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CFTIIP-015 Rev.0
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INSTALLATION, OPERATING
AND MAINTENANCE INSTRUCTIONS
D SERIES
TABLE OF CONTENTS
GENERAL INFORMATION
TERMS CONCERNING SAFETY
UNPACKING
INSTALLATIONS
VALVE MAINTENANCE
VALVE DISASSEMBLY AND REASSEMBLY
PLUG STEM PINNING
ILLUSTRATION INDEX
Figure 1 – Typical bolting torque sequence
Figure 2 – Exploded drawing
Figure 3 – Installation of carbon filled energized seal ring
Figure 4 – Installation of Grafoil seal ring
Figure 4.1 – Grafoil seal ring
Figure 5 – Plug stem pinning
Figure 5.1 – Plug
Figure 6 – End to End dimensions
Figure 7 – Trim types
Figure 7.1 – Single stage Balanced Trim
Figure 7.2 – Two stage Balanced Trim
Figure 7.3 – Standard Trim
This document is the property of Circor Flow Technologies India Pvt Limited should not copied or reproduced in one form or another.
Page 1 of 15
CFTIIP-015 Rev.0
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1 General Information
The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Circor D-series control valves.
Product users and Maintenance personnel should thoroughly review this bulletin prior to installing, operating or performing any maintenance on the valve.
To avoid possible injury to personnel or damage to valve parts, WARNING and CAUTION notes must be strictly followed. Modifying this product, substituting non-factory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment and may void existing warranties.
WARNING: Standard industry safety practices must be adhered to when working on this or any other process control product. Specifically, personal protective and lifting devices must be used as warranted.
2 Terms Concerning Safety
The safety terms DANGER, WARNING, CAUTION and NOTE are use in these instructions to highlight particular dangers and/or to provide additional information on aspects that may not be readily apparent.
DANGER: indicates that death, severe personal injury and/or substantial property damage will occur if proper precautions are not taken.
WARNING: indicates that death, several personal injury and/or substantial property damage can occur if proper precautions are not taken.
CAUTION: indicates that minor personal injury and/or property damage can occur if proper precautions are not taken.
NOTE: indicates and provides additional technical information, which may not be very obvious even
to qualified personnel.
3 Unpacking
1.While unpacking the valve, check the packing list against materials received. Lists describing valve and accessories are in each
shipping container.
2.When lifting the valve from shipping container, use the lifting lugs attached to the bonnet bolting. Take care to position lifting straps to avoid damage
to the tubing and mounted accessories.
WARNING: When lifting a valve using the lifting lugs, be aware that the center of gravity may be above the lifting point. Therefore, support must be given to prevent the actuator from rotating. Failure to do so can cause serious injury to personnel, damage to the valve or nearby equipment.
3.Contact your shipper immediately if there is shipping damage.
4.Should any problem arise, contact your Circor representative.
This document is the property of Circor Flow Technologies India Pvt Limited should not copied or reproduced in one form or another.
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CFTIIP-015
Rev.0
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4 Installations |
CAUTION: Do not over tighten |
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1. Before installing the valve, clean the line of dirt, |
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packing. This can cause excessive packing |
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welding chips, scale or other foreign material. |
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wear and high stem friction that may impede |
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2. Whenever possible, the valve should be installed |
plug movement. |
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in an upright position. Vertical installation permits |
5. Make sure the valve fails in the correct |
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easier valve maintenance. |
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direction in case of air failure. This is done |
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3. Be sure to provide proper overhead clearance for |
by turning off the air supply and observing |
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the failure direction. |
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the actuator to allow for disassembly of the plug |
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from the valve body |
6. After a temperature excursion has |
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4. Double-check flow direction to be sure the |
occurred, bonnet flange bolting should be re- |
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torqued to ensure bonnet gaskets do not leak. |
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valve is installed correctly. Flow direction is |
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(Refer table 1) |
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indicated by the arrow attached to the body. |
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5. If welding the valve into the line, use extreme |
Table 1 |
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care to avoid excess heat buildup in the valve. |
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SIZE |
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SIZE |
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OF |
NO. |
TORQUE |
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OF THE |
CLASS |
THE |
OF |
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6. Connect the air supply and instrument signal |
Nm |
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VALVE |
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NUT |
NUTS |
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lines. Throttling control valves are equipped with a |
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(in) |
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valve positioner. Refer to the appropriate positioner |
2" |
150 ~ 600 |
0.75 |
6 |
152 |
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900 ~ 1500 |
0.875 |
8 |
220 |
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bulletin for connections, maximum air supplies, and |
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150 ~ 600 |
0.875 |
8 |
233 |
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maintenance instructions. |
3" |
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900 ~ 1500 |
1.25 |
8 |
583 |
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4.1 Quick-check |
4" |
150 ~ 600 |
0.875 |
8 |
307 |
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900 ~ 1500 |
1.5 |
8 |
922 |
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Prior to start-up, check the control valve by |
6" |
150 ~ 600 |
1 |
12 |
391 |
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900 |
1.25 |
12 |
856 |
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following these steps: |
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1500 |
1.75 |
8 |
1798 |
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1. Stroke the valve and observe the plug position |
8" |
150 ~ 600 |
1 |
12 |
573 |
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900 |
1.75 |
8 |
2631 |
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indicator on the stem clamp compared to the stroke |
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1500 |
1.625 |
12 |
1629 |
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indicator plate. The plug should change position in |
10" |
150 |
1 |
8 |
879 |
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a smooth, linear fashion. |
300 |
1 |
12 |
586 |
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600 |
1.25 |
16 |
550 |
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NOTE: Due to excessive friction, graphite packing |
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150 |
1 |
12 |
873 |
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can cause the plug stem to move in a jerky fashion. |
12" |
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300 |
1.25 |
12 |
1091 |
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2. Check for full stroke by making appropriate |
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600 |
1.5 |
16 |
982 |
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16" |
150 |
1.25 |
12 |
1605 |
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instrument signal change. |
300 |
1.5 |
12 |
1926 |
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600 |
1.75 |
16 |
1685 |
3. Check all air connections for leaks.
4. Check packing box bolting for the correct adjustment.
This document is the property of Circor Flow Technologies India Pvt Limited should not copied or reproduced in one form or another.
Page 3 of 15
CFTIIP-015 Rev.0
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Typical Bolting torque sequence
Figure 1
This document is the property of Circor Flow Technologies India Pvt Limited should not copied or reproduced in one form or another.
Page 4 of 15
CFTIIP-015 Rev.0
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5 Valve Maintenance |
10. Clean any dirt and other foreign material |
At least once every six months, check for |
from the plug stem. |
proper operation by following the |
11. If an air filter is supplied, check and |
preventative maintenance steps outlined |
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below. These steps can be performed while |
replace cartridge if necessary. |
the valve is in-line and, in some cases |
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without interrupting service. If an internal |
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problem is suspected, refer to the “Valve |
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Disassembly and Reassembly” section. |
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1. Look for signs of gasket leakage through |
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the end flanges and bonnet. Re-torque flange |
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and bonnet bolting (if required). |
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2.Check for fluid leakage to the atmosphere through the body drain plug, if applicable.
3.Examine the valve for damage caused by corrosive fumes or process drippings.
4.Clean valve and repaint areas of severe oxidation.
5.Check packing box bolting for proper tightness.
6.If the valve is supplied with a lubricator fitting, check lubricant supply and add lubricant if necessary.
7.If possible, stroke the valve and check for smooth, full-stroke operation. Unsteady stem movement could indicate an internal valve problem.
NOTE: Due to excessive friction, graphite packing can cause the plug stem to move in a jerky fashion.
WARNING: Keep hands, hair and clothing away from all moving parts when operating the valve. Failure to do so can cause serious injury.
8.Ensure all accessories, brackets and bolting is securely fastened.
9.If possible, remove air supply and observe actuator for correct fail-safe action.
This document is the property of Circor Flow Technologies India Pvt Limited should not copied or reproduced in one form or another.
Page 5 of 15
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