Flowserve VL-ES User Manual

USER INSTRUCTIONS

Valtek VL-ES Actuators

FCD VLENIM0114-00 – 09/06

Installation

Operation

Maintenance

Experience In Motion

Valtek VL-ES Actuators FCD VLENIM0114-00 – 09/06

Contents

1 General Information 3

1.1 Using 3

1.2 Applicability 3

1.3 Terms Concerning Safety

1.4 Protective Clothing

1.5 Qualified Personnel

1.6 Installation 4

1.7 Spare Parts

1.8 Service / Repair

1.9 Storage 4

1.10 Product Variations
2 Unpacking
3 Valve Installation
4 Dissassembly of VL-ES Actuator
5 Assembly of the VL-ES Actuator
6 Maintenance 1
7 Decommissioning the Spring-Can 1

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Valtek VL-ES Actuators FCD VLENIM0114-00 – 09/06

1 General Information

1.1 Using

The following instructions are designed to assist in disassembling, reassembling and troubleshooting
Flowserve Valtek valves equipped with VL-ES actuators. Separate installation, operation and mainte
nance instructions cover additional features (such as handwheels, limit stops, fail-safe systems, limit
switches or positioners). Product users and maintenance personnel should thoroughly review this
bulletin in conjunction with any handwheels or other accessory equipment before installing, operating or
performing any maintenance on the valve. In most cases, Flowserve valves, actuators and accessories
are designed for specific applications (e.g. with regard to medium, pressure, 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 VL-ES actuators
only. This document should be used in conjunction with the appropriate Installation, Operation and
Maintenance Instructions specific to the model of the valve on which the actuator is installed.

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1.3 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

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if proper precautions are not taken.

WARNING: indicates that death, severe personal injury and/or substantial property damage can

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occur if proper precautions are not taken.

CAUTION: indicates that minor personal injury and/or property damage can occur if proper precau-

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tions 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 essential in order to avoid faults, which,
in and of themselves may 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 or
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 and respirator as required).

1.5 Qualified Personnel

Qualified personnel are people who, on account of their training, experience, instruction and knowledge
of relevant standards, specifications, accident prevention regulations and operating conditions, have

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Valtek VL-ES Actuators FCD VLENIM0114-00 – 09/06

been authorized by those responsible for the safety of the plant to perform the necessary work and who
are able to recognize and avoid possible dangers.

DANGER: Before installation, check the order number, serial number and/or the tag number to

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ensure that the valve/actuator is correct for the intended application.

WARNING: Standard industry safety practices must be followed when working on this or any

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process control product. Specifically, personal protection and lifting devices must be used as
warranted.

1.6 Installation

1.6.1 Do not insulate extensions that are provided for hot or cold services.

1.6.2 Pipelines must be correctly aligned to ensure that the valve is not fitted under tension.

1.6.3 The user must provide fire protection.

1.7 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 these products for
corrosion or deterioration before using them. The end user must provide fire protection for Flowserve
products.

1.8 Service / Repair

To avoid possible injury to personnel or damage to products, the safety terms must be strictly adhered
to (see Section 1.3). Modifying this product, substituting non-factory parts, or using maintenance
procedures other than those outlined in this instruction manual can 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.

WARNING: Before products are returned to Flowserve for repair or service, Flowserve must

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be provided with an MSDS (Material Safety Data Sheet) and a certificate, which confirms that
the product has been decontaminated. Flowserve will not accept deliveries if the MSDS and the
certificate have not been provided (a form can be obtained from Flowserve). Since the packing box
cannot be cleaned without removing packing, valve packing should be removed and the packing
area flushed as part of the cleaning.

1.9 Storage

In most cases, Flowserve products are manufactured from stainless steel. Products not manufactured

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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 adequately stored in a clean,
dry environment. Plastic caps are fitted to protect the flange faces by preventing the ingress of foreign
materials. These caps should not be removed until the valve is actually mounted into the system.

Valtek VL-ES Actuators FCD VLENIM0114-00 – 09/06

1.10 Product Variations

These instructions cannot claim to cover all the details of every possible product variation, nor in
particular can they provide information for every possible example of installation, operation and
maintenance. This means that the instructions normally include only the directions to be followed
by qualified personnel 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.

2 Unpacking

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

2.1 Position the lifting straps and hoist to avoid damage to the tubing and mounted accessories when
lifting the actuator from the shipping container.

WARNING: When lifting an actuator with lifting straps through the yoke legs, be aware that the

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center of gravity may be above the lifting point. Therefore, support must be given to prevent the
actuator from rotating, causing serious injury to personnel or damage to nearby equipment.

2.2 Contact your shipper immediately in the event of shipping damage.

2.3 Contact your Flowserve representative with any other problems.

3 Valve Installation

Prior to installation, make sure adequate overhead clearance is provided for the actuator to allow for
proper removal from the valve body and for proper maintenance. Refer to Table I.

Table I: Dissassembly Clearance

Actuator Size Spring

100 Standard 9 229

150 Standard 9 229

150 Heavy Duty 9 229

200 Standard 9 229

200 Heavy Duty 9 229

300 Standard 9 229

300 Heavy Duty 9 229

400 Standard 9 229

400 Heavy Duty 9 229

Disassembly Clearance

in. mm

3.1 Make sure the positioner mounting bolts, linkage and stem clamp are fastened securely.

3.2 Ensure all accessories, brackets and associated bolting are fastened securely.

3.3 Check rubber bellows for wear.

3.4 Spray soap solution around the base and top of the cylinder, lower actuator stem bushing and the

piston stem bushings to check for air leaks through the O-rings.

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