GE mn-36005 Technical Specifications

GE Oil & Gas

36005 Series V-Max

Masoneilan* High Capacity Control Ball Valve Instruction Manual

GE Data Classiﬁcation : Public

b | GE Oil & Gas

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC 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.

Masoneilan 36005 Series High Capacity Control Ball Valves | c

Contents

Important : Safety Warning � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �1 1�0 Introduction

Numbering System........................................................................................ 2

2�0 Installation

2.1 General................................................................................................4

2.2 Pipeline Mounting...................................................................................... 4

2.3 Air Piping ..............................................................................................4

2.4 Changing Actuator Position ............................................................................4

2.5 Changing valve ACTION ................................................................................6

3�0 Maintenance

3.1 Bracket Subassembly ..................................................................................8

3.3 Body Subassembly.....................................................................................9

3.3.1 PackinG.............................................................................................10

3.3.2 MN-7 Seal Ring......................................................................................10

3.3.3 Standard Metal Seal Ring ............................................................................10

3.3.4 Heavy Duty Metal Seal Ring .........................................................................11

3.3.5 Ball Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.4 Actuator Subassembly .................................................................................12

3.5 Handwheel Subassembly .............................................................................14

3.6 Diaphragm Replacement...............................................................................15

Figure 1 — Numbering System and Standard

Mounting Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Figure 2 — General Assembly .............................................................................17

Figure 3 — Actuator Sizes B & C Bracket & Linkage.........................................................18

Figure 4 — Handwheel Assembly, Actuator Sizes B & C .....................................................18

Figure 5 — Handwheel Detail, Actuator Sizes B & C.........................................................18

Figure 6 — Handwheel Bracket Detail, Sizes B & C..........................................................18

Figure 7 — Handwheel Lever Detail, Sizes B & C............................................................18

Figure 8 — Handwheel Clevis Detail, Sizes B & C ...........................................................18

Figure 9 — AcTuator General Assembly, Sizes B & C ........................................................19

Figure 10 — Lever Position Air to Open, Sizes B & C .........................................................19

Figure 11 — Lever Position Air to Close, Sizes B & C .........................................................19

Figure 12 — Position Indicator Detail, Sizes B & C...........................................................20

Figure 13 — Size AC Actuator Assembly ...................................................................20

Figure 14 — Size AC Actuator Bottom View ................................................................21

Figure 15 — Size AC Actuator Linkage Detail ...............................................................21

Figure 16 — Size AC Handwheel Detail.....................................................................22

Figure 17 — insulation Detail ..............................................................................22

Table 1 — Body Parts List .................................................................................23

Table 2 — Bracket and Linkage Parts List ..................................................................23

Table 3 — Handwheel Parts List ...........................................................................24

Table 4 — Actuator Parts List .............................................................................24

Table 5 — Line Bolting ....................................................................................25

d | GE Oil & Gas

Safety Information

WARNING

CAUTION

WARNING

DANGER

WARNING

CAUTION

WARNING

CAUTION

WARNING

Important - Please Read Before Installation

Masoneilan 36005 Series instructions contain DANGER, WARNING, and CAUTION labels, where necessary, to alert

you to safety related or other important information. Read the instructions carefully before installing and maintaining your control valve. DANGER and WARNING hazards are related to personal injury. CAUTION hazards involve equipment or property damage. Operation of damaged equipment can, under certain operational conditions, result in degraded process system performance that can lead to injury or death. Total compliance with all DANGER, WARNING, and CAUTION notices is required for safe operation.

This is the safety alert symbol. It alerts you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

About this Manual

• Theinformation in this manual issubjectto change without

prior notice.

• The information contained in this manual, in whole or part,

shall not be transcribed or copied without GE’s written permission.

• Pleasereportanyerrorsorquestionsaboutthe informationin

this manual to your local supplier.

• These instructionsare written specifically for the 36005 Series

control valves, and do not apply for other valves outside of this product line.

Warranty

Items sold by General Electric are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment provided said items are used according to GE recommended usages. GE reserves the right to discontinue manufacture of any product or change product materials, design or specifications without notice.

This instruction manual applies to the Masoneilan 36005 Series control valves.

The Control Valve MUST BE:

• Installed, put into service and maintained by qualified

and competent professionals who have undergone suitable training.

Indicates a potentially hazardous situation which, if not avoided, could result in serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

When used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

Note: Indicates important facts and conditions.

• Under certain operating conditions, the use of damaged equipment could cause a degradation of the performance of the system which may lead to personal injury or death.

• Changesto specifications, structure,andcomponentsused

may not lead to the revision of this manual unless such changes affect the function and performance of the product.

• All surrounding pipe lines must be thoroughly flushed to

ensure all entrained debris has been removed from the system.

Masoneilan 36005 Series High Capacity Control Ball Valves | 1

1�0 Introduction

The following instructions are designed to assist maintenance personnel in performing most of the maintenance required on the 36005 V-Max* valve and if followed carefully will reduce maintenance time.

GE Masoneilan has highly skilled Service Engineers available for start-up, maintenance and repair of our valves and component parts. In addition, regularly scheduled training programs are conducted to train customer service and instrumentation personnel in

Numbering System

the operation, maintenance and application of our control valves and instruments. Arrangements for these services can be made through your GE Masoneilan Representative or District Office. When performing maintenance use only Masoneilan replacement parts. Parts are obtainable through your local GE Masoneilan Representative or District Office. When ordering parts always include MODEL and SERIAL NUMBER of the unit being repaired.

1st

Actuator Type

33 Spring Diaphragm. Air to

extend action only.

1st

Body Series

2nd

Actuator Mounting

(See guide on page 4)

0 Undefined 1 Valve closes on stem

extension (Air to Close, Fail Open)

2 Valve opens on stem

extension (Air to Open, Fail Closed

3 Valve closes on stem

extension (Air-to-Close, Fail Open)

4 Valve opens on stem

extension (Air-to-Open, Fail Closed)

7 Valve closes on stem

extension (Air-to-Close, Fail Open)

8 Valve opens on stem

extension (Air-to-Open, Fail Closed)

4th3rd2nd

5th

Seal Type

1 MN-7 Seal Ring 2 316 SS Seal

Ring

3 Heavy Duty

Metal Seal Ring

Design Series

2 | GE Oil & Gas

V-Max Valves

Actuator Model 33, Size AC

3 X 3 6 X 0 5

Actuator Position in Relation to Valve Body Numbering System: 1 to 8

Actuator Model 33, Sizes B and C

Masoneilan 36005 Series High Capacity Control Ball Valves | 3

2�0 Installation

CAUTION

WARNING

CAUTION

WARNING

2�1 General

2�1�1 Unpack valve carefully to avoid damage to valve,

accessories, or tubing.

2�1�2 Record all valve and accessory serial plate data for future reference. Always provide serial and model numbers when ordering spare parts.

2�2 Pipeline Mounting

Do not remove button head screw (9) and washer (10) during installation� The function of these parts is to hold the retainer (3) and seal ring (8) in place and should be removed only when the valve is to be disassembled for maintenance (Figure 2)�

A. Before installing the valve in the line, clean pipe and

valve of all foreign materials such as welding chips, scale, oil, grease or dirt. Gasket surfaces must be thoroughly cleaned to ensure leak free joints.

B. Install valve in a horizontal or vertical line with the flow

tending to push the seal ring (8) against the ball (2) as indicated by the flow arrow cast into the body. It is recommended that if adjacent walls and piping permit, the valve be oriented such that the ball opens upward. This is especially important when handling slurries. See Figure 1 for actuator mounting positions and for flow direction and Table 5 for line flange bolting lengths. Note: Flange bolt lengths are non-standard on inlet and standard on outlet side.

C. Tighten bolting evenly and in crisscross fashion so that

the retainer (3) held in place by the line flange will bear evenly against the seal ring (8).

D. The linkage of the 36005 V-Max valve has been

properly adjusted at the factory and requires no further adjustment.

E. Where insulation of the valve body is required, do not

insulate the valve bonnet. See Figure 17.

2�3 Air Piping

2�3�1 Air piping must be adequately sized to provide the

regulated supply pressure specified on the nameplate. As a general guideline, use 1/4" O.D. tubing or equivalent for all air lines. If supply air line exceeds 25 feet in length, use 3/8" O.D. tubing.

2�3�2 The actuator is furnished with a 1/4" NPT instrument air port on the upper case.

Before proceeding with changing actuator position, air action or valve maintenance, isolate valve, vent process pressure and shut off air supply and signal air lines or electrical lines to unit� It is recommended that the valve be removed from the pipeline prior to maintenance work� Keep hands and tools away from the segmental ball, particularly when disconnecting the actuator stem from shaft arm as ball may rotate freely to its lowest position

For each valve action (air to open/air to close) the actuator may be positioned to either side of the pipe. Actuator position is usually determined by adjacent piping, obstacles of various types or air piping arrangements. To reposition the actuator and/or bracket follow the disassembly and reassembly instructions below.

Note: Actuator positioning should be performed prior to installing the valve in the pipeline. To change actuator position and/or valve action refer to Figure 1 for desired position.

A. Remove valve from process line after closing isolating

valves and disconnecting all pneumatic tubing and electrical wiring.

B. If valve is equipped with a handwheel (Figure 4)

disengage handwheel and remove retaining clips (63), clevis pin (66) and pivot pins (72); remove entire handwheel assembly from bracket (62).

C. Remove pivot pin retaining clips (40), pivot pin (39) and

spacer rings (69). Remove actuator hex nuts (75) and washers (76). Remove actuator.

Note: Spacer rings apply only on handwheel option.

D. Remove shaft cover (42) and screw (43). Loosen lever

cap screw (33). Remove packing flange stud nuts (24), bracket mounting stud nuts (24) and washers (18). Loosen ball plug indicator arm (35).

E. If necessary, scribe a witness line on the lever (32)

in relation to the slot on the end of the shaft (5). Note: Standard lever has arrows stamped into it for alignment. For handwheel lever use slot for alignment.

F. Slide bracket (31) away from body until it clears bracket

and packing flange studs (26 and 25), allowing lever (32) lever arm (64) and indicator arm (35) to be removed from shaft. Total removal of the bracket is not required.

4 | GE Oil & Gas

Before proceeding determine valve action (air

CAUTION

WARNING

CAUTION

WARNING

CAUTION

WARNING

CAUTION

WARNING

to open/air to close), refer to the appropriate figure (Figure 10 to open, Figure 11 to close)� To obtain proper alignment, the lever must be oriented on the shaft so that the slot in the end of the shaft and arrows or indicator lines are aligned as shown; with the ball in the closed position, the distance between the top of the bracket and the top of the pivot pin must be as shown�

G. Slide lever (32) and lever arm (64) back onto shaft in

desired position. Slide indicator arm (35) back onto shaft. Align bracket and slide back onto bracket mounting studs (26) and packing flange studs (25). Replace bracket mounting stud nuts (24) and washers (18). Slide packing flange (23) back onto packing flange studs (25) and replace packing flange stud nuts (24).

H. Remount actuator onto bracket and replace actuator

mounting hex nuts (75) and washers (76). Position lever (32) and lever arm (64) so that rod end bearing (94) lines up in lever (32). Tighten lever cap screws (34).

I. Rotate ball plug (2) to closed position. If actuator action

is air to open loosen rod end bearing locknut (93) and adjust position of rod end bearing (94) so that holes in lever (32) and rod end bearing (94) line up. Insert pivot pin (39) and replace spacer rings (69) and retaining rings (40).

When stroking valve keep hands and equipment clear of ball plug and seal ring to avoid injury or damage to personnel and equipment�

J. If action is air to close place ball plug (2) in closed

position and pneumatically stroke actuator fully.

Do not exceed maximum air supply pressure� Keep hands clear of actuator stem and linkage�

Loosen rod end bearing locknut (93) and adjust rod end bearing (94) so that holes in lever (32) and rod end bearing (94) line up. Insert pivot pin (39) and spacers (69) and replace retaining rings (40).

K. For both air to open and air to close action, stroke valve

fully to ensure proper closure of ball plug and operation of valve. It may be necessary to readjust rod end

bearing slightly by loosening locknut and rotating stem.

L. Replace handwheel assembly in bracket (62), pivot pins

(72) and retaining clips (63).

M. Replace shaft cover (42) and screw (43).

N. Set and lock indicator arm (35) to indicate plug position.

2�4�2 Changing Actuator Position Model 33, size AC only�

Note: Actuator positioning should be performed prior to installing the valve in the pipeline. To change actuator position and/or valve action refer to Figure 1 for desired position.

A. Remove valve from process line after closing isolating

valves and disconnecting all pneumatic tubing and electrical wiring.

B. If valve is equipped with a handwheel (Figures 13 & 16)

disengage handwheel and remove retaining clip (54-7) and washer (54-4). Remove entire handwheel assembly from actuator housing (31).

C. Remove pivot pin retaining clips (40), pivot pin (39).

Remove actuator hex nuts (75) and washers (76). Remove actuator.

D. Remove shaft cover (42) and screw (43). Loosen lever

cap screw (33). Remove packing flange stud nuts (24), bracket mounting stud nuts (24) and washers (18). Loosen ball plug indicator arm (35).

E. If necessary, scribe a witness line on the lever (32) in

relation to the slot on the end of the shaft (5).

F. Slide housing (31) away from body until it clears bracket

and packing flange studs (26 and 25), allowing lever (32) and indicator arm (35) to be removed from shaft. Total

Masoneilan 36005 Series High Capacity Control Ball Valves | 5

removal of the bracket is not required.

CAUTION

WARNING

CAUTION

WARNING

CAUTION

WARNING

CAUTION

WARNING

CAUTION

WARNING

Before proceeding determine valve action (air to open/air to close)�

G. Slide lever (32) back onto shaft in desired position.

Slide indicator arm (35) back onto shaft. Align bracket and slide back onto mounting studs (26) and packing flange studs (25). Replace mounting stud nuts (24) and washers (18). Slide packing flange (23) back onto packing flange studs (25) and replace packing flange stud nuts (24).

H. Remount actuator onto housing and replace actuator

mounting hex nuts (75) and washers (76). Position lever (32) so that rod end bearing (94) lines up in lever (32) and that the pads on the lever will contact the stop bolts (102). Tighten lever cap screw (33).

I. Rotate ball plug (2) to closed position. Adjust closed

position travel stop (102) until it contacts the pad on lever (32). Tighten locknut (101).

J. Rotate ball plug (2) to open position. Adjust open

position travel stop until it contacts pad on lever (32). Tighten locknut (101).

Ensure rotation of AC actuator does not exceed 90deg� Damage to actuator rod may result�

K. If actuator action is air to open, rotate ball plug (2) to

open position. Pneumatically stroke actuator to open position. Loosen rod end bearing locknut (93) and adjust position of rod end bearing (94) so that holes in lever (32) and rod end bearing (94) line up. Insert pivot pin (39) and retaining rings (40).

When stroking valve keep hands and equipment clear of ball plug and seal ring to avoid injury or damage to personnel and equipment�

L. If action is air to close place ball plug (2) in closed

position. The pad on lever should contact the closed position travel stop (102). If it does not, repeat adjustment as noted in step I above. Return ball plug (2) to open position. Pneumatically stroke actuator to open position.

Do not exceed maximum air supply pressure� Keep hands clear of actuator stem and linkage�

Loosen rod end bearing locknut (93) and adjust rod end bearing (94) so that holes in lever (32) and rod end bearing (94) line up. Insert pivot pin (39) and replace retaining rings (40).

M. For both air to open and air to close action, stroke

valve fully to ensure proper closure of ball plug and operation of valve. It may be necessary to readjust rod end bearing slightly by loosening locknut and rotating stem.

N. Replace handwheel assembly in housing (31), washer

(54-7) and retaining clip (54-4).

O. Replace shaft cover (42) and screw (43).

P. Set and lock indicator arm (35) to indicate plug position.

2�5 Changing Valve Action

Note: If the valve action is to be changed it should be done before the valve is installed in the line. This allows a positive visual check to ensure that the ball plug is fully closed when the actuator is in the proper position.

2�5�1 Model 33, sizes B & C only� For size AC refer to section 2�5�2

A. If the valve is equipped with a handwheel disengage

the handwheel and remove retaining clips (63), clevis pin (66), and pivot pins (39). Remove cap screws (70), washers (71) and handwheel bracket (62).

B. If necessary, scribe a witness mark on the lever

(32) in relation to the slot on the end of the shaft (5). Note: Standard lever has arrows stamped into it for alignment. For handwheel lever use slot for alignment.

C. Remove pivot pin retaining clips (40), pivot pin (39) and

spacer rings (69). Remove shaft cover (42) and screw (43). Remove actuator hex nuts (75) and washers (76). Remove actuator.

Note: Spacer rings apply only on handwheel option.

D. Loosen lever cap screw (33). Remove packing flange

stud nuts (24), bracket mounting stud nuts (24) and washers (18). Loosen ball plug indicator arm (35).

E. Slide bracket (31) away from body until it clears bracket

and packing flange mounting studs. Remove lever (32), lever arm (64) and indicator arm (35) from shaft.

Before proceeding determine valve action (air to open/air to close), refer to the appropriate

6 | GE Oil & Gas

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