Experience In Motion
USER INSTRUCTIONS
Installation
Operation
Maintenance
Valtek MaxFlo 4
Eccentric Rotary Plug Control Valve
FCD VLENIM0064-01-A4 – (11/15)
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 Applicability
The following instructions are applicable to the maintenance
and installation of Flowserve MaxFlo 4 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. Flowserve User Manuals are available at
www.flowserve.com.
1.3 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 require particular
attention.
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DANGER: Indicates that death, severe personal injury and/
or substantial property damage will occur if proper precautions
are not taken.
a WARNING: Indicates that danger of death or severe
personal injury and/or property damage can occur if proper
precautions are not taken.
a CAUTION: Indicates that minor personal injury and/or
serious damage to property can occur if the proper precautions
are not taken.
NOTE: Indicates and provides additional technical information
which may not be obvious, even to qualified personnel.
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 also essential in order to avoid faults,
which can directly or indirectly cause severe personal injury or
property damage.
1.4 Protective clothing
Flowserve products are often used in problematic applications
(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).
1.5 Qualified personnel
Qualified personnel are people who on account of their educa-
tion, 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.
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 manufacturers. If
Flowserve products (especially sealing materials) have been in
storage 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
Contents
1 General Information 2
2 Unpacking 3
3 Installation 3
4 Quick-Check 4
5 Preventative Maintenance 4
6 Valve Disassembly 6
7 Body Reassembly 6
8 Seat Replacement (No Shims) 8
9 Actuator Remounting (With Shims) 8
10 Actuator Remounting 9
11 Mounting Orientation - Air-to-Open - Diaphragm Actuator 11
12 Mounting Orientation - Air-to-Close - Diaphragm Actuator 12
13 Mounting Orientation - Air-to-Open - Cylinder Actuator 13
14 Mounting Orientation - Air-to-Close - Cylinder Actuator 14
15 Pipe Mounting Orientation Codes 15
16 Troubleshooting 15
Valtek MaxFlo 4 FCD VLENIM0064-01-A4 – 11/15
2
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. Flowserve will not accept deliveries if a certificate has not
been provided (a form can be obtained from Flowserve).
1.8 Storage
In most cases, Flowserve products are manufactured from
stainless steel. Products not manufactured from stainless steel
are provided with an epoxy resin coating. This means that
Flowerve products are well protected from corrosion. Nevertheless, Flowserve products must be stored adequately in a clean,
dry, environment. Plastic caps are fitted to 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. Take care to position lifting straps to
avoid damage to the tubing and mounted accessories.
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DANGER: When lifting a valve be aware that the center 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 or death and damage to the valve and
nearby equipment.
2.3 Contact you shipper immediately if there is shipping damage.
2.4 Should any problem arise, call your Flowserve representative.
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DANGER: Before installation check the 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 CAUTION: Do not insulate extensions that are provided for
hot or cold services.
3 Installation
3.1 Before installing the valve, clean the pipeline of all contamination, 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.
3.2 Fire protection must be provided by the user.
3.3 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.
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DANGER: To avoid serious injury, keep hands, hair, clothing,
etc away from the plug and seat when the valve is working.
3.4 Whenever possible, the valve should be installed so that actuator
is in an upright position. Vertical installation of the actuator
permits easier valve maintenance.
3.5 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.
a CAUTION: On valves equipped with air filters, the air filter
must point down to perform properly.
3.6 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.
3.7 Be sure to provide proper overhead clearance for the actuator to
allow for disassembly of the actuator from the valve body. Refer
to the appropriate to the MaxFlo 4 Technical Bulletin for proper
clearances. The MaxFlo 4 Technical Bulletin is available at www.
flowserve.com.
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Valtek MaxFlo 4 FCD VLENIM0064-01-A4 – 11/15
flowserve.com
Table I: Line Flange Bolting Specifications
Valve
size
Nominal
Pressure /
Rating
MaxFlo 4 flanged
Size x Length
MaxFlo 4 flangeless
Size x Length
Inches Metric Qty/ valve Inches Metric Qty/ valve
DN25
1"
ANSI 150 1/2 X 2.62 M12 X 65 8 1/2 X 6.75 M12 X 170 4
ANSI 300 5/8 X 3.12 M16 X 80 8 5/8 X 6.88 M16 X 175 4
PN 16 M12 X 70 8 M12 X 175 4
PN 40 M12 X 70 8 M12 X 175 4
DN40
1½"
ANSI 150 1/2 X 2.88 M12 X 70 8 1/2 X 7.50 M12 X 190 4
ANSI 300 3/4 X 3.62 M20 X 95 8 3/4 X 8.38 M20 X 215 4
PN 16 M16 X 80 8 M16 X 200 4
PN 40 M16 X 80 8 M16 X 200 4
DN50
2"
ANSI 150 5/8 X 3.25 M16 X 85 8 5/8 X 8.38 M16 X 215 4
ANSI 300 5/8 X 3.5 M16 X 90 16
5/8 X 3.50 M16 X 90 4
5/8 X 8.50 M16 X 220 6
PN 16 M16 X 85 8 M16 X 215 4
PN 40 M16 X 85 8 M16 X 215 4
DN80
3"
ANSI 150 5/8 X 3.62 M16 X 95 8 5/8 X 10.5 M16 X 265 4
ANSI 300 3/4 X 4.25 M20 X 110 16
3/4 X 4.25 M20 X 110 4
3/4 X 11.00 M20 X 280 6
PN 16 M16 X 85 16
M16 X 85 6
M16 X 255 5
PN 40 M16 X 95 16
M16 X 95 6
M16 X 265 5
DN100
4"
ANSI 150 5/8 X 3.62 M16 X 95 16
5/8 X 3.62 M16 X 95 4
5/8 X 11.5 M16 X 295 6
ANSI 300 3/4 X 4.5 M20 X 115
16 3/4 X 4.5 M20 X 115 4
3/4 X 12.25 M20 X 315 6
PN 16 M16 X 85 16
M16 X 85 6
M16 X 285 5
PN 40 M20 X 100 16
M20 X 100 6
M20 X 300 5
DN150
6"
ANSI 150 3/4 X 3.75 M20 X 105 16
3/4 X 3.75 M20 X 105 4
3/4 X 13.25 M20 X 340 6
ANSI 300 3/4 X 4.88 M20 X 125 24
3/4 X 4.88 M20 X 125 8
3/4 X 14.00 M20 X 360 8
PN 16 M20 X 100 16
M20 X 100 4
M20 X 335 6
PN 40 M24 X 115 16
M24 X 115 4
M24 X 350 6
DN200
8"
ANSI 150 3/4 X 4.25 M20 X 110 16 3/4 X 4.25 M20 X 360 8
ANSI 300 7/8 X 5.5 M22 X 140 24
7/8 X 5.5 M22 X 140 4
7/8 X 15.19 M22 X 390 10
PN 16 M20 X 100 24
M20 X 100 8
M20 X 350 8
PN 40 M27 X 135 24
M27 X 135 8
M27 X 385 8
DN250
10"
ANSI 150 7/8 X 4.62 M22 X 120 24
ANSI 300 1 X 6.25 M24 X 155 32
PN 16 M24 X 110 24
PN 40 M30 X 150 24
DN300
12"
ANSI 150 7/8 X 4.75 M22 X 120 24
ANSI 300 1 1/8 X 6.75 M27 X 170 32
PN 16 M24 X 115 24
PN 40 M30 X 160 32
4 Quick-Check
Before commissioning, check the control valve by following these steps:
4.1 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.
4.2 Check all air connections for leaks. Tighten or replace any
leaking lines.
4.3 Check packing box bolting for proper tightness.
a CAUTION: Do not overtighten packing box bolting. 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.
4.4 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.
5 Preventative Maintenance
At least once every six months, check for proper operation 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 “Valve Disassembly”.
5.1 Look for signs of gasket leakage through the end flanges and
bonnet. If necessary, re-torque flange, bonnet and post bolting.
5.2 Examine the valve for damage, such as damage caused by
corrosive fumes or process drippings.
5.3 Clean the valve and repaint areas of severe oxidation.
5.4 Check the packing-box for proper tightness. If there is a persistent leak, change the packing after referring to sections “Valve
Disassembly and Body Reassembly”.
a CAUTION: Do not overtighten packing box bolting. This can
cause excessive packing wear and high friction that may impede
shaft movement.
5.5 If the valve is equipped with a lubricator, add lubricant if necessary.
5.6 If possible, stroke the valve and check for smooth, full-stroke
operation. Unsteady shaft movement may indicate an internal
valve problem.
5.7 Check the calibration of the positioner. For further preventative
maintenance, see the instructions in the installation, operation
and maintenance manual for the applicable positioner.
Valtek MaxFlo 4 FCD VLENIM0064-01-A4 – 11/15
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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
Item 51 Shaft
Item 83 Shaft bearing
Item 50 Plug
Item 84 End post bearing
Item 1 Body
Item 23 Shims (if required)
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
Figure 1: MaxFlo 4 valve body assembly
item numbers correspond directly to the valve’s bill of material.
Refer to it for specific part numbers.
5
Valtek MaxFlo 4 FCD VLENIM0064-01-A4 – 11/15
flowserve.com
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