Figure 3 – Exploded View Mark One Body Assembly 8
Figure 4 – Soft Seat Assembly 10
Figure 5 – Actuator Stem / Stem Clamp Alignment 10
Figure 6 – Mark One with CavControl Trim Body Assembly 12
Figure 7 – Mark One with ChannelStream Trim Body Assembly 12
Figure 8 – Diamondback Trim Body Assembly 12
Figure 9 – Mark One with MegaStream Trim Body Assembly 13
Figure 10 – Mark One with Stealth Trim Body Assembly 13
Figure 11 – Mark One with TigerTooth Trim Body Assembly 13
Tables
Table I – Common Lubricants 7
Table II – Flange Bolting Torque per Bolt Material 9
Table III – Troubleshooting Chart 15
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1 General Information
1.1 Using
The following instructions are designed to assist in unpacking,
installing and performing maintenance as required on Flowserve
products. Product users and maintenance personnel should thoroughly
review this bulletin prior to unpacking, installing, operating, or
performing any maintenance. In most cases, Flowserve valves,
actuators and accessories are designed for specific applications (e.g.
with regard to medium, pressure, and temperature). For this reason,
they should not be used in other applications without first contacting
the manufacturer. The product Installation, Operation, and Maintenance
Instructions provides important additional safety information.
1.2 Applicability
The following instructions are applicable to the maintenance and
installation of Flowserve Valtek Mark One and Mark Two globe and
angle body design control valves. These instructions cannot claim to
cover all details of all possible product variations, nor can they provide
information for every possible example of installation, operation or
maintenance. This means that the instructions normally include only
the directions to be followed by qualified personal using the product for
its defined purpose. If there are any uncertainties in this respect,
particularly in the event of missing product-related information,
clarification must be obtained via the appropriate Flowserve sales office.
All Flowserve User Manuals are available at www.flowserve.com.
1.3 Terms Concerning Safety
1.3.1
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.
c
DANGER: Indicates that death, severe personal injury and/or
substantial property damage will occur if proper precautions
are not taken.
a
WARNING: Indicates that death, severe personal injury and/or
substantial property damage can occur if proper precautions
are not taken.
a
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 obvious, even to qualified personnel.
1.3.2 Compliance with other notes, which may not be particularly
emphasized, 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 can directly or indirectly cause severe personal injury
or property dam
age.
1.4 Protective Clothing
c
DANGER: Flowserve products are often used in problematic
applications (e.g. under extremely high pressures with dangerous,
toxic or corrosive mediums). When performing service, inspection,
or repair operations, always ensure that the valve and actuator are
depressurized and that the valve has been cleaned and is free from
harmful substances. In such cases, pay particular attention to
personal protection (e.g. protective clothing, gloves, glasses etc.).
1.5 Qualified Personnel
Qualified personnel are people who, on account of their training,
experience and instruction and their knowledge of relevant standards,
specifications, accident prevention regulations and operating conditions,
have been authorized by those responsible for the safety of the plant to
perform the necessary work and who can recognize and avoid possible
dangers. Contact your local Flowserve representation for a schedule of
training schools.
1.6 Spare Parts
Use only Flowserve original spare parts. Flowserve cannot accept
responsibility for any damages that occur from using spare parts or
fastening materials from other manufactures. If Flowserve products
(especially sealing materials) have been on store for long periods of time
check them for corrosion or deterioration before putting them into use.
1.7 Service / Repair
To avoid possible injury to personnel or damage to products, safety
terms must be strictly adhered to. Modifying this product, substituting
non-factory parts, or using maintenance procedures other than those
outlined in these Installation, Operation, and Maintenance Instructions
could drastically affect performance, be hazardous to personnel and
equipment, and may void existing warranties. Between the actuator and
the valve there are moving parts. To avoid injury, Flowserve provides
pinch-point-protection in the form of cover plates, especially where
side-mounted positioners are fitted. If these plates are removed for
inspection, service or repair special attention is required. After
completing work the cover plates must be refitted. Apart from the
operating instructions and the obligatory accident prevention directives
valid in the country of use, all recognized regulations for safety and
good engineering practices must be followed.
a
WARNING: Before products are returned to Flowserve for repair
or service, Flowserve must be provided with a certificate that
confirms that the product has been decontaminated and is clean.
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Flowserve will not accept deliveries if a cleaning certificate has
not been provided. Return authorization is also required before
parts are returned. Contact your local Flowserve representative
to obtain return authorization.
1.8 Storage
In many cases, Flowserve products are manufactured from stainless
steel. Products not manufactured from stainless steel are provided
with an epoxy resin coating. This means that Flowserve products
are well protected from corrosion. Nevertheless, Flowserve products
must be stored adequately in a clean, dry environment. Plastic caps
or plywood protectors are fitted to help protect the flange faces and
prevent the ingress of foreign materials. These caps should not be
removed until the valve is actually mounted into the system.
2 Unpacking
2.1 While unpacking the valve, check the packing list against the
materials received. Lists describing the valve and accessories are included in each shipping container.
2.2 When lifting the valve from shipping container, use straps
through the yoke legs, or the lifting lugs attached to the
body bolting for valves over four inch, or the adjusting screw
for valves four inch and under. Take care to position lifting
straps to avoid damage to the tubing, mounted accessories,
or stroke plate.
a
WARNING: When lifting a valve be aware that the centre of
gravity may be above the lifting point. Therefore, support
must be given to prevent the valve from rotating. Failure to
do so can cause serious injury to personnel and damage to
the valve and nearby equipment.
2.3 Contact your shipper immediately if there is shipping damage.
2.4 Should any problem arise, call your Flowserve representative.
Figure 1: Mark One Control Valve Body Assembly
Body
(Item # 1)
Seat Gasket
(Item # 55)
Seat Ring
(Item # 20)
Seat
Retainer
(Item # 30)
Plug
(Item # 50)
Bonnet Gasket
(Item # 58)
Lower Guide
(Item # 83)
Lower Packing
(Item # 83)
Bonnet
(Item # 40)
Upper Guide
(Item # 87)
Upper Packing
(Item # 88)
Packing Spacers
(Item # 94-99)
Bonnet Flange
(Item # 70)
Body Bolting
(Item # 108/114)
*
*Optional angle body
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3 Installation
c
DANGER: Before installation check the purchase order
number, serial number, and/or the tag number to ensure
that the valve and actuator being installed are correct for
the intended application.
a
WARNING: The maximum air supply for most Valtek
cylinder actuators is 150 psi (10.3 bar). In some 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
actuator design pressure indicated on the sticker.
a
CAUTION: Do not insulate extensions that are provided for
hot or cold services.
a
CAUTION: On valves equipped with air filters, the air filter
must point down to perform properly.
NOTE: 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. B8/8 (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.
3.1 Pipelines must be correctly aligned to ensure that the valve
is not fitted under tension.
3.2 Fire protection must be provided by the user.
3.3 Before installing the valve, clean the line of dirt, welding
chips, scale and other foreign material.
3.4 Whenever possible, the valve should be installed in an
upright position. Vertical installation permits easier valve
maintenance. This is also important for cryogenic applications to keep the packing isolated from the flowing medium,
permitting the packing temperature to remain close to
ambient temperature.
3.5 Be sure to provide proper overhead clearance for the
actuator to allow for disassembly of the plug from the valve
body. Refer to the appropriate actuator User Instructions for
proper clearances. Actuator User Instructions are available
at www.flowserve.com.
3.6 Double-check flow direction to be sure the valve is
installed correctly. Flow direction is indicated by the arrow
attached to the body.
3.7 If welding the valve into the line, use extreme care to avoid
excess heat buildup in the valve.
3.8 If the valve has separable end flanges, verify that the half
rings are installed on the valve body before bolting the valve
into the line.
a
WARNING: Failure to install half rings on the valve body can
cause serious personal injury.
3.9 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. An air filter
should be installed before the positioner. All connections
must be free of leaks.
a
CAUTION: On valves equipped with air filters, the air filter
must point down to perform properly.
4 Quick-check
Prior to start-up, check the control valve by following these steps:
4.1 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 a dry graphite packing can
cause the plug stem to move in a jerky fashion. Lubrication of
graphite packing will provide smoother stroking. Lubrication
can be done by using a bonnet lubricator or by liberally coating
each packing ring by hand during installation. Please refer to
Table I for lists of common lubricants.
a
WARNING: Keep hands, hair and clothing away from all
moving parts when operating the valve. Failure to do so can
cause serious injury.
4.2 Check for full stroke by making appropriate instrument signal
changes.
4.3 Check all air connections for leaks.
4.4 Check packing box bolting for the correct adjustment. Refer
to the packing installation manual for specific details on
maintaining the style of packing supplied.
a
CAUTION: Do not overtighten packing. This can cause excessive packing wear, high stem friction that may impede plug
movement and can damage the packing. Over-tightening packing will not improve the stem seal unless the packing has been
previously damaged. Damaged packing should be replaced.
4.5 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.
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5 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 Section 6, Valve Disassembly and Inspection.
5.1 Look for signs of gasket leakage through the end flanges
and bonnet. Re-torque flange and bonnet bolting (if
required). Refer to Table II for bonnet bolt torque values.
5.2 Examine the valve for damage caused by corrosive fumes
or process drippings.
5.3 Clean valve and repaint areas of severe oxidation.
5.4 Check packing box bolting for proper tightness and packing leakage. If packing leakage is noticed, packing maintenance is required. Refer to the packing installation manual
(document number VLAIM040) for specific details on
maintaining the style of packing supplied.
a
CAUTION: Do not overtighten packing. This can cause
excessive packing wear and high stem friction that may
impede stem movement. Packing that is tightened too tight
will typically not seal correctly.
5.5 If the valve is supplied with a lubricator fitting, check lubricant
supply and add lubricant if necessary. See Table I for
common lubricants.
5.6 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 a dry graphite packing can
cause the plug stem to move in a jerky fashion. Lubrication
of graphite packing will provide smoother stroking.
Lubrication can be done by using a bonnet lubricator or by
liberally coating each packing ring by hand during installation.
Please refer to Table I for lists of common lubricants.
Figure 2: Pressure Balanced Mark One Control Valve Body Assembly
*Optional angle body
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6 Valve Disassembly
6.1 To disassemble the valve body, refer to Figures 1, 2 and 3
then proceed as follows:
a
WARNING: Depressurize line to atmospheric pressure and
drain all fluids before working on the valve. Failure to do so
can cause serious injury.
6.2 If valve is air-to-open, apply air under the piston to lift the
plug off the seat before taking the valve apart. If valve is
air-to-close, proceed to step 6.3.
6.3 Remove the bonnet flange bolting and lift actuator, bonnet
and plug out of the valve. Once removed, the actuator,
bonnet and plug assembly (called the top works) should
be lowered and blocked to prevent rolling during the
disassembly of the top works.
a
WARNING: Danger exists in removing the actuator, bonnet
and plug, especially if a pressure balanced plug is used. The
pressure balanced sleeve may stick to the plug and fall during
disassembly, causing possible serious injury and damage to
the valve or nearby equipment. If sleeve is observed sticking
to the plug, steps 6.3.1 to 6.3.4 should be consulted.
a
CAUTION: Heavy actuators may require a hoist. Lift the valve
with the yoke legs using a lifting strap and a hoist. Great care
should be taken to lift the actuator and plug straight out of
the body to avoid damage to the plug and seat.
6.3.1 If the sleeve is observed sticking to the plug during removal,
fully extend the plug by applying air above the piston,
allowing the sleeve to remain in the body and the bonnet to
rise above the body.
a
WARNING: Keep hands, hair and clothing away from all
moving parts when operating the valve. Failure to do so
can cause serious injury.
5.7 Make sure positioner linkage and stem clamp are securely
fastened. If the stem clamp is loose, check plug thread
engagement (refer to the “Reassembly and Installation”
section for the correct procedure on aligning the plug with
the seat). Tighten stem clamp nut.
NOTE: Refer to the appropriate User Manuals when adjust-
ing positioners and providing maintenance to actuators.
Current User Manuals are available at www.flowserve.com.
5.8 Verify that the takeoff arm and follower arm are not binding
at either end of the stroke. The follower arm attached to
the positioner should be free to move slightly when the
valve is at both ends of the stroke.
5.9 Ensure all accessories, brackets and bolting are securely
fastened.
5.10 If possible, remove air supply and observe actuator for
correct fail-safe action.
5.11 Check rubber actuator bellows for splits, cuts or wear.
5.12 Spray a soap solution around the actuator cylinder retaining ring and actuator stem guide to check for air leaks
through the O-rings.
5.13 Clean any dirt and other foreign material from the plug
stem.
5.14 If an air filter is supplied, check and replace cartridge if
necessary. Drain any moisture accumulated in the air filter.
Lubricant Manufacturer
Temperature Range
Application Description
°F °C
Krytox® E.I DuPont -5 to 550 -20 to 285
Fluorinated general purpose grease; handles common liquids and gasses; good
lubricity in harsh mediums; nonflammable, chemically inert; will not harm plastic
or metal parts
GP 460
Acheson Colloids
Company
32 to 1000 0 to 540
Graphite in petrolatum; high pressure; anti-galling; graphite remains above
600°F / 316°C
725 Chesterton 32 to 2600 0 to 1425
Nickel, Aluminum and graphite in oil suspension; provides protection with an
ultra-thin coating of nickel particles
Table I: Common Packing Lubricants
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Gland Bolting
(Items #109, 117)
Gland Flange
(Item #80 )
Body Bolting
(Items #108, 114)
Bonnet Flange
(Item #70)
Upper Guide
(Item #87)
Upper Packing
(Item #88)
Packing Spacers
(Item #94-99)
Lower Packing
(Item #88)
Lower Guide
(Item #83)
Yoke Half Clamps
& Yoke Clamp Bolts
(Items #76, 107,118)
Bonnet
(Item #40)
Bonnet Gasket
(Item #58)
Plug
(Item #50)
Seat Retainer
(Item #30)
Seat Ring
(Item #20)
Seat Gasket
(Item #55)
Body
(Item #1)
Figure 3: Exploded View Mark One Body Assembly
*Optional angle
body
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parts to avoid damage to the parts of nearby equipment or
personnel.
6.7 Remove the packing gland bolting, yoke clamps and
remove the actuator.
6.8 If the seat surfaces need re-machining, both surfaces on
plug and seat ring must be reworked. The seat angle on
the plug is 30 degrees (36 degrees for CavControl and
ChannelStream valves); the seat ring, 33 degrees. Lapping
is not necessary if proper assembly procedures are
followed.
a
CAUTION: If re-machining, protect the stem while turning.
Ensure concentration of the seat surface with the plug
stem (or outside diameter of the seat ring, if machining the
seat)
6.9 To replace packing or change the packing box configuration, push out packing, spacer and guides from underneath
the bonnet with a dowel around 0.13 inch (3.3 mm) larger
in diameter than the plug stem.
a
WARNING: For valves equipped with separable end flanges,
do not machine body gasket surfaces. Machining could
cause failure of the separable flange lip causing end gasket
leakage and valve failure.
a
CAUTION: When using separable end flanges and spiral
wound gaskets, use gaskets with outer backup rings.
Failure to do so could result in excess stress in some
applications.
6.10 Check to see the seating surfaces on both the seat ring and
plug are free of damage to ensure tight shutoff. Make sure
the gasket surfaces on the seat ring, bonnet and body are
clean and undamaged. Examine the plug stem and bonnet
bore for scoring, scratches, pitting or other damage.
6.11 Refer to the appropriate actuator User Manual for detailed
instructions on actuators.
Table II: Pressurized Flange Bolting Required Torque Values
6.3.2 In the gap between the top of the sleeve and the bottom of
the bonnet, place wooden blocking of equal thickness in
at least three places. The wooden blocks must not extend
in far enough that they interfere with plug movement. The
plug must be allowed to stroke up to the bonnet.
6.3.3 By applying air below the piston, retract the plug until the
plug head is freed from the sleeve. Once the plug is free
from the sleeve, remove the plug and bonnet assembly from
the body.
6.3.4 Lift the pressure balanced sleeve out of the valve body
using lifting points on the top of the sleeve.
NOTE: In many small Mark One valves, the seat retainer
and pressure balancer sleeve are one and the same part. In
larger valves, there are separate pressure balancer sleeves
and seat retainers.
6.4 Lift retainer, seat ring and gaskets free of the body. Care
must be taken not to damage the gasket surfaces in the
body when the gaskets are removed.
6.5 Valves with soft seats (see figure 4) require the seat ring to
be inspected and possibly disassembled. Check to see that
seating surfaces on the plug and seat assemblies are free of
damage. If the seat insert is worn, remove it from the
assembly. Since the plug seating surface does not come
in contact with the seat insert retainer, it is not necessary
to correct any minor damage to that part. The plug seating
surface can be re-machined to a 30 degree angle. Lapping
is not required when proper reassembly procedures are
followed.
6.6 Loosen the stem clamp and unscrew the plug from the
actuator stem.
a
WARNING: Danger exists when working with large valves
and heavy parts. Take care to properly support large
Bolt Size
(in.)
Flange Bolting Torque per Bolt Material
A193-B7; A193-B16 A320-L7
A193-B7M
A320-L7M
A193-B8 Cl 1
A193-B8M Cl 1
A193-B8 Cl 2 *
Ft-lb N-m Ft-lb N-m Ft-lb N-m Ft-lb N-m
5
/
8
80 ± 8 110 ± 11 60 ± 6 80 ± 8 60 ± 6 80 ± 8 80 ± 8 110 ± 11
3
/
4
140 ± 14 190 ± 19 120 ± 12 160 ± 16 110 ± 11 150 ± 15 140 ± 14 190 ± 19
7
/
8
230 ± 23 310 ± 31 190 ± 19 260 ± 26 180 ± 18 240 ± 24 190 ± 19 260 ± 26
1 350 ± 35 470 ± 47 280 ± 28 380 ± 38 260 ± 26 350 ± 35 280 ± 28 380 ± 38
1
1
/
8
520 ± 52 710 ± 71 420 ± 42 570 ± 57 390 ± 39 530 ± 53 390 ± 39 530 ± 53
1
1
/
4
740 ± 74 1000 ± 100 590 ± 59 800 ± 80 550 ± 55 750 ± 75 550 ± 55 750 ± 75
1
3
/
8
1010 ± 101 1370 ± 137 810 ± 81 1100 ± 110 760 ± 76 1030 ± 103 760 ± 76 1030 ± 103
1
1
/
2
1330 ± 133 1800 ± 180 1060 ± 106 1440 ± 144 1000 ± 100 1360 ± 8136 1000 ± 100 1360 ± 136
1
5
/
8
1550 ± 155 2100 ± 210 1240 ± 124 1680 ± 168 1170 ± 117 1590 ± 159 NA NA
1
3
/
4
1960 ± 196 2660 ± 266 1570 ± 157 2130 ± 213 1480 ± 148 2010 ± 201 NA NA
1
7
/
8
2450 ± 245 3320 ± 332 1960 ± 196 2660 ± 266 1840 ± 184 2490 ± 249 NA NA
2 3000 ± 300 4070 ± 407 2400 ± 240 3250 ± 325 2260 ± 226 3060 ± 306 NA NA
2
1
/
4
4360 ± 436 5910 ± 591 3490 ± 349 4450 ± 445 3280 ± 328 4450 ± 445 NA NA
2
1
/
2
5580 ± 558 7570 ± 757 4850 ± 485 6580 ± 658 4560 ± 456 6180 ± 618 NA NA
2
3
/
4
7520 ± 752 10200 ± 1020 NA NA 6150 ± 615 8340 ± 834 NA NA
3 9860 ± 986 13370 ± 1337 NA NA 8060 ± 806 10930 ± 1093 NA NA
3
1
/412650 ± 1265 17150 ± 1715 NA NA 10340 ± 1034 14020 ± 1402 NA NA
* Contact Factory for deep cryo or bellows seal valves. NA = Studs not available in these sizes
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7 Assembly and Installation
NOTE: Separate User Manuals with instructions on assembling
actuators, positioners and other equipment can be found on
www.flowserve.com. Review any relevant User Manual before
proceeding
NOTE: It is recommended that all soft goods are replaced
when rebuilding Mark One and Two control valves. Soft
goods include gaskets, pressure balanced seals, soft seat
inserts, guide liners and packing seats.
Replacing these parts helps to ensure proper functioning of
the control valve.
7.1 To reassemble the valve body, refer to figures 1, 2 and 6
through 9 and proceed as follows:
7.2 If the packing has been removed, refer to the appropriate
packing User Manual (document number VLAIM040) and
reinstall the packing and lower guide exactly as shown. Make
sure at least 1/8 inch is left at the top of the packing box for
the top guide to sit into the bonnet. Different packing spacers
permit a wide variety of packing configurations, such as twin
seal and vacuum-pressure packing.
a
CAUTION: Valves with extended bonnets or metal bellows
seals must not have lower packing installed. Instead, lower
packing rings should be installed with the upper set. Lower
packing installed in extended bonnets or metal bellows seal
valves will diminish the integrity of the packing assembly.
NOTE: Guide liners should be replaced each time the valve
packing is replaced. Do not rebuild the valve without the
correct guide liners.
7.3 Re-insert the plug stem into the packing box, being careful
not to score the plug stem or the guides. Reinstall pressure
balanced seals if required.
7.4 Turn actuator back onto the plug, without turning the plug
inside the bonnet. Make sure the gland flange and bonnet
flange are in place before engaging the plug stem and
actuator stem threads. The gland flange chamfer must be
face down towards the valve body. Leave approximately
three to four plug stem threads exposed. Attach yoke clamp
and gland flange bolting. For valves with a 2-inch spud, be
sure the half rings are in place between the yoke and bonnet.
Firmly tighten yoke clamp bolting. The packing box nuts
should be just over finger tight.
NOTE: Do not allow the gland flange to contact and gall the
polished plug stem.
Figure 4: Soft Seat Assembly
Figure 5: Actuator Stem / Stem Clamp Alignment
Soft Seat Retainer
Soft Seat
Seat Ring
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7.5. Install new bonnet and seat gaskets with the bevelled edge
up for Teflon gaskets.
7.6 Insert the seat ring into the body with the step side down.
When the seat ring is properly in place it will turn easily in
the body. Place the seat retainer into the body with the thin
end of the cathedral window down. Most retainers have an
arrow pointing up to verify correct installation. For pressure
balanced valves, install the pressure balanced sleeve gasket.
Ensure that severe service retainers are correctly indexed by
turning the retainer in the body. Correctly aligned retainers
should turn easily.
a
CAUTION: Installing seat retainers upside down can damage
the control valve parts.
a
CAUTION: Seat rings, retainers and pressure balanced
sleeves must be installed squarely into the body to function
correctly. To check to make sure the parts are installed
correctly, rotate these parts a little by hand. The parts should
rotate freely without binding.
NOTE: When the seat retainer has only two ports, one of the
two ports should be aligned with the upper port of the body.
7.7 Place air under the actuator piston on air-to-open valves to
retract the plug.
7.8 Lower the plug and bonnet squarely into the body. Be careful
not to scratch or gall the plug as it enters the body.
7.9 To properly align the seat ring and plug, first bring the
bonnet bolting to finger-tightness.
7.9.1 With pneumatic actuators, apply air pressure above the
piston to seat the plug in the seat ring. Proceed to step 7.10.
7.9.2 With electric or hydraulic actuators, move the actuator
stem down until it is completely extended. Next, retract the
actuator stem 1/8 inch (3.2 mm). Install the stem clamp onto
the plug stem and actuator stem and tighten the associated
bolting. Move the actuator stem completely down. Adjust
actuator limit switches according to the actuator’s operating
manual. The actuator limit switches will need to be readjusted once the body bolting has been tightened.
NOTE: Step 7.10 applies only to valves with pneumatic
actuators. If an electric or hydraulic actuator is used, return
the plug to the mid-stroke position and proceed to tighten.
a
CAUTION: Failure to return the plug to a mid-stroke position
(electric or hydraulic operators only) will cause damage to
the actuator and / or the valve during the bonnet tightening
sequence. This is due to the inability of most electric / hy-
draulic actuators to accommodate the 1/16 inch / 1.60 mm
back-drive during the tightening sequence.
7.10 For air-to-close valves, skip this step and go to step 7.11.
For air-to-open valves, check for proper plug seating as
follows: When proper seating occurs, the bonnet flange will
be forced up against the finger-tight body bolting with such
force that it will be impossible to move the flange. If proper
seating does not occur, the bonnet flange can be wiggled
with light hand force for small valves and light wrench
force for larger valves. Should this occur, place air under
the actuator piston and retract the actuator to approximate
mid-stroke position. Turn the plug out of the actuator
plug stem one additional thread and repeat above seating
procedure. When the bonnet flange becomes tight against
the finger-tight body bolting, the plug is properly seated.
If necessary, repeat above procedure until proper seating
occurs.
7.11 Stroke the valve open and closed several times to center
the seat ring. Retract the plug (open position). Begin tightening the bonnet flange bolting in a manner that will keep
the bonnet flange square / parallel with the body. Tighten the first bolt 1/6 turn, or one nut flat, then tighten the
bolt directly opposite 1/6 turn and so on around the flange.
Firmly tighten all bolts evenly and completely to compress
the bonnet gasket and to seat the bonnet. Torque the bonnet bolts to the suggested torque values in Table II. The
bonnet will seat metal to metal with the body when the
bonnet bolts are correctly torqued into place
7.12 Apply air over the piston to seat the plug. For all throttling
valves with analog positioners, when the valve is in its fail
safe position, adjust the stem clamp slightly so that the full
open or full closed scribe line on the positioner cam points
to the center of the cam roller bearing. Adjustment can be
made by sliding the stem clamp on the actuator stem.
a
CAUTION: Make sure the slots of the stem clamp are
perpendicular to the bolting. See Figure 5.
NOTE: For on / off valves and valves with digital position-
ers, the bottom of the stem clamp should simply be lined
up with the bottom of actuator stem ± 1/16 inch (1.6 mm).
7.13 Tighten the stem clamp bolting. Proper tightness is
important since this adjustment secures the actuator stem
to the plug stem. Adjust the stroke plate so the stem clamp
points to the “closed” position.
7.14 If the valve has been taken out of the line, make sure the
flow arrow indicates proper flow direction upon reinstallation.
7.15 Adjust and test all accessories.
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
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8 Severe Service Trim Options
8.1 CavControl
8.1.1 CavControl replaces the standard Mark One retainer with
a drilled, stepped-hole retainer, see Figure 6. The plug and
bonnet have dimensional differences from the standard Mark
One design. Assembly and disassembly of the valve follows
the standard procedures.
8.1.2 CavControl retainers, plugs and seats should be examined for
excessive cavitation damage when disassembled. Holes in
the retainer should be checked for worn or eroded surfaces.
Check for plugged holes in the retainer. Plugs and retainer
mating surfaces should be examined for damage. Repair
and replacement of damaged parts is critical to maintaining
cavitation resistance.
a
CAUTION: To function properly, CavControl is always installed
flow over.
8.2 ChannelStream
8.2.1 ChannelStream replace the standard retainer with multiple
sleeves pinned together, see Figure 7. The plug, seat ring,
and bonnet have dimensional differences from the standard
Mark One design. Assembly and disassembly of the valve
follows the standard procedures.
8.2.2 ChannelStream retainers, plugs and seats should be examined
for excessive cavitation damage when disassembled. The
inner holes in the retainer should be checked for wear or
erosion, evidence of erosion should require that the retainer is
disassembled. Plugs and retainer mating surfaces should be
examined for damage. Repair and replacement of damaged
parts is critical to maintaining cavitation resistance.
8.2.3 ChannelStream retainers should be cleaned of debris whenever
the valve is opened.
8.2.4 Use the following steps if the retainer must be disassembled
to clean or inspect for damage. ChannelStream retainers in
pressure classes 900 and higher cannot be disassembled
in the field. Contact your local Flowserve representative for
service options.
8.2.4.1 Carefully grind away the small bead welds located on the
assembly pins near the top of the retainer. This will loosen
the pins which hold the retainer together. Using a punch,
locate the hole in the retainer opposite the pin and drive each
pin out of the retainer.
8.2.4.2 The retainer can now be inspected for damage or cleaned.
Figure 6: Mark One with CavControl Trim Body Assembly
Figure 7: Mark One with ChannelStream Trim Body Assembly
Figure 8: Diamondback Trim Body Assembly
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
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8.2.4.3 Reassemble the retainer sleeves and reinstall the pins making sure to leave an open hole opposite each pin so that the
pin can be driven out in the future. Apply a small (1/8 inch)
bead of weld to each pin to hold it in place.
NOTE: Do not weld more than the approved 1/8 inch.
Excessive heat from the bead welds that are too large can
disturb critical retainer tolerances. Use an appropriate weld
rod which is compatible with the retainer material. If
uncertain, contact the factory.
a
CAUTION: To function properly, ChannelStream is always
installed flow over.
8.3 DiamondBack
8.3.1 DiamondBack replaces the standard Mark One retainer with
a stacked-disk retainer that is either welded or bolted and
pinned, see Figure 8. Several of the parts, including the plug,
seat ring and bonnet may have dimensional differences from
the standard Mark One design. Assembly and disassembly
of the valve follows the standard procedures.
8.3.2 DiamondBack retainers, plugs and seats should be examined
for excessive cavitation damage when disassembled. The
inner holes in the retainer should be checked for wear or
erosion, evidence of erosion should require that the retainer
is disassembled or replaced. Plugs and retainer mating
surfaces should be examined for damage. Repair and
replacement of damaged parts is critical to maintaining
cavitation resistance.
8.3.3 DiamondBack retainers should be cleaned of debris
whenever the valve is opened.
8.3.4 It is rare that DiamondBack stacks require disassembly to
clean. The passages of the DiamondBack can be cleaned
by pushing a wire through the passages from the inside of
the stack, by air or by water rinsing. When required, pinned
and bolted DiamondBack retainers can be disassembled and
cleaned in the field. Welded DiamondBack retainers should
not be disassembled outside a qualified service center.
8.3.5 Disassembly of Bolted DiamondBack Retainers:
Remove the nuts from the bolts/studs. Place the retainer with
the crown disk facing down and remove the bolts/studs from
the stack. Remove the bottom indexed disk. Press the pins
out away from the crown disk. Take the discs apart, maintaining the order of assembly. Replace damaged discs, alignment
pins bolts or nuts. Inspect and clean out disc passages.
Figure 9: Mark One with MegaStream Trim Body Assembly
Figure 11: Mark One with TigerTooth Trim Body Assembly
Figure 10: Mark One with Stealth Trim Body Assembly
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
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8.3.6 Reassembly:
Care should be taken when reassembling to stack up the discs
in the same order and the same rotation. Start by driving the
pins into the crown disk. Then place each disk in descending
order until all disks, except the bottom indexed disc, are in
place. Drive the pins until they are bottomed out. Place the bottom disk on and replace the bolts/studs. Bolts must be torqued,
torque values are available from your local Flowserve contact.
a
CAUTION: To function properly, DiamondBack is always
installed flow under.
8.4 MegaStream
8.4.1 MegaStream replaces the standard Mark One retainer with a
drilled hole retainer, see Figure 9. The plug and bonnet are
typically identical to the standard Mark One design. Assembly
and disassembly of the valve follows the standard procedures.
8.4.2 MegaStream retainers, plugs and seats should be examined for
damage when disassembled. Holes in the retainer should be
checked for worn or eroded surfaces. Check for plugged holes
in the retainer. Multi-stage MegaStream retainers cannot be
disassembled. Repair and replacement of damaged parts is
critical to maintaining noise control.
a
CAUTION: To function properly, MegaStream is always installed
flow under.
8.5 Stealth
8.5.1 Stealth replaces the standard Mark One retainer with a braised,
stacked-disk retainer, see Figure 10. Several of the parts,
including the plug, seat ring and bonnet have dimensional
differences from the standard Mark One design. Assembly and
disassembly of the valve follows the standard procedures.
8.5.2 Stealth retainers, plugs and seats should be examined for
damage when disassembled. Holes in the retainer should be
checked for worn or eroded surfaces. Check for plugged holes in
the retainer. Stealth retainers cannot be disassembled. Repair
and replacement of damaged parts is critical to maintaining noise
control.
a
CAUTION: With rare exception, to function properly, Stealth is
always installed flow under.
8.5.3 When reinstalling Stealth retainers, care must be given to
orientating the retainer correctly. Stealth retainers have an
arrow that must be aligned with the valve outlet.
8.6 TigerTooth
8.6.1 TigerTooth replaces the standard Mark One retainer
with a welded or pinned, stacked-disk retainer, see
Figure 11. Several of the parts, including the plug, seat
ring and bonnet have dimensional differences from the
standard Mark One design. Assembly and disassembly of the valve follows the standard procedures.
8.6.2 TigerTooth retainers, plugs and seats should be
examined for damage when disassembled. The retainer
should be checked for worn or eroded surfaces. Check
for debris lodged in the retainer. Pinned TigerTooth retainers can be disassembled and cleaned. Care should
be taken when reassembling to stack up the discs in
the same order. Each disc has been etched with a
number for that purpose. Welded TigerTooth retainers
should not be disassembled outside a qualified service
centre. Repair and replacement of damaged parts is
critical to maintaining noise and/or cavitation control.
a
CAUTION: With rare exception, to function properly,
TigerTooth is always installed flow under.
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
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flowserve.com
Problem Probable Cause Corrective Action
Stem motion impeded
1. Over-tightened packing Adjust the packing box nuts to slightly over finger-tight
2.
Service temperature is beyond operating
limits of trim design
Reconfirm service conditions and contact factory
3. Inadequate air supply
Check for leaks in air supply or instrument signal system;
tighten loose connections and replace leaky lines
4. Malfunctioning positioner Refer to positioner User Instructions
Excessive seat leakage
1. Improperly tightened bonnet
Refer to step 7.11 Assembly and Installation section for
correct tightening procedure
2. Worn or damaged seat ring Disassemble valve and replace or repair seat ring
3. Worn or damaged seat or bonnet gasket Disassemble and replace gaskets
4. Inadequate actuator thrust
Check for adequate air supply to actuator; if air supply is
adequate, reconfirm service conditions and contact factory
5. Incorrectly adjusted plug
Refer to steps 7.9 to 7.11 Assembly and Installation section
for correct plug adjustment
6. Improper flow direction Refer to original specifications or contact factory
7.
. Improper handwheel adjustment acting as a
limit-stop
Adjust handwheel until plug seats properly
8. Worn or damaged pressure balanced seals Disassemble and replace pressure balanced seals
9. Inadequate air supply pressure
Check for leaks in air supply or instrument signal system;
tighten loose connections and replace leaky lines
Inadequate flow
1. Improper plug adjustment, limiting stroke
Refer to steps 7.9 to 7.11 Assembly and Installation section
for correct plug adjustment
2. Malfunctioning positioner Refer to positioner maintenance instructions
3.
Service conditions exceed trim design
capacity
Verify service conditions and consult factory
4. Incorrect actuator stroke Verify actuator stroke
5. Inadequate air supply pressure
Check for leaks in air supply or instrument signal system;
tighten loose connections and replace leaky lines
Plug slams
1.
Incorrect plug adjustment allowing improper
cushion of air between actuator piston and
yoke
Refer to steps 7.9 to 7.11 Assembly and Installation section
for correct plug adjustment
2. Inadequate air supply
Check air supply to actuator; repair leaks and remove any
restrictions in supply line
3. Trim sized too large for flow rate
Verify the service conditions and actuator sizing, install
reduced trim
Valve does not fail in
correct position
1. Incorrect flow direction
Reconfirm direction and, if necessary, correct flow direction
through valve
2. Incorrect actuator fail direction Consult actuator User Manual and change fail direction
Table III: Troubleshooting Chart
flowserve.com
To find your local Flowserve representative
or for more information about Flowserve Corporation, visit
www.flowserve.com.
FCD VLENIM0001-02-A4 Printed in USA. 05/16 (Replaces VLAIM001-00)
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed
to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might
be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot
provide specific data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection,
installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation Maintenance (IOM) instructions
included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be
considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or
implied, regarding any matter with respect to this product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions
and information contained herein are subject to change without notice. Should any question arise concerning these provisions, the purchaser/user should contact
Flowserve Corporation at any one of its worldwide operations or offices.
© 2015 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.
USA
Flowserve Flow Control Division
1350 N. Mt. Springs Parkway
Springville, UT 84663
USA
Phone: +1 801 489 8611
Fax: +1 801 489 3719
Austria
Flowserve Control Valves GmbH
Kasernengasse 6
9500 Villach
Austria
Phone: 43 (0) 4242 41 181 0
Fax: 43 (0) 4242 41181 50
France
Flowserve France S.A.S.
BP 60 63307 Thiers Cedex
France
Phone: 33 4738 04266
Fax: 33 4738 01424
India
Flowserve India Controls Pvt Ltd.
Plot # 4, 1A, Road #8 EPIP
Whitefield
Bangalore, Karnataka, 560066
India
Phone: 91 80 40146200
Fax: 91 80 28410286
China
Flowserve Fluid Motion and
Control (Suzhou) Co., Ltd.
No. 35, Baiyu Road
Suzhou Industrial Park, Suzhou
Jiangsu Province, P.R. 215021
China
Phone: 86 512 6288 8790
Fax: 86 512 6288 8736
Singapore
Flowserve Pte. Ltd.
12 Tuas Avenue 20
Republic of Singapore 638824
Phone: 65 6879 8900
Fax: 65 6862 4940
Saudi Arabia
Flowserve Abahsain Flow Control
Co., Ltd.
Makkah Road, Phase 4
Plot 10 & 12, 2nd Industrial City
Damman, Kingdom of Saudi
Arabia
Phone: +966 3 857 3150 ext. 243
Fax: +966 3 857 4243
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