Jordan Valve Mark EW User Manual

I & M Mark EW Series

3170 Wasson Road • Cincinnati, OH 45209 Phone 513.533.5600 • Fax 513.871.0105 (f) info@richardsind.com • www.jordanvalve.com

Warning: Jordan Valve Control Valves must only be used, installed and repaired in accordance with these Installation & Maintenance Instructions. Observe all applicable public and company codes and regulations. In the event of leakage or other malfunction, call a qualiﬁed service person; continued operation may cause system failure or a general hazard. Before servicing any valve, disconnect, shut off, or bypass all pressurized ﬂuid. Before disassembling a valve, be sure to release all spring tension.

IntroductIon

Contained in this manual are installation instructions, maintenance procedures and parts information for the Mark EW Series Valve Body designs EWD, EWS and EWT. Refer to the appropriate manuals for instructions for the accompanying actuator and additional accessories.

Trained or experienced personnel should carry out operation and installation of all pressure equipment. If you have any questions regarding the equipment, contact your Jordan Valve representative.

InstallatIon

Exceeding the recommended pressure and temperature limits indicated on the nameplates of your Jordan valve control valve, can result in personal injury and property damage. Jordan Valve recommends the installation of a relief valve to protect against overpressure situations.

The Mark EW Series valve bodies are designed to meet speciﬁc conditions for ﬂuid control, temperature, pressure and pressure drop. The limiting factor on these valves can be the body/trim material combinations. Do not install these valves in any other applications without ﬁrst consulting with your Jordan Valve representative.

During installation, Jordan Valve recommends the use of a sling to protect the painted surfaces of the valve. Position the sling to avoid damage to tubing and accessories.

1. Inspect the valves for shipping damage and foreign debris while uncrating.

Installation & Maintenance Instructions for the

Mark EW Series Globe Style Control Valve

2. Ensure the pipeline is free of welding slag, chips and other debris by blowing out the line before installation.

3. Position the valve so the arrow on the valve body is in the same direction as the pipeline ﬂow.

4. Speciﬁc orientation of the control valve as sembly is ﬂexible, unless limited by the seismic criteria. Normal positioning is with the actuator vertical above the valve body. Should a different position be required, be aware that the result may be uneven valve plug and cage wear, and inefﬁcient opera tion of the control valve system. Also, be aware that the actuator may need addi tional support. Consult Jordan Valve for further information on orientation.

5. Always employ proper piping and welding practices when installing the valve in the line. If welding is required, internal elastomeric parts may remain in place. If the valve has buttwelding ends and composition trim, remove the composition trim prior to welding into the line.

6. For ﬂanged bodies, install an appropriate gas ket between the pipeline and valve body ﬂang es.

7. With leak-off bonnet construction, remove the pipe plugs (Figure 1, Keys 14 and 23) to connect the leak-off piping. To avoid an interruption of service during inspection or maintenance, install a three-valve bypass around the control valve assembly.

8. Most Jordan valves are shipped with the actuator already installed according to customer speciﬁcations. If your actuator has been shipped separately, refer to the appropri ate mounting instructions in the actuator manual.

Mark EW SEriES GlobE StylE Control ValVES

MaIntenance

Internal valve components are subject to normal deterioration and must be inspected and replaced as required. The necessity of inspections and replacement of parts will depend on the severity of service conditions. Inspections and maintenance must be carried out on a regularly scheduled basis.

To ensure the safety of personnel and to protect against property damage, the following steps should be carried out before beginning disassembly.

1. To prevent the valve from opening suddenly, disconnect any operating lines to the actuator. This would include air pressure, electrical power or control signal lines.

2. Isolate the valve by using the bypass valve or by shutting down the process completely. Relieve the pressure and drain the process ﬂuid from both sides of the valve.

3. Relieve the pressure contained in the actuator by venting the actuator loading pressure and relieving any power actuator spring compression.

4. Lock-out procedures should be strictly adhered to while the equipment is being serviced.

Packing Maintenance

This section provides instruction for maintenance of TFE V-Ring packing. If your Jordan Valve Mark EWD, EWS or EWT Control Valve uses graphite laminate or ﬁlament packing, refer to the appropriate manuals. Refer to Figure 2 for appropriate key numbers unless otherwise indicated.

For packing that is spring-loaded single TFE V-ring packing, a sealing force is maintained by the spring (Figure 1, Key 5). If leakage around the packing follower (Figure 1, Key 3) is detected, tighten the packing ﬂange nuts (Figure 1, Key 16). If this does not stop the leakage, refer to the Replacing Packing section of this manual.

With packing that is other than spring-loaded, unwanted leaking can be limited by tightening the packing ﬂange nuts to create a stem seal.

If leakage occurs from the inside diameter of the packing, and tightening the ﬂange nuts does not stop the leaking, the valve stem may be worn or nicked. If the leakage originates from the outside diameter of the packing, the leakage may be caused by nicks and scratches around the packing box wall. While performing the following procedures, carefully inspect the valve stem and packing box wall for imperfections.

Also, anytime that a gasket seal is removed or disturbed, a new gasket should be installed during reassembly, ensuring a proper seal.

The following instructions include packing maintenance, trim replacement and lapping of metal seats.

Adding Packing Rings

If using packing with a lantern ring (Figure 1, Key 5), packing rings may be installed above the lantern ring as a temporary measure, which does not involve removing the actuator from the valve body.

1. Remove the packing ﬂange nuts (Figure 2, Key

16) and lift the packing ﬂange and follower (Fig ure 2, Keys 20 and 3) away from the valve body.

2. Old packing rings that have been installed on top of the lantern ring may be removed, but use caution to avoid any damage to the valve stem or packing box wall. All metal parts should be cleaned to remove any grit that would prevent the packing from creating a seal.

3. If split-ring packing is being used, spread the rings over the valve stem and slide them into the packing box.

4. If solid-ring packing is used, take off the stem connector and slip the rings over the end of the valve stem.

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Mark EW SEriES GlobE StylE Control ValVES

Adding Packing Rings Continued,

5. After replacing the packing ﬂange and packing follower, tighten the packing ﬂange nuts (Figure 2, Key 16) just far enough to prevent leakage under operating conditions.

6. If the valve-actuator stem connection was disassembled during this process, refer to the actuator manual for reassembly instructions.

7. While returning the valve to service, monitor for leakage around the packing follower. If required, retighten the packing ﬂange nuts.

Replacing Packing

Note: Prior to performing this procedure, isolate the control valve from all line pressure and release the pressure from both sides of the valve. Drain the process media and release all pressure from the actuator. Practice lockout procedures during the operation.

1. Remove the operating lines from the actuator as well as any leak-off piping from the bonnet.

2. Disconnect the stem connector and unscrew the yoke locknut (Figure 2, Key 17) to remove the actuator from the valve body.

3. Loosen the packing on the valve stem by unscrewing the packing ﬂange nuts (Figure 2, Key 16). Remove all travel indicator parts and stem locknuts from the valve stem threads.

Note: When lifting the bonnet (Figure 2, Key 18), it is very important to ensure that the valve plug and stem assembly remain in the valve and on the seat. If the assembly were to drop out after being partially lifted, damage to the seating surfaces would result. Parts are also easier to handle in this way.

4. Remove the hex nuts (Figure 4, Key 39) holding the bonnet and body together, and lift

the bonnet off of the valve stem.

5. When lifting the bonnet, if the valve plug and stem assembly begin to lift as well, use a brass or lead hammer and lightly tap on the end of the stem to release them.

6. Place the bonnet on a protective surface to pre- vent damage to the surface of the bonnet gasket.

7. Remove the bonnet gasket (Figures 3 and 4, Key 33) and cover the valve body opening in or der to prevent debris from entering the body cavity and to protect the gasket surface.

8. Remove the following parts (Figure 2): a. packing ﬂange nuts (Key 16) b. packing ﬂange (Key 20) c. upper wiper (Key 2) d. packing follower (Key 3)

9. Use a rounded rod to push out the remaining packing parts from the body side of the bonnet. Be careful not to scratch the packing box wall. Clean the packing box and metal packing parts.

10. Inspect the valve stem threads and packing box surfaces for any edges which might cut the packing. Any defects could create leak ing in the packing box and damage to the new packing. If any surface nicks or burrs cannot be improved by light sanding replace the damaged parts.

11. Remove the covering which protects the body covering and install a new bonnet gasket (Figures 3 and 4, Key 33). Ensure that the gasket seating surfaces are clean and smooth.

Note: When the tightening procedures in Step 13 are completed properly, the spiral wound gasket (Figures 3 and 4, Key 35) will be compressed enough to load and seal the seat ring gasket (Figures 3 and 4, Key

36) and compress the edge of the bonnet gasket (Figures 3 and 4, Key 33) and seal the body-to-bonnet joint.

The lubricated stud bolt nuts (Figure 4, Key 39) can be identiﬁed by the black ﬁlm that coats the nut threads.

The bolting procedures in Step 13 will ensure that the bolting threads are clean, and will evenly tighten the nuts onto the studs in a crisscross pattern. Be sure to follow the crisscross pattern since the tightening of one spiral wound gasket may loosen an adjacent nut. Continue repeating the pattern until each nut is tight, creating the body-to-bonnet seal. Repeat this torquing procedure once the operating temperature has been reached.

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Mark EW SEriES GlobE StylE Control ValVES

Table 1: Body-to-Bonnet Bolt Torque Guidelines

Bolt Torques

Body Size, Inches

Nonlubricated Bolting Stud Bolt Nuts Factory Lubricated

Ft•Lb N•m Ft•Lb N•m

8 x 6 Class 300 or 600 400 545 300 407

Class 900 970 1315 --- ---

12 x 6 400 545 300 407

10 x 8 550 745 --- ---

12 x 8 Class 300 or 600 540 732 --- ---

Class 900 2000 2712 --- ---

Table 2: Packing Flange Nut Torque Guidelines

Valve Stem Dia. ANSI

Class

Inches mm Lb•in N•m Lb•in N•m Lb•in N•m Lb•in N•m

1/2 12.7 300 28 3 42 5 59 7 88 10

600 39 4 58 7 81 9 122 14

3/4 19.1 300 64 7 95 11 133 15 199 23

600 87 10 131 15 182 21 274 31

1 25.4 300 108 12 162 18 226 26 339 38

600 149 17 223 25 310 35 466 53

1-1/4 31.8 300 152 17 228 26 318 36 477 54

600 209 24 314 36 437 49 655 74

PTFE Type Packing GRAPHITE Type Packing

Min. Torque Max. Torque Min. Torque Max. Torque

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Mark EW SEriES GlobE StylE Control ValVES

Packing Follower

Packing Ring

Lantern Ring

Packing Box Ring

**Garlock

*Grafoil

Upper Wiper

Packing Follower

Packing Ring

Lantern Ring

Packing Box Ring

Packing Ring

PTFE/Composition

*Grafoil

V - Ring

Upper Wiper

Packing Follower

Upper Wiper

Packing Follower

Female Adaptor

V - Ring

Male Adaptor

Lantern Ring

washer

Spring

Male Adaptor

Packing Box Ring

Lower Wiper

Packing Box Ring

Figure 1: TFE V-Ring Packing Arrangements

All Yoke Sizes

Single Packing

PTFE V-Ring

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Packing Ring

Upper Wiper

Packing Follower

Lantern Ring

Packing Follower

V - Ring

Male Adaptor

Female Adaptor

Packing Ring

Packing Box Ring

Lantern Ring

Packing Box Ring

All Yoke Sizes

Double Packing

PTFE V-Ring

Lower Wiper

Notes:

* Grafoil

is a Registered Trademark for Packings, Seals, Gaskets and other Products of Garlock Garlock Inc.

** Garlock

Mark EW SEriES GlobE StylE Control ValVES

Replacing Packing Continued,

12. Place the bonnet over the stem and onto the stud bolts (Figure 4, Key 38) and lubricate with an appropriate lubricant. If factory lubricated stud bolt nuts will be used, additional lubrication is unnecessary. Follow standard bolting procedures and install the stud bolt nuts (Figure 4, Key 39), ensuring that the body-to-bonnet joint will withstand test pressures and application service conditions. Refer to Table 1 for bolt torque guidelines, unless accepted bolting procedures demand otherwise.

13. Refer to Figures 1 and 2 and install new packing and metal packing box parts. Using a smooth- edged pipe placed over the pipe stem, gently tap each soft packing part into the packing box. Ensure that air is not trapped between adjacent soft parts.

14. Slide the packing follower, upper wiper and packing ﬂange (Figure 2, Keys 3, 2 and 20) into position. Lubricate the packing ﬂange studs (Figure 2, Key 21) as well as the packing ﬂange nuts (Figure 2, Key 16), and replace the packing ﬂange nuts.

15. If using spring-loaded TFE V-Ring packing, tighten the packing ﬂange nuts using accepted bolting procedures.

16. Install the actuator onto the valve body assem- bly and refer to the actuator instruction manual for directions on reconnecting the actuator and valve stem.

Trim Removal

Unless otherwise indicated, key numbers in this section reference Figure 3 for Design EWD and Restricted Trim, Figure 4 for Mark EWS and Figure 5 for Mark EWT constructions, as well as Class 900 12 x 6-inch construction.

1. Remove the actuator and bonnet, referring to Steps 1 through 8 in the Replacing Packing section.

The graphite piston ring(s) (Key 29) in a Mark EWD body is brittle and in two pieces. Handle with care to avoid dropping or rough handling of the piston ring(s).

The surface ﬁnish of the valve stem (Key 30) is critical for creating a good packing seal. Also, the inside surface of the cage (Key 26) is important for smooth valve plug operation and for creating a seal with the piston ring (Key 29) or seal ring (Key 50). Seating surfaces of the valve plug (Key 25) and the seat ring (Key 32) on a metal-seat construction are important for a tight shutoff. Protect these parts and their surfaces, and include them in any inspections.

2. If packing parts require replacement, remove them at this time according to instructions in the Packing Replacement section of this manual. Remove the cage adaptor (Key 27) for any restricted trim body through 8 x 4-inches. Wrap these parts for protection.

3. Remove the valve plug and stem assembly from the valve body, setting it on a clean surface. If the valve plug is being reused, protect the valve plug seating surface from scratches.

4. Remove the cage (Key 26) and associated gas kets (Keys 33, 34 and 35). If the cage becomes stuck in the valve body, tap the exposed portion of the cage around the circumference, using a rubber mallet.

5. Remove the following parts: a. Seat ring (Key 32) b. Disc seat (Key 44) c. Seat ring gasket (Key 36) d. Seat ring adaptor (Key 28) e. Adaptor gasket (Key 37)

6. The Mark EWS and EWT TFE-seat construction use a disc (Key 45) placed between the disc seat and disc retainer (Key 43).

7. Inspect all parts for wear or damage that would interfere with operation of the control valve. If replacement or repair of trim parts is necessary, refer to Lapping Metal Seats or Valve Plug Maintenance procedures in this manual.

Note: When lifting the valve plug stem (Key 30) and the attached valve plug (Key 25) from the valve body, ensure that the cage (Key 26) remains in the body (Key 24). If the cage were to drop out of the body after being lifted partially out, cage damage will result.

Use caution to avoid damage to the gasket sealing surfaces.

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