Jordan Valve Mark V-100 User Manual

I & M Mark V-100 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

These instructions apply speciﬁcally to the 2 through 12 inch Mark V-100 Ball Series Valve Bodies. This manual provides maintenance, operation, installation, and parts ordering information. The valve bodies are normally equipped with actuators and accessories. Please refer to the appropriate instruction manuals.

InstallatIon

The valve body and internal components are made of speciﬁc materials, and are designed for speciﬁc temperature, ﬂuid control, pressure, and pressure drop conditions. The following listed parts may compromise the valve if temperature ranges and service drops have been exceeded; Body, bushings, shaft, and ball seals.

Operation of these valves outside the speciﬁed application ranges may cause damage to equipment and or personal injury.

These valves must not be used outside the speciﬁed condition ranges without contacting your Jordan Valve sales representative.

Jordan Valve recommends the installation of pressure control or pressure relieving devices.

Inspect the valves for shipping damage and foreign debris when uncrating.

Jordan Valve recommends the installation of a standard three-valve maintenance by-pass system. This allows for isolation of the valve body without shutting down the pipeline.

Installation & Maintenance Instructions for the

Mark V-100 Series Control Valves

1. Ensure the pipeline is free of welding slag, and foreign debris by blowing out the pipe lines before installation.

2. When mounting between pipeline ﬂanges, ensure the two connecting ﬂanges are in line. Install approved gaskets between the valve body and the pipeline ﬂanges.

3. Position the valve on the line so that the ﬂow direction indicator corresponds to to the direction of the ﬂow of the pipeline. If the valve body is being used in a bi-directional ﬂow application then the ﬂow direction indicator should correspond to the direction of the highest ﬂow condition.

4. When installing ﬂange bolts, use ﬁgure No. 4 to obtain necessary clearances.

5. Tighten the bolts in a crisscross pastern to ensure all bolts are evenly torqued.

6. Install the Mark V-100 ball valve horizon tally in the pipeline with the ball valve closing downward. The actuator can be installed in a number of positions; refer to ﬁgure 3 and the actuator instruction manual.

7. When a manual actuator is used in combination with a power actuator, it will be necessary to install a bypass valve on the power actuator This will allow the operation of the manual actuator. Following the power actuator instruction, connect the pressure line to the actuator.

Note: Grounding the valve shaft is required when the valve is exposed to hazardous goods or installed for oxygen use. Without grounding the valve shaft, an explosive situation may result from the static electricity from the valve parts.

Mark V-100 SerieS Control ValVeS

MaIntenance

Scheduled inspections and maintenance are vital to continued operation of all pressure control valves and systems. Parts are subject to wear and tear and must be replaced as necessary, depending on the intensity of service conditions.

Warning:

To avoid personal injury or damage to the process system, disconnect operating lines providing air pressure, control signals or electrical power to the actuator. Ensure the actuator cannot suddenly open or close.

Isolate the valve from the system by using by-pass valves or by shutting off the process entirely. Relieve any pressure contained on both sides of the valve and drain the process media.

Vent the power actuator, relieve actuator spring pressure and use proper lock-out methods during all maintenance procedures.

Split Ring Packing

Before beginning any maintenance, it is important to isolate the control valve and release all pressure contained in the valve body and the actuator.

Note: exercise caution during disassembly. Nicks and scratches will affect the ability to seal the valve in the future.

1. Remove packing ﬂange nuts (key 3) and lift the packing follower (key 15) from the packing box.

2. With a formed wire hook remove the packing rings.

3. Clean the packing box, all metal parts, and co- mplete the required maintenance.

4. Expand the split ring of the new packing to allow it to pass over the valve shaft. Stager the con- necting lines, then slide the rings into the pack- ing box.

5. Tighten the packing ﬂange nuts until they are ﬁn ger tight. Test under ﬂow conditions. Continue tightening the nuts until all leakage has stopped.

Replacing Packing

When conducting packing maintenance, the actuator must be removed from the valve. It is also recommended that the valve be removed from the pipeline to allow for adjustment of the valve closed position.

If the packing is new and tight on the shaft, and if leakage cannot be stopped by tightening the packing nuts, it is likely that the shaft has become worn or nicked.

If the leakage originates from the outside diameter of the packing, nicks or scratches may have damaged the packing box wall. Inspect the shaft and packing box during the following procedures.

If it is not possible to control leakage around the valve shaft by tightening packing ﬂange bolts, the packing may need to be replaced.

Solid Ring Packing

Isolate the control valve. Release all pressure contained in the valve body, and the actuator. Prior to disassembly, note the orientation of the actuator and lever in relation to the valve body.

Use caution when removing the actuator lever, using a wheel-puller if necessary. If the actuator lever is forced off the valve shaft the ball could move from the centered position, damaging the V-Ball, seal and valve body.

Figure 1. Section view of Heavy Duty Composition (TCM) Ball Seal

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Mark V-100 SerieS Control ValVeS

Solid Ring Packing Continued,

1. Remove the actuator cover.

2. Remove the lever.

3. Disconnect the actuator and body cap screws (key 4) and hex nut if used (key 5).

4. Remove the packing ﬂange nuts (key 3), pack ing ﬂange, if used, and packing follower.

5. Remove the packing rings (key 6) with a formed wire hook. To remove the TFE V-ring packing, the wire hook should have a sharp end to allow you to pierce the packing for removal.

6. Clean the packing box, all metal parts and com- plete all required maintenance.

7. Replacing single packing

7.1 Replace the packing box ring (key 18).

7.2 Next, replace the packing rings (key 6).

8. Replacing double packing arrangements

8.1 Replace the packing box ring (key 18).

8.2 Replace one half of the total number of packing rings (key 6).

8.3 Install the packing washer, if used.

8.4 Replace the lantern ring and the remain ing packing rings.

8.5 If used, replace the packing

8.6 Install the packing follower (key 15)

8.7 Replace the packing ﬂange, if used

8.8 Replace and tighten the packing ﬂange nuts until they are ﬁnger tight.

9. Reconnect the actuator following the previously noted orientation.

10. Replace the cap screws (key 4) and hex nuts (key 5) using the torques from table 6.

11. Follow the actuator instruction manual to com plete the actuator assembly and to set the travel adjustment.

12. After the valve is placed in service, the packing ﬂange nuts may require retightening to prevent leakage.

Ball Seal or Flow Ring Maintenance

Caution must be used when working near the V-ball. The V-Ball closes with a shearing, cutting motion and can cause personal injury or property damage if objects become caught in a closing valve. Be sure to keep the path of the V-notch valve clear while stroking the valve.

Disassembly:

1. Isolate the valve from the line.

1.1 It is necessary for the removed valve to be positioned so that the seal ring or ﬂow ring is pointed upward

1.2 Ensure that V-ball (key 21) is in the open position.

2. Remove the cap screws that secure the seal protector ring in place.

3. Carefully remove the ring from the body, ensuring that the surface of the ball is not nicked or scraped.

4. Remove the O-ring (key 24), if used.

5. Mark the position of the ball seal and the valve body, so that it can be returned to its original position when it is reinstalled.

6. Carefully remove:

6.1 The bi-directional metal or TCM ball seal (key 23)

6.2 The back-up ring

6.3 Shim seals

7. Clean all parts and inspect for damage.

Installation of Metal, Bi-directional Metal or Heavy-Duty Composition (TCM) Ball Seal

1. Inspect the sealing surface of the valve body for nicks and scratches that will prevent the shims from sealing.

2. Turn the V-ball to the closed position and install the appropriate number of shims (Key 20) from table 3. For the bi-directional metal ball seal, use a 1/1000-inch or 1/4 mm thick test shim. A piece of paper would be a suitable alternative. Place the test shim across the ball face.

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Mark V-100 SerieS Control ValVeS

Installation of Metal, Bi-directional Metal or Heavy-Duty Composition (TCM) Ball Seal Continued,

3. Check for nicks and scratches on the ball seal, sealing surface, and backup ring. Install the ball seal and the backup ring on top of the shim seals. If damage was detected on any of the components, the damage should be turned away from the V-ball. Install the bi-directional ball seals, to ensure proper orientation, use the marks made in step number 5 of the removal.

4. Metal and TCM ball seals:

4.1 Install seal protector ring (key 22) on the ball seal and shim seals (key 23 and key

20).

4.2 Secure the seal protector ring and the ball seal to the valve body by threading and tightening the capscrews. To obtain the closest ball deﬂection to zero, add and remove shim seals (key 20).

4.3 Zero ball seal deﬂection is when a .005 inch or 0.13 mm shim causes the seal to be broken between the v-notched ball and the ball seal. The parts must be secure or an inaccurate zero will result.

5. Bi directional metal ball seals:

5.1 Install seal protector ring (key 22) on the ball seal and shim seals (key 24 and key

20).

5.2 Secure the seal protector ring, ball seal and shims (key 24 and 20) by threading and tightening the capscrews (key 19).

5.3 Zero ball seal deﬂection can be tested by removing the 1/1000 of an inch or .025 mm thick test shim from under the ball seal. If this is possible, remove the seal protector ring, the ball seal, and the back-up ring.

5.4 To check the zero deﬂection, remove one shim, and assemble the parts. Attempt to remove one 1/1000 inch or 0.025mm shim. If the shim is neither too tight or too loose, then zero deﬂection is obtained.

6. Once zero deﬂection is obtained remove:

6.1 The seal protector ring

6.2 The ball seal

6.3 The back up ring (if the bi-directional metal seal is used)

6.4 The number of seals indicated in table

6.5 For the bi-directional metal ball seal leave at least one shim seal in the body.

7. Install the ball seal and the backup ring, if one is used.

8. For metal ball seals, install one shim seal (key

20) on top of the metal ball seal.

9. Install 0-ring (key 24), if used, into the body.

10. Ensure that the ball seal is centered on the V ball. For the bi-directional ball match orienta tion marks that were made in step 5 of the removal section.

11. Install the seal protector ring (key 22) and screw the cap screws and washers, (if used) to secure the body.

Installation of Flow Ring

1. Ensure that the V-ball (Key 21) is in the closed position. Replace the shim seals in the body Table #3

2. Install the O-ring (Key 24) in the body and posi tion the ﬂow ring to ensure that it is centered and that it does not touch the v-ball.

3. Install the washers that hold the seal protector and twist on the cap screws.

4. Check the minimum clearance of the ﬂow ring and the V-ball from table 5. Measure the exist ing clearance and adjust to obtain the minimum clearance by adding and removing shims.

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Mark V-100 SerieS Control ValVeS

Drive Shaft and V-Ball

Disassembly:

Caution: Use care when removing the actuator lever, using a wheel-puller if necessary. If the actuator lever is forced off the valve shaft the ball could move from the centered position, damaging the V-Ball, seal and valve body.

Before disassembly, note the orientation of the actuator in relation to the body and note the orientation of the lever in relation to the valve body.

1. Remove the actuator cover.

2. Remover the lever.

When the actuator is removed from the valve body, the ball/shaft assembly may rotate and cause personal injury or damage to equipment. Prevent rotation by turning the V-Ball to a stable position in the body.

3. Detach the valve from the line. It is necessary for the removed valve to be positioned so that the seal ring or ﬂow ring is pointed upward.

4. Unscrew the cap screws (key 19) that hold the seal protector ring in place (key 22).

5. Carefully remove the ring from the body ensur- ing that the surface of the ball is not nicked or scraped

6. Remove the O-ring (key 24). 7 Remove the ball seal (key 23) from the ball seal constructions.

8. Lift the shim seals (key 20).

9. Clean all parts and inspect for damage.

10. Remove packing ﬂange nuts (key 3) and lift the packing ﬂange and follower (key 15) from the packing box.

11. With a formed wire hook, remove the packing rings.

12. Clean the packing box and all metal parts com- plete all required maintenance.

13. Locate and remove the groove pin (key 10).

14. Unscrew the guidepost retaining nuts (key 14) or the retainer, depending on valve body size.

15. Support the V-ball securely and remove the guidepost, not allowing the guidepost to scratch the seal.

16. Remove:

16.1 Guide post retainer (key 25)

16.2 Guide post (key 13)

16.3 Gasket (key 12)

16.4 Spring retainer washer (for sizes 3 inch and larger).

17. The drive shaft is pushed into the body from the bonnet. The drive shaft is aligned with the guidepost bushing. (key 11) 18 Find the groove pin hole, noting that the V-Ball has a raised ﬂat surface on one side. To remove the groove pin, place a punch on the side of the ball opposite the raised ﬂat surface and drive the out pin (Key 10). See Figure 12.

19. Slip the drive shaft through the body out the guidepost end. Remove the thrust washer.

20. Carefully remove the ball from the body ensuring that the surface of the ball is not nicked or scraped.

To remove the bearings (Keys 8 and 11) see Figure 5 for replacing the bearings. Refer to the bearing replacement procedure. When a new body (Key 7) and drive shaft bearing (Key 8) or V-Ball (Key 21) and guide post bearing (Key 11) is ordered, the bearing will be pressed in at the factory.

Assembly

1. Follow the instructions on the bushing replace ment from this manual.

2. Carefully insert the V-ball in the body ensuring the surface of the ball is not nicked or scraped. Provide secure support for the V-ball.

While installing the drive shaft, hold the thrust washer(s) (Key 9) between the drive shaft bearing (Key 8) and the V-Ball (Key 21).

3. Slip the drive shaft into the guidepost end through body.

4. Match the index mark on the shaft with index mark on the V-ball.

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