Jordan Valve Mark HPX, Mark HPAX User Manual

I & M Mark HPX and HPAX 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.

IntroductIon

Contained in this manual are installation instructions,
maintenance and parts information for the 2 through
6-inch Mark HPX2D, HPX5T, HPAX2, HPAX5, ASME
Class 900 and 1500 ratings. 2 inch ASME Class 2500
also included. Refer to the appropriate manuals for
instructions for the accompanying actuator, positioner
and additional accessories.

Only trained or experienced personnel should carry
out the operation and installation of all pressure
equipment. If you have any questions regarding the
equipment, contact your Jordan Valve representative.
A serial number identifies each Series H valve and
is stamped on the valve body. Please reference this
number when communicating with your Jordan Valve
representative.

Installation & Maintenance Instructions for the

Mark HPX and Mark HPAX Globe and Angle Style

Control Valves

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

3. Position the valve on the line so the flow
direction indicator corresponds to the di­ rection of the flow of the pipeline.

4. Jordan Valve recommends the installation
of a standard three-valve maintenance by
pass. This will allow isolation of
the control valve without shutting down
the pipeline system.

5. Install approved gaskets between the
valve body and the pipeline flanges.

6. If the actuator has been shipped sepa-
rately, refer to the mounting procedure in
the applicable instruction manual.

InstallatIon

Exceeding the recommended pressure and tem­perature limits from Table 1, or those indicated on the
nameplates of your Jordan Valve Controls valve, can
result in personal injury and property damage. Jordan
Valve recommends the installation of a relief valve to
protect against overpressure situations.

Mark HPX900 and 1500 Series, HPX2D and HPX5T 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.

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

7. If the valve body arrives without packing
installed in the packing box, it will be
necessary to install the packing before
putting the valve into service. To
complete these procedures, follow the
instructions under “packing maintenance”
in this manual.

8. Note: It may be necessary to adjust the
packing to prevent leakage. Prior
to shipping the packing was tightened,
and may require some adjustment
for specific conditions.

Mark HPX and HPaX SerieS Globe and anGle Style Control ValVeS

Table 1: Approximate Shipping Weights: Valve and Bonnet Assembly

Valve Type Valve Size

(Inches)

2 900 & 1500 158 72

2 2500 229 104

3 900 276 125

Globe Valve

4 900 507 230

6 900 1127 511

Angle Valve 2 900 & 1500 153 69

Class Pounds

Flanged

1500 284 129

1500 548 249

1500 1228 557

Kilograms

Flanged

MaIntenance

Internal valve components are subject to normal
deterioration and must be inspect 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. Relive the pressure contained in the actuator
by venting the actuator loading pressure and
relieving any power actuator spring compre­ ssion.

4. Lock-out procedures should be strictly ad­ hered to while the equipment is being ser­ viced.

5. The Mark HPX Series use spiral-wound gas
kets that are compressed to provide
their seal. Spiral-wound gaskets are
designed for single service, and if they are
disturbed they must be replaced upon reas­ sembly. Used spiral-wound will not seal prop­ erly within the assembly.

Table 2: Torque for Body-To-Bonnet Bolting (using Nickel Never Seez Lubricant)

Torque

Valve

Rating

Class 900

and 1500

Class 2500 2 540 390 7i30 530

Valve Size,

Inches

2 290 180 390 240

3 540 390 730 530

4 720 540 970 730

6 1250 950 1700 1300

B7, B16, BD and

660 Studs

Lbf•ft N•m

B8 and B8M

Studs

-2-

B7, B16, BD and

660 Studs

B8 and B8M

Studs

Mark HPX and HPaX SerieS Globe and anGle Style Control ValVeS

Packing Lubrication

These instructions are for the lubricator or lubricator
isolating valve (Figure 1). If the lubricator or lubrica­tor isolating valve have been installed, they will be in
place of the pipe plug (Key 16, Figures 3 and 5) and are
designed for packing that requires lubrication, including
PTFE/composition. Jordan Valve recommends a silicon­based lubricant. Lubricant is not recommended for
oxygen services or for processes that operate in excess
of 500F. To add lubricant to the packing box, turn the
capscrew in a clockwise direction.

For Lubricator/Isolating Valve

1. Open the isolating valve.

2. Turn the capscrew in a clockwise direction.

3. Close the isolating valve.

Packing Leakage

Spring-Loaded PTFE V-ring packing

To eliminate leakage, tighten the packing flange nuts
(key 2, Figures 3 and 5). If leakage cannot be controlled
in this manner, the packing will need to be replaced.

Other Packing

If packing other than Spring-Loaded PTFE V-ring has
been used, attempt to eliminate the leaking and create
a stem seal by tightening the packing flange nuts to the
minimum recommended torque given in Table 4. If leak­age continues, the packing will need to be replaced.

Figure 1: Lubricator and

Lubricator/Isolating Valve

New Packing

If tightening the appropriate flange nuts does not solve
the leakage problem and the packing is relatively new,
leakage could indicate damage to the packing box wall
or to the stem. Inspect the valve plug stem for a good
surface finish as well as the packing box wall for nicks
and scratches that could compromise the seal.

Hint:

If leakage originates from the outside diameter of
the packing, check the packing box wall for nicks or
scratches. If leakages originates from the inside diam­eter of packing, check the stem for nicks or scratches.

Table 3: Recommended Torque for Packing Flange Nuts (non live-loaded)

Stem Diameter Valve Body

Inches mm Lbf•ft N•m

1/2 12.7 900 9 13 12 18

1/2 12.7 1500 11 16 15 22

1/2 12.7 2500 13 18 18 24

3/4 19.1 900 20 30 27 41

3/4 19.1 2500 30 45 41 61

Rating

Min Max Min Max

-3-

Torque

Mark HPX and HPaX SerieS Globe and anGle Style Control ValVeS

Figure 2: Mark HPX and HPAX Series Packing Arrangements

Replacing Packing

Prior to beginning any maintenance, it is important to
isolate the valve from the line pressure, and to release
all pressure from the valve body. Disconnect all operat­ing lines to the actuator, including air pressure, electri­cal power or control signal lines. The process pressure
should be released both upstream and downstream of
the valve. Drain the process fluid from both sides of the
valve.

Employ lock-out procedures to ensure the safety of per­sonnel and equipment during valve service.

Note: Extreme caution must be used during disas­sembly. Nicks and scratches will affect the ability to
seal the valve in the future.

1. Remove the cap screws in the stem connector
and separate the two halves.

2. Exhaust any actuator pressure and disconnect
the actuator supply line and any leakoff piping.

3. Remove the actuator from the bonnet (key 6)
by removing the yoke lock nut (key 15) and
then remove the actuator from the bonnet.

-4-

Mark HPX and HPaX SerieS Globe and anGle Style Control ValVeS

4. Back off the packing flange nuts (key 2) until
the packing is free of constriction against the
valve plug stem (key 20). Remove any
additional equipment from the valve plug
stem threads, including the travel indicator disk
and stem locknuts.

5. When removing the bonnet ensure the valve
plug and stem assembly (keys 20 and 22)
remain off the seat ring (key 23). This will
prevent damage to the seating surfaces as a
consequence of the assembly falling from
the bonnet after being partially raised.

6. Apply caution to avoid damage to the gasket
seating surface.

7. Caution must be used when handling the Mark
HPXd and HPAX2 piston rings. These rings are
brittle and in two pieces.

8. Remove the bonnet in the following steps. Do
not remove a jammed bonnet with equipment
that can store energy. Sudden release
of the bonnet can result in unexpected and
potentially dangerous movement. If the
cage becomes jammed it is important to provide
support for the cage. This will prevent the cage
from falling unexpectedly.

9. Loosen the bonnet hex nuts (key 8) which attach
the bonnet to the valve, by approximately 1/8 of
an inch (3mm).

10. Pry between the bonnet (key 6) and valve body
(key 21) to loosen the body to bonnet gasket
joint. Continue prying around the bonnet until the
bonnet loosens. If no fluid is released from the
joint, unscrew the bonnet nuts (key 28)
completely.

11. Carefully remove the bonnet and valve plug
assembly (key 6, 20, 22) as a unit. Ensure that
the valve plug and stem assembly (keys'
20 and 22) remains on the seat ring (key 23)
and avoid nicking or scratching the gasket seal-
ing surface.

12. To remove the bonnet from the valve stem
remove the bonnet hex nuts (key 8). Carefully
lift the bonnet off the valve stem. In the event
that the valve plug and stem assembly become
detached they can be tapped back down with a
lead or brass hammer. Place the bonnet on a
suitable surface such as wood or cardboard to
protect it from damage.

13. Remove parts in this order:

13.1. Valve Plug Assembly (key 20, 22)

13.2. Bonnet Gasket (key 19)

13.3. Cage (key 12)

13.4. Seat Ring (key 23)

13.5. Seat Ring Gasket (key 24)

14. Clean all gasket surfaces with a wire brush, fol-
lowing the direction of the serrations.

15. Cover the valve body openings to protect the
gasket surfaces.

16. Unscrew the packing flange nuts (key 2)

17. Remove the following from the bonnet:

17.1. Packing flange (key 3)

17.2. Upper wiper (key 13)

17.3. Packing follower (key 14)

18. Push the remaining packing parts from the valve
side of the bonnet. This can be done with a
rounded rod or any other tool that will not cause
damage or scratch the packing wall.

19. Clean the packing box and the following metal
components: spring or lantern ring,
packing box ring, packing follower and,
if required, the v-ring packing washer. Finish all
required maintenance.

20. Examine the valve stem threads for sharp edges
that may damage the new packing. Emery cloth
or a whetstone can be used to smooth out any
sharp edges or burrs.

21. Remove the protective covering from the valve
body. Using a new seat ring gasket (key 24) and
bonnet gasket (key 19), install the seat ring (key

23) and cage (key 12).

22. Install the stem and plug assembly (key, 20, 22).
Slip the bonnet (key 6) over the stem and line it
up with the studs.

23. Replace the packing hex nuts (key 2)

23.1. For pre-lubricated hex nuts (identified
by the black film coating on the nut
threads) tighten the hex nuts finger tight.

23.2. For all other nuts, Jordan Valve recom-
mends that you lubricate the stud
threads with Never Seez Pure Nickel
special lubricant or equivalent. Tighten
the hex nuts finger tight.

24. To centre the trim, the valve will need to be
stroked several times. Using proper bolt
ing procedures tighten the nuts to no more than
1/4 of the torque values specified in Table 4.

-5-

Mark HPX and HPaX SerieS Globe and anGle Style Control ValVeS

25. Increase the torque on each nut by an additional
1/4 of the torque value using the standard
crisscross pattern. Repeat this pattern
until the torque values in Table 4 have
been reached. Apply the final torque value
again and if any bolts turn, all of the bolts
will require retightening.

26. Using the appropriate arrangement from Table
2, install new packing and metal packing box
parts. It may be necessary to pre-lubricate
packing parts with silicone-based grease.

27. Using a smooth-edged pipe, cautiously tamp
each soft packing part into the packing
box. To prevent trapping air between the rings,
add one ring at a time without forcing them
below entrance chamber of the packing
box. With each additional ring the stack should
only be pushed down the thickness of one ring.

28. Install:

28.1. Packing Follower (key 14)

28.2. Wiper (key 13)

28.3. Packing Flange (key 3)

29. Lubricate both the packing flange studs (key 1)
and the faces of the packing flange nuts (key 2).
Finger tighten the packing flange nuts.

30. For packing type:

30.1. Spring-loaded PTFE V-Ring (Figure 2):
tighten the packing flange nuts
until there are no leaks.

30.2. Graphite: initially tighten the packing
flange nuts to the maximum torque
value in Table 3. Release the
packing flange nuts and retighten
them to the maximum torque value given
in Table 3.

30.3. Other packing types: tighten the pack
ing flange nuts in small increments alter-
nately. Repeat the process until
one of the nuts reaches the maximum
torque value from Table 5. Now
continue tightening the flange nuts
until the packing flange is level and at
right angles (90 degrees) to the
valve stem.

Table 4: Valve Stem Connection Torque and Drill Size for Groove Pin Hole

Valve Size,

Inches

2 1/2 12.7 HPX2D, HPAX2,

3

4 3/4 19.1 HPX2D,

6

Trim Removal

1. Remove the actuator and the bonnet. Refer to
steps 1-4 in replacing packing.

2. Remove the valve plug and stem assembly (key
20, 22). If the assembly is to be reused protect
the valve stem and plug seating surface
from nicks and scratches by taping them.

Valve Stem Diameter

Valve Design

Inches mm Lbf•ft N•m

3/4 19.1 175-250 237-339 1/8

1/2 12.7 HPX2D,

3/4 19.1 175-250 237-339 3/16

1 25.4 310-355 420-481 1/4

1 25.4 310-355 420-481 1/4

3/4 19.1

1 25.4 310-355 420-481 1/4

1-1/4 31.8 610-670 827-908 1/4

HPX5T, HPAX5

HPX5T

HPX5T

HPX2D,

HPX5T

3. Remove:

3.1. Cage (key 12)

3.2. Bonnet Gasket (key 19)

3.3. Seat Ring (key 23)

3.4. Seat Ring Gasket (key 24)

4. Follow the steps in the valve plug maintenance
procedure to complete the remaining steps for
rim removal.

Valve Stem

Connection

60-85 81-115 1/8

60-85 81-115 1/8

175-250 237-339 3/16

175-250 237-339 3/16

Drill Size for Groove

Pin Inches

-6-