These instructions provide information about safe handling and operation of the valve.
If you require additional assistance, please contact the manufact urer or manufactu rer's representa tive.
Addresses and phone numbers are printed on the back cover.
SAVE THESE INSTRUCTIONS!
Subject to change without notice.
All trademarks are property of their respective owners.
1 T5 71 en3
1GENERAL
1.1Introduction
These instructions describe the installation, operation
and main-tenance of Top 5
Entry Rotary Control Valve series.
Top 5 is a generic name for a product series group
comprising the following valve series:
❑T5 — flanged, reduced bore, single seated
❑T4 — like T5, with weld ends
❑T25 — full bore, flanged, otherwise like T5
❑T35 — like T25, with weld ends.
When the valve is equipped with a control ball reducing
the flow rate and thus preventing noise and cavitation, it
is called Q-T5 etc.
Further information on the installation, operation and
maintenan-ce of actuators is given in the individual
manuals for each actuator model.
NOTE:
Selection and use of the valve in a specific application
requires close consideration of detailed aspects. Due
to the nature of the product, this manual cannot cover
all the individual situations that may occur when the
valve is used. If you are uncertain about use of the
valve or its suitability for your intended purpose,
please contact Metso’s Automation business for more
information.
®
, a valve in the Metso Top-
1.2Valve structure
The Top 5 valve series is intended for either control or
special shut-off applications. It is tight in one direction.
The ball may be equipped with an attenuator element
(Q attenuator). The ball has been mounted on the body
and on the bonnet with bearings.
Thanks to its top entry structure, the valve is also applicable for use as a butt weld end version, because the
valve can be serviced without removing it from the
pipeline.
1.3Markings
positioner id plate
Note. When the actuator
cover is removed, the ball
position can be checked at
the line stamped at the end
of the stem
actuator id plate
customer’s tag or position
number (if exists)
identification plate,
see fig. 3
manufacturing number
arrow showing the tight
direction, on both sides
of the body
Fig. 2Valve markings
In addition to the markings shown in Figure 2, the valve
may have directional arrows:
FLOW DIRECTION
TIGHT DIRECTION
When standard seats are used, the arrow on the body
shows the tight direction.
(1) (2) (5)(7)(8)
ATTENTION : READ INSTRUCTIONS BEFORE INSTALLATION OR SERVICING. CONTACT METSO AUTOMATION FOR COPY.
BODY
TRIM
(3) (4)(6)(9)(10)
T max
SHAFT
SEAT
MAX. OPER. psatRATINGTYPE
T min
No.
Fig. 3 Identification plate markings
MADE BY METSO AUTOMATION
MOD
XXXX
Fig. 1The valve bonnet is bolted to the body
Identification plate markings:
1.Body material
2.Stem material
3.Trim material
4.Seat material
5.Maximum and minimum operating temperatures
6.Maximum shut-off pressure differential / temperature
7.Pressure class
8.Type designation
9.Valve manufacturing parts list no.
10.Model
The type designation is explained in Metso standard
S389. An extract of the standard is shown on page 16.
41 T5 71 en
1.4Technical specifications
The identification plate must be checked for the essential safety limits in the extreme range, such as pressure
and temperature resistance and the highest operable
pressure difference.
The selected actuator size or the available instrument
air pressure may place restrictions on the highest operable pressure so that it becomes lower than the limits
determined by the mechanical strength of the valve.
Face-to-face length:
series T5ANSI/ISA S75.03,
IEC 534-3-3
series T25, T4, T35 API Class 600
Body pressure and
temperature rating: ANSI B16.34*), see Table 1
Ball bearings:
bearings, code EMetal-reinforced PTFE
easy, low Δp use:
max. +230 °C
demanding, high Δp use:
max +200 °C
bearings, code BCobalt based alloy
+450 °C
max. pressure difference
according to a separate
specification
Dimensions:See pages 14 and 15
Weights:See pages 14 and 15
*) Unless the selected ball bearings or flange standards impose a lower pressure and temperature restriction.
1.5Valve approvals
The valve is fire safe for hydrocarbon applications
according to API 607 and BS 6755.
1.6CE marking
The valve meets the requirements of the European
Directive 97/23/EC relating to pressure equipment, and
has been marked according to the Directive.
recycling and disposal instructions are available from
the manufacturer. A valve can also be returned to the
manufacturer for recycling and disposal against a fee.
1.8Safety precautions
CAUTION:
Do not exceed the valve performance limitations!
Exceeding the limitations marked on the valve may
cause damage and lead to uncontrolled pressure
release. Damage or personal injury may result.
CAUTION:
Do not dismantle the valve or remove it from the
pipeline while the valve is pressurized!
Dismantling or removing a pressurized valve will result in
uncontrolled pressure release. Always isolate the relevant part of the pipeline, release the pressure from the
valve and remove the medium before dismantling the
valve. Be aware of the type of medium involved. Protect
yourself and the environment from any harmful or poisonous substances. If the valve is equipped with an
actuator, do not forget to close and detach the actuator
pressure supply pipeline. Failure to do this may result in
damage or personal injury.
CAUTION:
Beware of the cutting movement of the ball!
Keep hands, other parts of the body, tools and other
objects out of the open flow port. Leave no foreign
objects inside the pipeline. When the valve is actuated,
the ball functions as a cutting device. Close and detach
the actuator pressure supply pipeline for valve maintenance. Failure to do this may result in damage or personal injury.
CAUTION:
Protect yourself from noise!
The valve may produce noise in the pipeline. The
noise level depends on the application. It can be
measured or calculated using the Metso Nelprof software. Observe the relevant work environment regulations on noise emission.
1.7Recycling and disposal
Most valve parts can be recycled if sorted according to
material. Most parts have material marking. A material
list is supplied with the valve. In addition, separate
CAUTION:
Beware of a very cold or hot valve!
The valve body may be very cold or very hot during
use. Protect yourself against cold injuries or burns.
Table 1Body materials commonly used by Metso and their resistance to pressure and temperature according
ANSI 16.34,
Pressur
e class
1)
ANSI
300
ANSI
600
Flange
code 1)
D A216 gr WCB
F A216 gr WCB
Body materialMaterial
Carbon steel
A351 gr CF8M
Stainless steel
Carbon steel
A351 gr CF8M
Stainless steel
code
D
A
D
A
°C
3850100150200250300350400
51,1
49,6
102,1
99,3
50,1
48,1
100,2
96,3
46,4
42,2
92,8
84,4
45,2
38,5
90,5
77,0
43,8
35,7
87,6
71,3
41,7
33,4
83,4
66,8
38,7
31,6
77,5
63,3
37,0
30,4
73,9
60,8
34,5
29,1
69,0
58,2
1) Flange codes according to PN standards, see Chapter 13. Max resistance to pressure and temperature
depending to the flange and its material. Resistance in the middle part of the valve up to size DN 400 (16") according to table A600.
1 T5 71 en5
2TRANSPORTATION, RECEPTION
AND STORAGE
Check the valve and the accompanying devices for any
damage that may have occurred during transpor t.
Store the valve carefully before installation, preferably
indoors in a dry place. Do not take the valve to the
intended location and do not remove the flow port protectors until the valve is installed. The valve is delivered
in the open position, with the exception of valve packages where the actuator spring closes the valve.
NOTE:
Valves with a carbon steel body may become badly
corroded on the inside if the inside is left damp during
storing.
CAUTION:
Never lift the valve or valve package by the actuator, positioner, limit switch or their piping. Place
the lifting ropes securely around the valve body.
3INSTALLATION IN THE PIPELINE
Remove the protecting plates around the valve and
check that the valve is clean. Flush and blow the pipeline carefully before installing the valve. Foreign particles, such as sand or pieces of welding electrode, will
damage the valve.
Check that the pipeline is supported properly. Do not
attempt to correct any pipeline misalignment by means
of the flange bolting or welding of the valve. Do not support the pipeline using the valve as help.
An arrow pointing at the tight direction of a seat that is
tight in one direction (the most commonly used version)
is cast on both sides of the valve. This is usually the
flow direction. If the flow direction and the tight direction can be opposite to each other, the piping plan must
be checked for the correct position.
Check that the unbroken side of the ball faces the seat
when the valve is in the CLOSED position.
dimensional drawing of the valve.
There should be enough free space around the valve
so that the actuator can be removed and the valve dismantled without detaching the valve from the pipeline.
Check that the indicator arrow on the actuator is parallel to the ball flow opening.
The actuator must not touch the pipeline or any permanent structures, because pipeline vibration may damage it or interfere with its operation. If the pipeline
drawings show a support for the actuator, the support
must be installed.
Make sure that the valve is in the OPEN position when
welding a weld end valve into the pipeline.
Note! A valve equipped with a BJ actuator is in the
CLOSED position when it is not pressurized. Direct
compressed air into the cylinder to turn the valve open.
When welding a valve into a pipeline, protect the valve
from welding spatter, see Fig. 5. Always ground the
welding apparatus on the side of the pipeline.
4COMMISSIONING
The gland packing may leak after long storage. If the
packing leaks, tighten it steadily until the leaking stops.
Do not tighten the packing unnecessarily as this will
increase the required torque and impair the control
properties. (More information about the gland packing
in section 5.1.).
Check that the valve has been installed correctly in
relation to the flow direction.
Fig. 4Installation of the valve into the pipeline
Install the valve in the position shown in the piping
installation drawing. The position code shows the installation position that should be used when the actuator
has been installed at the factory. The position code has
been given either on the specification sheet or in the
Fig. 5Protecting the valve during welding
5SERVICING
CAUTION:
Observe the safety precautions listed in section
1.8 before starting work.
The valve can be serviced without removing it from the
pipeline. Servicing in a workshop is, however, recommended whenever possible.
If the valve is removed from the pipeline, the body must
be supported for servicing with the stem standing
upright.
The numbers in parentheses refer to the exploded view
and the parts list on pages 12 and 13, unless otherwise
61 T5 71 en
indicated.
NOTE:
If you send the valve to the manufacturer for servicing,
do not dismantle it. Clean the valve. If the medium is
dangerous, inform the manufacturer when you send
the valve.
5.1Gland packing
The gland packing of the valve may be made of graphite with a PTFE finish or it may be a model where the
lowest graphite ring has been replaced with a metallic
O-ring sleeve, see Fig. 6. If the gland packing is tightened too much, the control properties of the valve may
suffer. The need to tighten the packing may be reduced
by means of the O-rings.
Even if the O-rings were damaged, there will be enough
graphite rings to enable tightening of the packing and
to ensure reliable operation.
The standard is a graphite gland packing with a PTFE
finish.
graphite
O-ring
Fig. 7Using a special tool to remove the gland
packing
5.2Dismantling the valve
CAUTION:
Do not dismantle the valve or remove it from the
pipeline while the valve is pressurized!
❑Remove the actuator and the actuator mounting
shelf.
❑Remove the key (10). Check that there are no
burrs on
❑the edges of the key slot.
❑Loosen the gland packing by unscrewing the
nuts (18).
❑Remove the hexagon nuts (16) on the bonnet.
❑Lift the bonnet. You may use an extractor as help,
see Fig. 8.
Fig. 6Gland packing
5.1.1Changing the gland packing
CAUTION:
Do not dismantle the valve or remove it from the
pipeline while the valve is pressurized!
❑Remove the actuator.
❑Make sure the valve is not pressurized.
❑Detach the gland (9).
❑Remove the old packing rings (69), see Fig. 7.
❑Clean the packing ring counterbore.
❑Check that there are no burrs on the edges of the
key slot.
❑Install the new packing rings one by one using
the gland as a tool.
❑Tighten the gland packings uniformly.
If the packing has O-rings, lubricate them with silicone
grease before installation. Put the outer O-ring on the
bottom of the packing ring counterbore and the inner
O-ring on the gland.
Cover the stem key slot with tape, a plastic bag or other
similar material that protects the O-ring when you push
the gland over the key slot.
Fig. 8Detaching the bonnet
❑Turn the valve ball 180 degrees from the
CLOSED position, see Fig. 9.
❑Lift the ball. Check that the unbroken side of the
ball does not rest on the seat, see Fig. 10.
❑Remove the seat (7). You may use a tool to pull
out a seat that has been installed by means of Orings, see Fig. 11.
5.3Assembly
Check all sealing surfaces with care. If necessary, lap
the sealing
surfaces with diamond powder and thereafter with
water sanding
1 T5 71 en7
Fig. 9Turning the ball
Fig. 10Lifting the ball from the body
Fig. 12Installing the seat
5.3.1.1 A-seat, Figure 13
❑Check the sealing surfaces.
❑Install the back seal (130) on the seat (7).
❑Install the ring (129).
❑Install the spring (62) into the seat body.
❑Install the support ring (35).
❑Spread some anticorrosive agent, e.g. Cortec
VCI-369, in the seat recess of a carbon steel
body.
❑Push the seat into its place.
Fig. 11Using a tool to pull out the seat
paper no. 1200. Clean all parts carefully.
Spray the sealing surfaces of the ball and the seat
thinly with e.g. Molykote 321R dry lubricant. Wipe the
surfaces with a soft cloth after the lubricant has dried.
Check the gland packing. If it shows any signs of dam-
age, remove it and clean the packing ring counterbore.
Do not install a new gland packing until you have put
the bonnet back.
5.3.1Installing a seat
The same seat selection is available for all Top 5 series
valves. The dimensions of seat recesses have been
standardized to be of equal sizes since June, 1990.
Push the seat into the body by hand; the final installa-
tion is done using a tool (in the reverse order compared
Fig. 13A seat
5.3.1.2 F-seat, Figure 14
❑Check the sealing surfaces.
❑Check the sealing surfaces at the ends of the
spring (62).
❑Check the spring countersurface in the body.
❑Spray both ends of the spring and their counter-
surfaces thinly with dry lubricant.
❑Install the spring on the seat (7).
❑Spread some anticorrosive agent, e.g. Cortec
VCI-369, on the countersurface of the spring in a
carbon steel body.
❑Push the seat into its place.
81 T5 71 en
❑Install the O-ring (63).
❑Install the support ring (64) into its groove. Cut
the ribbon ends diagonally to make a flexible
seam.
❑Only in the Fire Safe version:
❑Install the back seal (130) and the ring (129). See
Fig. 17.
❑Install the spring (62) into the seat body (7).
❑Install the spring support ring (131).
Fig. 14F seat
5.3.1.3 G-seat, Figure 15
❑Check the sealing surfaces.
❑Lubricate the O-rings (63, 75) with silicone
grease before installation.
❑Install the O-ring (63).
❑Install the support rings (64) into their groove.
Cut the ribbon ends diagonally to make a flexible
seam.
❑Install the back seal (130) and the ring (129).
❑Install the spring (62) into the seat body (7).
❑Install the O-ring (75).
❑Install the support ring (76) into its groove. Cut
the ribbon ends diagonally to make a flexible
seam. See Fig. 15.
❑Spread some anticorrosive agent, e.g. Cortec
VCI-369, on the seat recess of a carbon steel
body.
❑Push the seat into its place.
Fig. 16R-seat. Delivered after 4/95 only as a spare
part.
The G-seat has been replaced with the A-seat
Deliveries of the G-seat ceased in 1990
Fig. 15G seat
5.3.1.4 R-seat, Figures 16 and 17
❑Check the sealing surfaces.
❑Lubricate the O-ring (63) with silicone grease
before installation.
Fig. 17R-seat (Fire Safe)
5.3.1.5 E1-seat, Figure 18
❑Check the sealing surfaces.
❑Install the back seal (130) on the seat (7).
❑Install the ring (129).
❑Install the spring (62) into the seat body.
❑Install the ring (133).
❑Install the seal (135).
❑Install the support ring (35).
❑Spread some anticorrosive agent, e.g. Cortec
VCI-369, in the seat recess of a carbon steel
body.
❑Push the seat into its place.
1 T5 71 en9
using a press-on fit. See Fig. 20.
If the surfaces are badly damaged and cannot be
‘restored’ using an abrasive cloth, the bearings and the
ball must be replaced.
When installing new bearings (4, 5), lock them securely
to the bonnet and the body using a nail punch.
thrust bearing (4)
bearing (60)
sleeves made of
Fig. 18E1-seat
5.3.2Installation of bearings
Check the bearings and the bearing surfaces. If neces-
sary, grind the bearing surfaces with an abrasive cloth
and replace worn bearings. Spray the bearing surfaces
special steel have been
installed in the ball
using a press-on fit
Fig. 20Heat-resistant bearings
5.3.3Installing the ball
(5, 61)
lightly with dry lubricant.
If the ball surface has deep scratches that cannot be
5.3.2.1 Standard bearings
The bearing material is PTFE reinforced with an acid-
resistant steel
net. If the bearings are so worn that the net is visible on
the wear
surface, you should replace the bearings (60, 61, 89,
94). See Fig. 19.
removed using an abrasive cloth or if it is not completely round, you should send the ball to the manufacturer for repair.
Adjust the seat to the ball by lapping them together with
diamond powder before you install the ball (and the
seat) into the body.
Install the ball into the body with the ‘cut’ side against
the seat. Take care not to damage the bearing and the
seat with the ball. In valves that have PTFE bearings
and have a size of 6" or more, the bearings (94, 61, 5)
are ready-fitted on the ball and locked using a lock ring
bearing (60)
(27).
When the ball is in its place, turn the ball against the
seat and check visually that the ball has enough room
to complete the operating circle and that it turns easily
thrust bearing (89)
(61, 94)
against the seat.
5.3.4Installing the bonnet
The bonnet is installed in the reverse order compared
to the disassembly, see section 5.2. Spray the bolts
lightly with Molykote 321R dry lubricant.
Fig. 19Standard bearings
Twist the bonnet gasket (graphite ribbon) around two
times so that the ends overlap for about 25 mm, see
5.3.2.2 Heat-resistant bearings
Fig. 21.
The position of the ball in the direction of the stem is
determined by means of the bearings (4, 60). Pipeline
pressure causes a pressure force towards the cross
section of the ball stem; this force removes the clear-
ances against the bearings (4, 60) supported on the
bonnet.
The bearings (4, 5) are precision-machined cobalt
based alloy sleeves.
The bearing countersurface is a sleeve (60, 61) of spe-
cial steel, which has been installed against the ball
101 T5 71 en
Fig. 21Installing a gasket for the bonnet
Pull at the stem to make the ball perpendicular. The
bonnet settles in the correct position, and the necessary pre-compression between the ball and the seat is
achieved, see Fig. 22.
CAUTION:
Pressure testing should be carried out using
equipment conforming to the correct pressure
class!
We recommend that the valve body be pressure tested
after the valve has been assembled.
The pressure test should be carried out in accordance
with an applicable standard using the pressure rating
required by the pressure class or flange bore of the
valve. The valve must be in an open position during the
test.
If you also want to test the tightness of the closure
member, contact the manufacturer.
7INSTALLING THE ACTUATOR
CAUTION:
Beware of the cutting movement of the ball!
Installation of the actuator must not cause bearing
loads on the valve. The valve has two bearings, and the
actuator serves as the third bearing. They must all be
aligned.
Fig. 22Adjusting the bonnet by pulling at the ball stem
Tighten the bonnet nuts crosswise as shown in Table 2.
Stages 1 to 4: all bolts are tightened crosswise.
Stage 5: the bolts are tightened in succession along the
circumference.
Install the gland packing as explained in section 5.1.
final
Stage 2
0,5xM
(Nm)
10
50
50
50
90
200
200
200
415
415
415
final
Stage 3
0,8xM
(Nm)
16
80
80
80
145
320
320
320
665
665
665
final
Stage 4
1xM
final
(Nm)
20
100
100
100
180
400
400
400
830
830
830
Stage 5
1xM
final
(Nm)
20
100
100
100
180
400
400
400
830
830
830
If the actuator causes extra torsion on the stem, it is
seen as increased need for torque and impaired control properties.
More detailed information on actuators can be obtained
from the installation, operation and maintenance
instructions for each actuator type.
7.1Installing the BC/B1C-series
actuator
❑Drive the actuator piston to the extreme outward
end and turn the valve into the closed position.
❑Clean the stem bore and file off any burrs.
❑If a coupling is needed between the actuator and
the valve stem, install it into the stem bore. Lubricate the coupling and stem bore. Note the correct position. The line at the end of the stem
indicates the direction of the ball flow bore.
❑Fasten the bracket loosely to the valve.
❑Push the actuator carefully onto the valve stem.
Avoid forcing it, since this may damage the ball
and seats. We recommend mounting the actuator so that the cylinder is pointing upwards.
❑Align the actuator as accurately as possible
using the valve as help. Lubricate the mounting
1 T5 71 en11
screws. Install the washers and tighten all
screws. Final tightening may not change the
position of the fixture.
❑Adjust the ball open and closed positions (limits
to piston movement) by means of the actuator
stop screws (see Fig. 23). An accurate open
position can be seen in the body flow bore.
Check that the yellow arrow indicates the direction of the ball flow bore. "Times"Keep your fin-
gers out of the flow bore!
There is no need to adjust the stop screw if the actuator
is re-installed in the same valve. Drive the actuator piston to the housing end (open position). Turn the actuator by hand until the valve is in the open position
(unless it is already open). Fasten the actuator in this
position.
❑Check the tightness of the stop screw at the end
of the cylinder during cylinder operation. An O-
ring is used for sealing.
❑Check that the actuator is functioning correctly.
Check the ball flow bore position and the actua-
tor movement relative to the valve (clockwise:
close, counterclockwise: open) after installing
the actuator. The valve should be closed when
the piston is in the extreme outward position.
❑Check that the yellow arrow indicates the direc-
tion of the flow bore. If necessary, change the
position of the arrow.
7.2.1BJ/B1J-type
Install the actuator so that the piston is in the extreme
outward position. The cylinder must not be pressurized
and air supply connections must be open. The valve
must be in the closed position.
7.2.2BJA/B1JA-type
Install the actuator so that the piston is in the cylinderend position at housing side. The cylinder must not be
pressurized and the air supply connection must be
open. The valve must be in the open position.
The rest of the installation procedure is the same as for
the BC/B1C actuator.
8ORDERING SPARE PARTS
When ordering spare parts, always include the following information:
❑type code, sales order number, serial number
(stamped on a valve body)
❑number of the parts list, part number, name of
the part and quantity required
This information can be found from the identification
plate or documents.
Limiting screw for the
CLOSED position
Limiting screw for the
OPEN position
Fig. 23Open and closed position in a B1 actuator
7.2Installing the BJ/B1J-series actuator
Spring-return actuators are used in applications where
valve opening or closing movement is needed in case
the air supply is interrupted. The BJ/B1J type is used
for spring-to-close operation; the spring pushes the piston towards the cylinder end, the extreme outward
position. In turn, the BJA/B1JA type is used for springto-open operation; the spring is between the piston and
the cylinder end and pushes the piston towards the
housing.
Spring-return actuators are installed in a manner similar
to BC/B1C-series actuators, taking into account the following.
121 T5 71 en
9EXPLODED VIEW
1 T5 71 en13
10PARTS LIST
ItemQty.DescriptionSpare part category
1 1 Body
3 1 Ball 3
4 1 Thrust bearing 3
5 1 Trunnion bearing 3
7 1 Seat 2
8 1 Bonnet
9 1 Gland
10 1 Key 3
11 Stud
12 Stud
14 Stud
15 Hexagon nut
16 Hexagon nut
18 Hexagon nut
19 1 Identification plate
20 2 Screw
27 1 Lock ring
35 1 Support ring 2
60 1 Bearing 3
61 1 Bearing 3
62 1 Spring 2
63 1 O-ring
64 1 (G-seat: 2) Support ring
65 1 Gasket 1
69 Gland packing 1
75 1 O-ring
76 1 ( 4") Support ring
89 1 Thrust bearing 1***
94 1 Thrust bearing 1***
125 1 O-ring sleeve
129 1 Ring 2
130 1 Back seal 2
131 1 Spring retainer
133 1 Ring
135 1 Seal
Spare part category 1: Recommended soft parts, always needed for the repair. Delivered as a set.
***) Bearing set
Spare part category 2: Parts for replacing of the seat. Delivered as a set.
Spare part category 3: Parts for replacing of the closing element.
Spares for the full overhaul: All parts from the categories 1, 2 and 3
141 T5 71 en
11DIMENSIONS AND WEIGHTS
T5D-BC, B1C
Type DN A _B _D F G H I J V X NPT kg
T5D01 - B1C6 25 197 124 25 400 260 335 215 191 36 90 1/4 14
T5D01 - B1C9 25 197 124 25 455 315 330 220 192 43 110 1/4 20