Flowserve Valtek Mark Two, Valtek Mark One User Instructions
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
2
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
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
3
flowserve.com
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.
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
4
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
Valtek Mark One and Mark Two Control Valves FCD VLENIM0001-02-A4 - 05/16
5
flowserve.com
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.
Loading...