Valtek MaxFlo 3
®
User Instructions - MaxFlo 3 - VLEEIM7001-03 07.07
USER INSTRUCTIONS
Valtek MaxFlo 3
Control Valves
Installation
Operation
Maintenance
1
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User Instructions - MaxFlo 3 - VLEEIM7001-03 07.07
SUMMARY
1 GENERAL INFORMATION
2 INSTALLATION
3 QUICK-CHECK
4 PREVENTATIVE MAINTENANCE
5 VALVE DISASSEMBLY
6 BODY REASSEMBLY
7 SEAT REPLACEMENT
8 ACTUATOR REMOUNTING
9 PRINCIPLES OF SHAFT ANTI-BLOWOUT SYSTEM
10 MOUNTING ORIENTATION– AIR-TO-OPEN CONFIGURATION
11 MOUNTING ORIENTATION – AIR-TO-CLOSE CONFIGURATION
12 TROUBLESHOOTING
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User Instructions - MaxFlo 3 - VLEEIM7001-03 07.07
STOP!
STOP!
1 GENERAL INFORMATION
1.1 Use
The following instructions are designed to assist in
the unpacking, installation, and maintenance as required for Flowserve products. Product users and
maintenance personnel should thoroughly review this
manual prior to installing, operating, or performing
any maintenance.
In most cases, Flowserve accessories, actuators and
valves 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.
1.2 Terms related to safety
The terms DANGER, WARNING, CAUTION, NOTE are
used in this document to highlight particular dangers
and/or to provide additional information on points
which may not be clearly obvious.
DANGER: Indicates that death, severe personal injury
and/or substantial property damage will occur if proper precautions are not taken.
WARNING: Indicates that danger of death or severe
personal injury and/or property damage can occur if
proper precautions are not taken.
CAUTION: Indicates that minor personal injury and/or
serious damage to property can occur if the appropriate precautions are not taken.
NOTE: Indicates and provides additional technical in-
formation which may not be obvious, even to qualified
personnel.
Compliance with other notes, which may not be partic-
ularly 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
damage..
2 INSTALLATION
2.1 Before installing the valve, clean the pipeline of all con
tamination, carbon deposits, welding chips, and other
foreign material. Carefully clean gasket surfaces to ensure a tight seal. Pipelines must be correctly aligned to
ensure that the valve is not fitted under tension.
2.2 Check the direction of fluid flow to ensure that the valve
is correctly installed. Flow direction is indicated by the
arrow attached to the body. All installation orientations
for fitting the valve into the pipeline are defined at the
end of this manual.
DANGER: To avoid serious injury, keep hands, hair,
clothing, etc away from the plug and seat when the
valve is working.
2.3 Connect the air supply and instrument signal lines.
Throttling control valves are equipped with a valve
positioner. Connections are marked for the air supply
and the instrument signal. Check that the actuator and
positioner can withstand the maximum air supply from
the network. The required air supply is indicated on a
sticker located on the actuator. An air regulator will be
necessary in certain cases in order to limit the supply
pressure. A filter is recommended unless the air supplied is exceptionally clean and dry (air quality without
humidity, oil, or dust as per IEC 770 and ISA-7.0.01).
All connections must be completely tight.
2.4 Use the bolts indicated in table I for installing the valve
in the pipeline, and then tighten alternately according
to good practice. The user must in all cases confirm
the capacity of the bolts to ensure a sufficiently tight
gasket seal for the expected service conditions.
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1.3 Protective clothing
Flowserve products are often used in problematic ap-
plications (e.g. under extremely high pressures with
dangerous, toxic or corrosive mediums). When performng service, inspection, or repair operations, always ensure that the valve and the actuator are depressurized and that the valve has been cleaned, and
that it is free of harmful substances. In such cases, pay
particular attention to personal protection (e.g. protective clothing, gloves, glasses etc).
1.4 Qualified personnel
Qualified personnel are people who on account of their
education, experience, training, and knowledge of relevant standards, specifications, accident prevention,
and operating conditions have been authorized by
those responsible for the safety of the plant to perform
the necessary work, and recognize and avoid possible
dangers.
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Table I: Line Flange Bolting Specifications
Size
Nominal
vanne
Pressure /
Rating
ANSI 150 1/2 X 2.62 M12 X 65
ANSI 300 5/8 X 3.12 M16 X 80 8 5/8 X 6.88 M16 X 175 4
DN25
1"
PN 16
PN 40 M12 X 70 8 M12 X 175 4
ANSI 150 1/2 X 2.88 M12 X 70
ANSI 300 3/4 X 3.62 M20 X 95 8 3/4 X 8.38 M20 X 215 4
DN40
1½"
PN 16
PN 40 M16 X 80 8 M16 X 200 4
ANSI 150 5/8 X 3.25 M16 X 85
ANSI 300 5/8 X 3.5 M16 X 90 16
DN50
2"
PN 16
PN 40 M16 X 85 8 M16 X 215 4
ANSI 150 5/8 X 3.62 M16 X 95
ANSI 300 3/4 X 4.25 M20 X 110 16
DN80
3"
PN 16
PN 40 M16 X 95 16
ANSI 150 5/8 X 3.62 M16 X 95 16
ANSI 300 3/4 X 4.5 M20 X 115
DN100
4"
PN 16
PN 40 M20 X 100 16
ANSI 150
ANSI 300 3/4 X 4.88 M20 X 125 24
DN150
6"
PN 16
PN 40 M24 X 115 16
ANSI 150 3/4 X 4.25 M20 X 110 16 3/4 X 4.25 M20 X 360
ANSI 300 7/8 X 5.5 M22 X 140 24
DN200
8"
PN 16
PN 40 M27 X 135 24
ANSI 150 7/8 X 4.62 M22 X 120 24
ANSI 300 1 X 6.25 M24 X 155 32
DN250
10"
PN 16
PN 40 M30 X 150 24
ANSI 150
ANSI 300 1 1/8 X 6.75 M27 X 170 32
DN300
12"
PN 16
PN 40 M30 X 160 32
MaxFlo 3 flanged
Size x Length
Inches Metric
M12 X 70 8 M12 X 175 4
M16 X 80 8 M16 X 200 4
M16 X 85 8 M16 X 215 4
M16 X 85 16
M16 X 85 16
3/4 X 3.75 M20 X 105 16
M20 X 100 16
M20 X 100 24
M24 X 110 24
7/8 X 4.75 M22 X 120 24
M24 X 115 24
Qty /
vanne
8 1/2 X 6.75 M12 X 170 4
8 1/2 X 7.50 M12 X 190 4
8 5/8 X 8.38 M16 X 215 4
8 5/8 X 10.5 M16 X 265 4
16
MaxFlo3 flangeless
Size x Length
Inches Metric
5/8 X 3.50 M16 X 90 4
5/8 X 8.50 M16 X 220 6
3/4 X 4.25 M20 X 110
3/4 X 11.00 M20 X 280
M16 X 85 6
M16 X 255
M16 X 95 6
M16 X 265
5/8 X 3.62 M16 X 95
5/8 X 11.5 M16 X 295
3/4 X 4.5 M20 X 115 4
3/4 X 12.25 M20 X 315
M16 X 85 6
M16 X 285
M20 X 100 6
M20 X 300
3/4 X 3.75 M20 X 105 4
3/4 X 13.25 M20 X 340
3/4 X 4.88 M20 X 125 8
3/4 X 14.00 M20 X 360
M20 X 100 4
M20 X 335
M24 X 115 4
M24 X 350
7/8 X 5.5 M22 X 140 4
7/8 X 15.19 M22 X 390 10
M20 X 100 8
M20 X 350
M27 X 135 8
M27 X 385
Qty /
vanne
4
6
5
5
4
6
6
5
5
6
8
6
6
8
8
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3 QUICK-CHECK
Before commissioning, check the control valve by fol
lowing these steps:
3.1 Check for full stroke by varying the instrument signal
settings appropriately. Observe the plug position indicator located on the actuator or the positioner. The
plug should change position with a smooth turning
movement.
3.2 Check all air connections for leaks. Tighten or replace
any leaking lines.
3.3 Check packing box bolting for proper tightness.
User Instructions - MaxFlo 3 - VLEEIM7001-03 07.07
CAUTION: Do not overtighten packing. This can cause
excessive packing wear and high stem friction that
may impede shaft movement. After the valve has been
in service for a short period, recheck the packing-box
nuts. If the packing-box leaks, tighten the nuts just
enough to stop the leak.
3.4 Make sure the valve fails in the correct direction in case
of air failure. This is done by positioning the valve at
mid-stroke and turning off the air supply and observing the failure direction. If the action is incorrect, see
the section “Reversing the Air-action” in the instructions of the installation, operation and maintenance
manual of the appropriate actuator.
4 PREVENTATIVE MAINTENANCE
At least once every six months, check for proper oper-
ation by following the preventative maintenance steps
outlined below. These steps may be performed while
the valve is in-line and without interrupting service. If
an internal problem is suspected, refer to section “Disassembling the Valve”.
4.1 Look for signs of gasket leakage through the end
flanges and bonnet. If necessary, re-torque flange,
bonnet and post bolting.
4.2 Examine the valve for damage caused by corrosive
fumes or process drippings.
4.3 Clean the valve and repaint areas of severe oxidation.
4.4 Check the packing-box for proper tightness. If there is
a persistent leak, change the packing after referring to
section “Valve Disassembly and Body Reassembling”.
CAUTION: Do not overtighten packing. This can cause
excessive packing wear and high friction that may impede shaft movement.
4.5 If the valve is equipped with a lubricator, add lubricant
if necessary.
4.6 If possible, stroke the valve and check for smooth,
full-stroke operation. Unsteady shaft movement may
indicate an internal valve problem.
4.7 Check the calibration of the positioner. For further
preventative maintenance, see the instructions in the
installation, operation and maintenance manual for the
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applicable positioner.
4.8 Ensure all accessories, brackets and bolting are securely fastened.
4.9 If possible, remove air supply and observe actuator for
correct fail-safe action.
4.10 Check the actuator and all air connections for leaks.
4.11 If an air filter is supplied, check and replace the cartridge if necessary.
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User Instructions - MaxFlo 3 - VLEEIM7001-03 07.07
Item 117 Packing box nuts
Item 109 Packing box studs
Item 80 Gland flange
Item 87 Packing follower
Item 114 Bonnet nuts
Item 108 Bonnet studs
Item 93 Packing spacer
Item 88 Packing set
Item 99 Packing stop
Item 40 Bonnet
Item 42 Purge plug (optional)
Item 58 Bonnet gasket
Item 46 Thrust bearing
Figure 1: MaxFlo 3 valve body assembly
item numbers correspond directly to the valve’s bill of material. Refer
to it for specific part numbers.
Item 51 Shaft
Item 83 Shaft bearing
Item 50 Plug
Item 84 End post bearing
Item 1 Body
Item 23 Shims
Item 20 Seat
Item 30 Seat retainer
Item 61 End post gasket
Item 122 End post
Item 115 End post studs
Item 119 End post nuts
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