GE mn-28000 Technical Specifications

GE Oil & Gas

28000 Series

Masoneilan* VariPak*
Adjustable-Cv Control Valves

Instruction Manual

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT­SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL
OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE
PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND
AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC
LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL
UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND
ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE
INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY
RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS
FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT
NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH
INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED
OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR
THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE
STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE
SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE
REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE
INSTRUCTIONS.

THESE INSTRUCTIONS CONTAIN PROPRIETARY INFORMATION OF GE, AND ARE FURNISHED TO
THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION,
AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE
REPRODUCED IN WHOLE OR IN PART NOR SHALL ITS CONTENTS BE DISCLOSED TO ANY
THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE.

2 | GE Oil & Gas

Contents

1. General ......................................................................................................4

1.1 Spare Parts ............................................................................................4

1.2 After Sales Department ................................................................................4

1.3 Training ................................................................................................4

2. Operation ...................................................................................................5

2.1 Precise Adjustment of the Varipak 28002 Adjustable-Cv Valve ............................................5

2.2 Flow Coefficient of Varipak 28001 Single-Lever and 28002 Adjustable-Cv Valves ..........................5

2.3 Actuator ...............................................................................................7

2.4 Handwheel ............................................................................................7

2.5 Reversing the Valve Action ..............................................................................8

3. Installation .................................................................................................10

3.1 Preliminary Steps ......................................................................................10

3.2 Valve Installation ......................................................................................10

3.3 Pneumatic and Electrical Circuit .......................................................................11

3.4 Limit Switches .........................................................................................11

4. Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.1 Piston Rod Clevis Adjustment ..........................................................................12

4.2 Plug Stem Adjustment .................................................................................12

4.3 Limit Stop Adjustment .................................................................................13

4.4 Varipak 28002 Cv Adjustment ..........................................................................14

4.5 Positioner Start-Up Pressure Adjustment ...............................................................14

5. Maintenance ...............................................................................................14

5.1 Actuator Diaphragm Removal .........................................................................14

5.2 Adding Packing Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

5.3 Disassembly ..........................................................................................15

5.4 Reassembly ...........................................................................................16

5.5 Packing Quick Change Method (Only For Valves With Max. Cv Of 0.6 To 3.8) ..............................18

5.6 7700P or 7700E Positioner Maintenance ................................................................18

5.7 Maintenance Operations Specific to the 7700E Positioner ...............................................19

5.8 Converting a 7700P Positioner (Pneumatic) into a 7700E Positioner (Electro-Pneumatic) ..................20

Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 3

1. General

These installation, operation, and maintenance instructions apply to Masoneilan VariPak* 28000 series control
valves. They also include a parts reference list with recommended spare parts (see page 21).

IMPORTANT REMARKS

Before installing, operating, or performing maintenance on this equipment, you should read

these instructions carefully and make sure you have understood them.

Work on this equipment should only be carried out by qualified personnel.

Failure to follow the instructions and precautions given in this document could lead to a

malfunction and seriously damage the equipment.

1.1 SPARE PARTS

For maintenance purposes, always use original
Masoneilan spare parts obtained through your local
GE representative or Spare Parts Department. When
ordering, always give the references of the original
order for the equipment concerned and, in particular,
the number indicated on the serial plate. (135).

1.3 TRAINING

GE organizes regular training courses in the operation,
maintenance, and application of its Masoneilan
control valves and instruments for customer service
and instrumentation personnel at its Condé-sur­Noireau plant. For further details, contact your local
GE representative or the Training Department at the
Condé-sur-Noireau plant, in France.

1.2 AFTER SALES DEPARTMENT

GE has a highly skilled After Sales Department to assist
customers with start-up, maintenance, and repair of
valves and instruments. Contact your nearest GE Sales
Office or Representative, or the After Sales Department
at the Condé-sur-Noireau plant, in France.

Based on general field failure data and product design analysis, a useful life period of
25 years or longer can be expected for the Masoneilan 28000 Series Varipak valves.
To maximize the useful life of the product it is essential to conduct annual inspections,
routine maintenance and ensure proper installation to avoid any unintended stresses
on the product. The specific operating conditions will also impact the useful life of the
product. Consult the factory for guidance on specific applications if required prior to
installation.

4 | GE Oil & Gas

2. Operation

The Masoneilan VariPak microflow control valve
features a very wide range of rated flow coefficients
(Cv), from 0.004 to 3.8.

Two types of actuators are available:

- The VariPak 28001 with a single lever, designed for
just one rated Cv. This version is used when enough is
known about the operating conditions when sizing the
valve.

- The VariPak 28002 with an adjustable rated Cv. This
valve uses a patented lever system to adjust the rated
Cv on site to suit the actual operating conditions,
thereby avoiding any oversizing in flow capacity.
Each plug and seat ring combination can be adjusted
without changing the control signal.

2.1 PRECISE ADJUSTMENT OF THE VARIPAK 28002

ADJUSTABLE-Cv VALVE

The valve is adjusted using a simple, but robust,
crossed-lever system with an adjustable fulcrum. This
can be done easily by hand, either before installation or
during operation. For example, an application requiring
a theoretical Cv of 0.006 could be handled using a
VariPak 28002 with a maximum Cv of 0.010, that can
subsequently be calibrated on site between 0.004 and

0.010.

2.2 FLOW COEFFICIENT OF VARIPAK 28001
SINGLE-LEVER AND 28002 ADJUSTABLE-Cv
VALVES

2.2.1 Plug/seat ring combinations (trim)

Eight plugs and five seat rings are used to

make up the ten available plug and seat ring
combinations, identified by codes from 0 to 9
(see figure 2). The shape of each plug and the
port diameter of the seat ring can be used to
match parts with the table in figure 2.

The difference between the four plugs in trim

Nos. 6 to 9 lies in the angle of the flat machined
on the tip. The same seat ring (3e) and the
same spacer (3f) are used in all four cases (see
figure 2).

Use the table in figure 1 to select the plug and

seat ring combination to obtain the Cv value or
range of Cv values you require.

Trim No.

9

8

7

6

5

4

3

2

1

0

FLOW COEFFICIENT C

VARIPAK

28001

0.0040 0.0016 0.0020 0.0024 0.0028 0.0032 0.0036 0.0040

0.010 0.004 0.005 0.006 0.007 0.008 0.009 0.010

0.025 0.010 0.013 0.016 0.019 0.021 0.023 0.025

0.050 0.020 0.025 0.030 0.035 0.040 0.045 0.050

0.10 0.04 0.05 0.06 0.07 0.08 0.09 0.10

0.25 0.10 0.13 0.16 0.19 0.21 0.23 0.25

0.6 0.25 0.30 0.35 0.4 0.45 0.5 0.55 0.6

1.2 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

2.3 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3

3.8 1.5 1.9 2.3 2.6 2.9 3.2 3.5 3.8

MIN. RISK FREE MAX.

Figure 1

VARIPAK 28002

v

Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 5

VariPak
28001

VariPak
28002

Plug and
seat rin g
No. 9

Cv 0.004 Cv 0.010 Cv 0.010 Cv 0.050 Cv 0.10 Cv 0.25 Cv 0.60 Cv 0.2 Cv 2.3 Cv 3.8

Cv 0.00 4
to 0.0016

Plug and
seat rin g
No. 8

Cv 0.010
to 0.00 4

Plug and
seat rin g
No. 7

Cv 0.010
to 0.00 4

Plug and
seat rin g
No. 6

Cv 0.050
to 0.010

Plug and
seat rin g
No. 5

Cv 0.10
to 0.04

Plug and
seat rin g
No. 4

Cv 0.25
to 0.10

Plug and
seat rin g
No. 3

Cv 0.60 to

0.25

Plug and
seat rin g
No. 2

Cv 1.2 to

0.9

Plug and
seat rin g
No. 1

Cv 2.3 to

0.9

Plug and
seat rin g
No. 0

Cv 3.8 to

1.5

3f

3d

Orifice Dia.
2 mm

3e

Orifice Dia.

1.6 mm

2.2.2 Changing the plug and seat ring combination

The plug and seat ring combination can be changed
very easily for trim Nos. 1 to 9 inclusive. Simply replace
the following parts:

- The plug and seat ring (see figures 1 and 2 to select
the combination required for the new Cv).

Plug/Seat

No.

Coefficient C

0 3.8 to 1.5

1 2.3 to 0.9

2 1.2 to 0.5

3 0.6 to 0.25

4 0.25 to 1.10

5 0.10 to 0.04

6 0.050 to 0.020

7 0.025 to 0.010

8 0.010 to 0.004

9 0.004 to 0.0016

Flow

v

Spring Range (134)

m.bar Psi Color Code bar (Psi) bar (Psi) bar (Psi) ATO ATC

414

-

6-24 Red 2.1 (30) 2.1 (30) 2.1 (30)

1660

207

-

3-15 Green 1.4 (20) 1.4 (20) 1.4 (20)

1035

Figure 3 - Actuator spring ranges and supply pressures

3c

3b

3a

Orifice Dia.

Orifice Dia.

4.5 mm

Orifice Dia.

9.5 mm

14.3 mm

- The Cv adjustment plate (25) in the case of the VariPak
28002 adjustable-Cv valve.

- If necessary, the actuator spring (134) (see figure 3 to
check the spring range corresponding to the new Cv.

Max. Pressure Supply

Adjustable C

v

CI. IV CI. V CI. IV CI. V

Single Lever

2.8

(40)

1.7

(25)

6 | GE Oil & Gas

Follow the procedure described in the "Disassembly/
Reassembly" section of the "Maintenance" chapter on
pages 14 to 18.

- Loosen adjustment knob (24) and slide it along the
lever to the required value. Tighten the adjustment
knob again firmly.

- Also change the serial plate (135) or correct the
information on the existing plate.

Caution: If the valve in question includes
a 1/2" or 3/4" NPT threaded end, the
maximum capacity of the body is
respectively limited to trim Nos. 9 to 3
inclusive or 9 to 2 inclusive. A trim No. 9
cannot be installed in a VariPak valve body
designed for a trim No. 0. Likewise, a trim
No. 0 cannot be installed in valve bodies
designed for other trim numbers.

2.2.3 Adjusting the Cv of a Varipak 28002 valve for

each plug and seat ring combination

This is done by moving adjustment knob (24) along
adjustment plate (25) fastened to the top of lever No.
1 (21).

The adjustment plate (25) gives the range of Cv
values offered by the selected plug and seat ring
combination. Carry out this adjustment operation as
follows:

Note:

- This operation entails moving lever No. 2, either
pneumatically (by allowing air into the actuator),
or manually (by pressing piston clevis (140b) with a
screwdriver or similar tool) so that the slides of the
two levers are perfectly parallel.

- It may be necessary to reset the zero to calibrate the
closure point after changing the Cv.

2.3 ACTUATOR

A single actuator allows VariPak valves to act in
direct Air-to-Close (ATC), or reverse Air-to-Open (ATO).

Valve action can be changed with no additional part
by simply shifting:

- the pivot pin and the attachment hole of the
positioner balance spring clamp for the singlelever
VariPak 28001 valve,

- the two pivot pins for the adjustable-Cv VariPak
28002 valve, then calibrating as required.

Follow the instructions given under "Reversing the
valve action" on page 8.

2.4 HANDWHEEL(Figure 5)

Figure 4 - Adjusting the Cv of VariPak 28002 valve for each

plug/seat ring combination

The handwheel is an optional feature located on top
of the cover and fitted with a locking lever. Access
can be gained to it directly without removing any
other parts. It consists of a threaded rod, equipped
with a handwheel (120) and a lever arm stop (122).
The threaded rod rests freely on the actuator bracket
(108) and is guided through the cover (110) by
handwheel bushing (119). The stop consists of a block
screwed onto the threaded rod. The block is guided
by the actuator bracket (108).

Figure 5

Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 7

When the handwheel (120) is turned clockwise, the
stop (122) moves up the threaded rod, compressing the
spring (134) and raising lever No. 2 (22) (VariPak 28002)
or (113) (VariPak 28001). This closes the valve if the valve
is equipped with a direct-action actuator (Air-to-Close)
and opens the valve if it is equipped with a reverse­action actuator (Air-to- Open).

The valve can be returned to automatic mode (neutral
position), by turning the handwheel counterclockwise
until the stop (122) comes into contact with the bracket
(108).

Note: During this operation, the compression is released
when the stop (122) moves away from the lever (22)
(VariPak 28002) or (113) (VariPak 28001). Continue the
operation until a slight tension reappears, then tighten
the handwheel lock (121).

VariPak actuators are equipped with a limit stop. This
consists of parts (180) and (181), and is designed to
prevent damage to the plug and seat ring assembly
and/or the plug stem in the event of handwheel or
actuator overstroke.

Note: The limit stop is not used with air-to-open valves
fitted with a handwheel, and must be screwed down at
the bottom of the piston.

2.5.1 VariPak 28001 single-lever valve

E. Remove retainer clips (112b) from pin (18), and remove

the pin from lever (113) and plug clevis (104a).

Note: This operation will be simplified by relieving
the load exerted on the plug clevis by the conical
compression spring (106). To do this push against the
plug stem end with a screwdriver while driving out the
pins.

F. Remove the two retainer clips (112a) from the pin (105)

and disengage it to uncouple the lever (113) from the
bracket (108).

G. Refit the levers (113) making sure that the pin (105) is

fitted into the correct holes in the lever and bracket
for the new action of the actuator (see figure 6). Fit
the spring clamp (115) into the corresponding lever
hole.

Note: Ensure that the clevis is correctly positioned before
fitting the lever on the bracket.

H. Couple the plug stem clevis (104a) to the lever (113)

following the normal reassembly procedure (step
I. in the "Reassembly" section on page 17). Then
follow the same procedure as for the VariPak 28002
adjustable-Cv valve as from step L.

2.5 REVERSING THE VALVE ACTION

(Figures 5, 6, 26, 27 and 29)

Caution: The valve must be isolated and
pressure vented before disassembly.

A. Loosen and remove cover (110). On valves equipped

with a handwheel, loosen cover screw (109), back
off handwheel lock (121), and turn handwheel (120)
counter-clockwise to release cover (110).

B. Adjust the signal so that the valve closes. Change the

signal slightly so that the plug just moves off the seat
ring. On the VariPak 28002 adjustable-Cv valve, set
the adjustment knob (24) to the minimum Cv setting.

C. Loosen locknut (103) and, using a screwdriver,

turn the plug stem one and three-quarter turns
counter-clockwise. Shut off the signal and the supply
pressure. Slightly tighten locknut (103) against the
clevis.

D. Unlock nut (117) and completely loosen screw (116).

Unhook spring (114) from spring clamp (115).

2.5.2 VariPak 28002 adjustable-Cv valve (2 levers)

E. Remove retainer clips (112b) from each of the two

pins (184) and remove pins from lever (113) and plug
clevis (104a).

Note: This operation will be simplified by relieving
the load exerted on the plug clevis by the conical
compression spring (106). To do this push against the
plug stem end with a screwdriver while driving out the
pins.

F. Remove the two retainer clips (112a) from pin No. 1

(105) and disengage it to uncouple lever No. 1 from
bracket (108). Loosen adjustment knob (24) and slide
it to the maximum Cv setting. Disengage the smooth
end of the adjustment pin (23) from the groove in lever
No. 2 while removing lever No. 1.

G. Drive out pin No. 3 (18) and remove lever No. 2 (22)

from the bracket.

H. Remove the two screws (26) and refit Cv adjustment

plate (25) after turning it round to comply with the
new action.

I. Refit levers No. 1 and 2 in sequence, making sure that

pins (105) and (108) are fitted into the correct holes
in the levers and bracket for the new action of the
actuator (see figure 6).

8 | GE Oil & Gas