Jordan Valve Mark EZ User Manual

I & M Mark EZ Series

3170 Wasson Road • Cincinnati, OH 45209
Phone [phone] • Fax [phone] (f)
[e-mail] • 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.

InstallatIon

Sudden release of pressure may result personal
injury or equipment damage if the valve assembly
is installed where service conditions could exceed
the limits on the nameplates. Provide a relief valve
for overpressure protection as required by govern­ment or accepted industry codes and good engi­neering practices to avoid such injury or damage.

Upon ordering, the valve conguration and con­struction materials were selected to meet particular
pressure, temperature, pressure drop, and con­trolled uid conditions.

1. Prior to installation of the valve, inspect it and
any associated equipment for damage and
any foreign material. Ensure the valve interior
is clean, that pipelines are free of foreign
material, and that the valve is oriented so that
pipeline flow is in the same direction as the
arrow on the side of the valve.

2. Typical installation of the Mark EZ control
valve is with the actuator vertical above the
valve; however it may be installed in any orien­ tation unless limited by seismic criteria. Other
positions may result in uneven valve plug
and seat ring retainer wear, and
improper operation. With some applications,
the actuator may also need to be supported
when not in a vertical position. For more infor­ mation, contact your Jordan Valve Represen-
tative.

Installation & Maintenance Instructions for the

Mark EZ Series Globe Style Control Valves

3. Use accepted piping and welding prac-
tices when installing the valve in the line.
During the welding procedure internal
elastomeric parts may stay in place.
For flanged valves, use a suitable
gasket between the valve body flange
and pipeline flanges.

Note:
Post weld heat treating may be required depend­ing on valve body materials used. It is recom­mended that all trim components be removed
if post weld heat treating is to be performed to
prevent damage to internal elastomeric and plas­tic parts, as well as internal metal parts. Shrunk­t pieces and threaded connections may also
loosen. Contact your Jordan Valve representative
for more information.

4. With a leak-off bonnet construction,
remove the pipe plugs (key 14) to hook up
the leak-off piping.
Install a three-valve bypass around the
control valve assembly if continuous
operation is required during inspection
or maintenance.

5. Refer to the actuator mounting procedure
in the appropriate instruction manual if the
actuator and valve are shipped
separately.

Personal injury could result from packing leak­age. Valve packing was tightened prior to ship­ment; however, the packing might require some
readjustment to meet specic service condi­tions.

Mark EZ SEriES GlobE StylE Control ValVE

MaIntenance

The Mark EZ Series valve components are subject to
normal wear and must be inspected and replaced on a
regular scheduled basis. Severe service conditions may
require shorter inspection and maintenance intervals.
This section includes instructions for packing lubrication,
packing maintenance, and trim maintenance.

Prior to performing any maintenance operations:

1. Disconnect any operating lines providing air
pressure, electric power, or a control signal to
the actuator. Ensure the actuator cannot
suddenly open or close the valve.

2. Use bypass valves or completely shut off the
process to isolate the valve from process pres-
sure. Relieve process pressure from both sides
of the valve. Drain the process media from both
sides of the valve.

3. Vent the pneumatic actuator loading pressure
and relieve any actuator spring pre-
compression.

4. Use lock-out procedures to be sure that the
above measures stay in effect.

Packing Lubrication

An optional lubricator or lubricator/isolating valve
(figure 1) is available for PTFE/composition or other
packings that require lubrication. It will be installed
in an optional tapped hole in the bonnet. Use a good
quality silicon-based lubricant. Packing used in oxy­gen service or in processes with temperatures over
260°C (500°F) do not require lubrication. To operate
the lubricator, turn the cap screw clockwise to force
the lubricant into the packing box. The lubricator/iso­lating valve must first be opened and then closed after
lubrication is completed.

Lubricator

The valve packing box may contain process uids
that are pressurized, even when the valve has been
removed from the pipeline. Process uids may spray
out under pressure when removing the packing hard­ware or packing rings, or when loosening the pack­ing box pipe plug.
Should a gasket seal be disturbed by removing or
shifting gasketed parts, install a new gasket upon
reassembly.

Lubricator/ Isolating Valve

Figure 1: Optional Packing Lubricator and
Lubricator/ Isolating Valve

Figure 2: PTFE V-Ring Packing Arrangements for Plain and Extension Bonnets

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Mark EZ SEriES GlobE StylE Control ValVE

Packing Maintenance

This section covers PTFE V-ring packing as used in
plain and extension bonnets. Unless otherwise indi­cated, key numbers refer to figure 2 for PTFE V-ring
packing.

For spring-loaded single PTFE V-ring packing, the
spring (key 8, figure 2) maintains a sealing force on
the packing. If leakage is noted around the packing
follower (key 13, figure 2), check to be sure the
shoulder on the packing follower is touching the
bonnet. If the shoulder is not touching the bonnet,
tighten the packing flange nuts (key 5, figure 10),
until the shoulder is against the bonnet. If leakage
cannot be stopped in this manner, proceed to the
replacing packing procedure.

If there is unacceptable packing leakage with other
than spring-loaded packing, first try to limit the
leakage and establish a stem seal by tightening the
packing flange nuts.

If the packing is relatively new and tight on the stem,
and if tightening the packing flange nuts does not stop
the leakage, the valve stem may be worn or nicked
so that a seal cannot be made. The surface finish of
a valve stem is critical for making a good packing
seal. If the leakage comes from the outside diameter
of the packing, the leakage may be caused by nicks
or scratches around the packing box wall. If perform­ing any of the following procedures, inspect the valve
stem and packing box wall for nicks and scratches.

Replacing Packing

The following section covers packing replacement as
used in plain and extension bonnets. Refer to figure 2
for PTFE V-ring packing.

1. Isolate the control valve from the line pressure and
release pressure from both sides of the valve body.
Drain the process media from both sides of the
valve. If using a power actuator, also shut off all
pressure lines to the power actuator, and release all
pressure from the actuator. Use lock-out procedures
to be sure that the above measures stay in effect while
you work on the equipment. Observe the warning at
the start of the Maintenance section.

2. Disconnect the operating lines from the actuator
and any leak-off piping from the bonnet. Disconnect
the stem connector and then remove the actuator
from the valve by unscrewing the yoke locknut (key
15, figure 10).

Loosen the bonnet by following the instructions
in the next step to avoid personal injury or prop­erty damage. Do not remove a stuck bonnet by
pulling on it with equipment that can stretch or
store energy in any other manner. The sudden
release of stored energy can cause uncontrolled
movement of the bonnet.
The following step also provides additional assur­ance that the valve body uid pressure has been
relieved.

3. Hex nuts (key 16, figure 11) attach the bonnet to
the valve. Loosen these nuts or cap screws approxi­mately 3 mm (1/8 inch). Then loosen the body-to­bonnet gasketed joint by either rocking the bonnet
or prying between the bonnet and valve body. Work
the prying tool around the bonnet until the bonnet
loosens.

4. Loosen the packing flange nuts (key 5, figure 10)
so that the packing is not tight on the valve stem.
Remove any travel indicator parts and stem locknuts
from the valve stem threads.

When lifting the bonnet, temporarily install a valve
stem locknut on the valve stem. Avoid damaging
the seating surface caused by the valve plug and
stem assembly dropping from the bonnet after be­ing lifted part way out.
This locknut will prevent the valve plug and stem
assembly from dropping out of the bonnet.

5. Completely remove the cap screws (not shown)
or hex nuts (key 16, figure 11) that bolt the bonnet
and valve body together and carefully lift the bonnet
off.

6. Remove the locknut and separate the valve plug
and stem from the bonnet. Set the parts on a
protective surface to prevent damage to gasket or
seating surfaces.

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Mark EZ SEriES GlobE StylE Control ValVE

Replacing Packing Continued,

7. Remove the bonnet gasket (key 10, figure 11)
and cover the opening in the valve to protect the
gasket surface and to prevent foreign material from
getting into the valve body cavity.

8. Remove the packing flange nuts, packing flange,
upper wiper, and packing follower (keys 5, 3, 12, and
13, figure 10). Carefully push out all the remaining
packing parts from the valve side of the bonnet using
a rounded rod or other tool that will not scratch the
packing box wall. Clean the packing box and the metal
packing parts.

9. Inspect the valve stem threads and the packing
box surfaces for any sharp edges which might cut
the packing. Scratches or burrs could cause pack­ing box leakage or damage to the new packing. If the
surface condition cannot be improved by light sanding,
replace the damaged parts.

10. Remove the covering protecting the valve cavity
and install a new bonnet gasket (key 10, figure 11),
making sure the gasket seating surfaces are clean
and smooth. Then slide the bonnet over the stem
and onto the stud bolts (key 15, figure 11), or onto
the valve cavity if cap screws (not shown) are used
instead.

Using proper tightening procedures in step 11 com­presses the spiral wound gasket (key 12, gure 12)
enough to both load and seal the seat ring gasket
(key 13, gure 11). The tightening procedures also
compresses the outer edge of the bonnet gasket
(key 10, gure 11) enough to seal the body-to-bon­net joint.

Use accepted bolting practices thread the nuts onto
the studs, and in a crisscross pattern tighten the
nuts. Because of the boltup characteristics of spiral
wound gaskets, tightening one cap screw or nut
may loosen an adjacent cap screw or nut. Repeat
the crisscross-tightening pattern several times until
each cap screw or nut is tight and the body-to-bon­net seal is made. When the operating temperature
has been reached, perform the torque procedure
once again.

11. Install bolting, using accepted bolting procedures.
The bolt torques in table 1 may be used as guidelines
unless accepted bolting procedures dictate otherwise.

12. Install new packing and the metal packing box
parts according to the appropriate arrangement in
figure 2. Place a smooth-edged pipe over the valve
stem and gently tap each soft packing part into the
packing box, being sure that air is not trapped
between adjacent soft parts.

13. Slide the packing follower, upper wiper, and
packing flange (keys 13, 12, and 3, figure 10) into
position. Lubricate the packing flange studs (key 4,
figure 10) and the faces of the packing flange nuts
(key 5, figure 10). Install the packing flange nuts.

The torque values discussed in step 14 and shown
in table 2 are recommended guidelines only and
are presented as a starting point for this procedure.
Tightening the packing ange nuts to a torque value
that exceeds the table guidelines, in order to obtain
a seal, may indicate other problems.

14. For spring-loaded PTFE V-ring packing,
tighten the packing flange nuts until the shoulder on
the packing follower (key 13, figure 10) contacts the
bonnet.

For other packing types, tighten the packing flange
nuts alternately in small equal increments until one of
the nuts reaches the minimum recommended torque
shown in table 2. Then, tighten the remaining flange
nuts until the packing flange is level and at a 90-de­gree angle to the valve stem.

15. Mount the actuator on the valve body and
reconnect the actuator and valve stem according to
the procedure in the appropriate actuator instruction
manual.

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Mark EZ SEriES GlobE StylE Control ValVE

Trim Maintenance

The following procedures describe how the valve trim
can be completely disassembled. When inspection or
repairs are required, perform only those steps neces­sary to accomplish the task. Refer to the warning at the
start of the Maintenance section.

Disassembly

Key numbers referenced in the following steps are
found in figure 11, unless otherwise indicated.

1. Remove the actuator and the bonnet according
to steps 1 through 6 of the Replacing Packing
Procedure of the Maintenance section.

NOTE:
To avoid personal injury due to leaking uids, avoid
damaging gasket sealing surfaces.

The surface nish of the valve stem (key 7) is critical
for making a good packing seal. The inside surface
of the seat ring retainer is critical for smooth opera­tion of the valve plug.

The seating surfaces of the valve plug and seat ring
(keys 2 and 9) are critical for proper shutoff.

Unless inspection reveals otherwise, assume all
these parts are in good condition and protect them
accordingly. Gasket selection criteria is provided on
page 20 of this instruction manual.

2. Packing parts can be removed if desired.
Replace these parts as described in the Re
placing Packing procedure.

With some valve plug sizes and congurations, the
seat ring retainer and bushing assembly (keys 3 and
26, gures 11 and 12) will come out of the valve body
with the valve plug and stem assembly, and in other
valve plug sizes and congurations, the valve plug
or tip will slide through the seat ring retainer and
bushing assembly, leaving the retainer and bushing
assembly in the valve body.

2. With the valve plug and stem assembly out of
the valve, either slide the seat ring retainer and
bushing assembly (keys 3 and 26), and
gaskets and shim (keys 10, 12, and 25)
up over the valve plug and stem or lift the
seat ring retainer and bushing assembly
and associated gaskets and shim out of
the valve body. If the valve plug is to be
reused, protect the valve plug seating surface to
prevent scratches.

3. For valves with metal seats, drive out the pin
(key 8) and unscrew the valve stem (key 7) from
the valve plug (key 2).

4. For valves with 1/4 and 3/8-inch ports and
composition seats, refer to figure 13. Drive out
the pin (key 8) and unscrew the valve stem (key

7) from the valve plug guide (key 27).
Unscrew the disk retainer (key 28) from
the valve plug guide. Remove the disk (key 29)
from the valve plug tip (key 30).

For valves with 1/2 through 2-inch ports and
composition seats, refer to figure 13. Drive out the pin

(key 8) and unscrew the valve stem (key 7) from the
valve plug guide (key 27). Drive out pin (key 31) and
unscrew the tip (key 30) from the valve plug guide. Re­move the disk (key 29) from the valve plug guide.

Valves with Plain or Extension Bonnets

Perform the following steps to remove the valve trim.

1. Lift the valve plug and stem assembly or the
plug guide, disk retainer, and disk (keys 27,
28, and 29, figure 12) if used, out of the valve
body and set it on a protective surface.

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Mark EZ SEriES GlobE StylE Control ValVE

Lapping Metal Seats

With metal-seat constructions, seating surfaces of
the valve plug and seat ring (key 2, figure 11) can be
lapped for improved shutoff. (Deep nicks should be ma­chined out rather than ground out.) Use a good quality
lapping compound of a mixture of 280 to 600-grit. Apply
the compound to the bottom of the valve plug.
Assemble the valve to the extent that the seat ring
retainer is in place and the bonnet is bolted to the
valve body. A simple handle can be made from a
piece of strap iron locked to the valve plug stem with
nuts. Rotate the handle alternately in each direction to
lap the seats. After lapping, remove the bonnet and
clean the seat surfaces. Completely assemble as de­scribed in the assembly portion of the Trim Maintenance
procedure and test the valve for shutoff. Repeat the
lapping procedure if leakage is still excessive.

Assembly

The following procedure assumes that all the trim and
associated gaskets were removed from the valve body.
If these parts were not all removed, start the assem­bly procedure at the appropriate step. Key numbers
referenced in the following steps are found in figure 11,
unless otherwise indicated.

Table 1: Body to Bonnet Bolt Torques and Drill Size

Valve
Stem

mm Inch N•m Lbf•ft mm Inch

9.5 3/8 40-47 25-35 3/32 16 5/8

12.7 1/2 81-115 60-85 1/8 19 3/4

19.0 3/4 237-339 175-250 3/16 25 1

Bolt Torque

Drill

Size,

Inch

D

Dimension

Valves with Plain or Extension Bonnets

Perform the following steps to assemble and install
the trim.

To avoid weakening the stem that may cause failure
in service, never reuse an old stem with a new valve
plug. Using an old stem with a new plug requires
drilling a new pin hole in the stem, which will weaken
the stem. However, a used valve plug may be reused
with a new stem.

1. For valves with metal seats, screw the valve
stem (key 7) into the valve plug (key 2). Tighten
to the torque valve given in figure 9. Refer
to figure 3 to select the proper drill size. Drill
through the stem using the hole in the valve
plug as a guide. Remove any chips or burrs
and drive in a new pin (key 8) to lock the as
sembly.

2. For valves with 1/4 and 3/8-inch ports and
composition seats, refer to figure 12. Place the
disk (key 29) on the valve plug tip (key 30).
Place the disk retainer (key 28) over the disk,
and then thread the disk retainer onto the valve
plug guide (key 27).

To avoid failure in service for valves with 1/2 through
1-inch ports and composition seats, never reuse an
old valve plug guide with a new valve plug tip. Using
an old valve plug guide with a new plug tip requires
drilling a new pinhole in the valve plug guide, which
will weaken the guide. However, a used valve plug tip
may be reused with a new valve plug guide.

For valves with 1/2 through 1-inch ports and
composition seats, refer to figure 12. Insert the

disk (key 29) in the valve plug guide (key 27). Screw the
tip (key 30) onto the valve plug guide to clamp the disk
in place. Using a 3/32-inch bit, drill through the valve
plug guide using the hole in the tip as a drilling guide.
Remove any chips or burrs and drive in a new pin (key

31).

Figure 9. Bolt Torque for Plug/Stem Connection and
Plug/Adaptor Connection and Pin
Replacement

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Mark EZ SEriES GlobE StylE Control ValVE

Assembly Continued,

To avoid failure in service for valves with 1-1/2 and
2-inch ports and composition seats, never reuse an
old valve plug tip with a new valve plug guide. Us­ing an old valve plug tip with a new valve plug guide
requires drilling a new pinhole in the valve plug tip
which will weaken the tip. However, a used valve plug
guide may be reused with a new valve plug tip.

For valves with 1-1/2 and 2-inch ports and
composition seats, refer to figure 13. Insert the

disk (key 29) in the valve plug guide (key 27). Screw the
tip (key 30) into the valve plug guide to clamp the disk in
place. Using a 3/32-inch bit, drill through the valve plug
tip using the hole in the valve plug guide as a drilling
guide. Remove any chips or burrs and drive in a new pin
(key 31).

To avoid failure in service, never reuse an old stem
with a new valve plug guide. Using an old stem with a
new valve plug guide requires drilling a new pin hole
in the stem, which will weaken the stem. However,
a used valve plug guide may be reused with a new
stem except for valves with ½ through 1-inch ports
and composition seats (see to gure 12). For these
constructions, a used valve plug guide should only be
used if the tip is
reused.

3. For all valves with composition seats, screw
the valve stem (key 7) into the valve plug guide
(key 27, figure 12). Tighten to the torque
value given in figure 10. Refer to figure 9
to select the proper drill size. Drill through
the stem, using the hole in the
valve plug guide as a drilling guide. Remove any
chips or burrs and drive in a new pin (key 8) to
lock the assembly.

5. If the valve plug (key 2) or valve plug tip (key
30, figure 12) will not slide through the seat ring
retainer and bushing assembly (keys 3 and 26),
proceed as follows:

a. Place the seat ring retainer and
bushing assembly (keys 3 and

26) over the stem of valve plug
and stem assembly or over the stem of
the valve plug guide and stem assembly.

b. Install the seat ring retainer and bush
ing assembly, which also includes the
valve plug and stem assembly or
valve plug guide and stem assembly,
on the top of the seat ring, ensur
ing that the seat ring retainer slips onto
the seat ring properly. Any rotation orien
tation of the seat ring retainer
with respect to the valve body is
acceptable.

c. Place the spiral wound gasket, shim,
and bonnet gasket (keys 12, 25, and 10)
on the shoulder of the seat ring retainer.

6. If the valve plug (key 2) or the valve plug tip
(key 30, figure 12) will slide through the seat ring
retainer and bushing assembly (keys 3 and 26),
proceed as follows:

a. Install the seat ring retainer and
bushing assembly on the top of
the seat ring, ensuring that the
seat ring retainer slips
onto the seat ring properly. Any rotation
orientation of the seat
ring retainer with respect to
the valve body is acceptable.

4. Install the seat ring gasket (key 13), and replace
the seat ring (key 9). With some valve plug sizes
and configurations, the valve plug or tip will slide
through the seat ring retainer and bushing assem
bly (keys 3 and 26), and in other configurations it
won’t.

-7-

b. Place the spiral wound gasket, shim,
and bonnet gasket (keys 12, 25,
and 10) on the shoulder of
the seat ring retainer.

c. Slide the valve plug and stem assem
bly or the valve plug guide and stem
assembly into the seat ring retainer and
bushing assembly (keys 3 and 26).