FlowTop General Service Control Valves - Flowserve

1 Valtek No. 18506360-1ing instruction, product documentation or on theproduct itself) is essential, in order to avoid faults,which in themselves might directly or indirectly causesevere personal injury or property INFORMATIONThe following instructions are designed to assist inunpacking, installing and performing maintenance asrequired on FlowTop General Service Control users and maintenance personnel should thor-oughly review this bulletin prior to installing, calibrating,operating, troubleshooting or performing any mainte-nance on the valve or actuator. Separate instructionscover additional features such as positioners, solenoidvalves, limit switches, avoid possible injury to personnel or dam-age to valve parts, WARNING and CAUTION notes must be strictly followed.

2 Modifying thisproduct, substituting non-factory parts or us-ing maintenance procedures other than out-lined could drastically affect performance andbe hazardous to personnel and equipment andmay void existing : The FlowTop is a General Service , light-duty valve and is not intended for severe ser-vice applications such as cavitation, flashing orextreme noise levels. Refer to the FlowTop Con-trol Valves technical bulletin for applicationguidelines and other : Standard industry safety practicesmust be followed when working on this or anyother process- Control product. Specifically, per-sonal protection and lifting devices must be usedas : Selecting the proper fastener material is theresponsibility of the user. Typically, the supplier doesnot know the valve Service conditions or user therefore must consider the material sresistance to stress corrosion cracking in additionto General corrosion.

3 As with any mechanicalequipment, periodic inspection and maintenanceis CONCERNING SAFETYThe safety terms DANGER, WARNING, CAUTION andNOTE are used in these instructions to highlight par-ticular dangers and/or to provide additional informationon aspects that may not be readily : indicates that death, severe personalinjury and/or substantial property damage willoccur if proper precautions are not : indicates that death, severe personalinjury and/or substantial property damage canoccur if proper precautions are not : indicates that minor personal injuryand/or property damage can occur if proper pre-cautions are not : indicates and provides additional technicalinformation, which may not be very obvious even toqualified personnel.

4 Compliance with other, not par-ticularly emphasized notes, with regard to transport,assembly, operation and maintenance and with re-gard to technical documentation ( , in the operat-Table of ContentsGeneral Information .. 1 Unpacking .. 2 Valve Installation .. 2 Preventive Valve Maintenance .. 2 Overhauling Procedure .. 3 Actuator Removal .. 3 Mounting Actuator .. 3 Replacing Plug .. 4 Replacing Seat Ring .. 5 Packing Replacement .. 5 Reversing Single Actuator Action .. 12 Actuator Service .. 12 Diaphragm Replacement .. 12 Stem Seal Assembly Replacement .. 12 Actuator Mounting .. 12 Air Supply .. 15 Troubleshooting, Actuator/Valve .. 15 FlowTop General ServiceControl ValvesIM049 FlowTop , 12:34 PM160-2 Flowserve Corporation, Valtek Control Products, Tel.)

5 USA 801 489 8611 NOTE: The air supply should conform to ISA specific positioner IOM for : On Valves equipped with air filters,the air filter bowl must point down otherwise,the air filter will not perform Excessive piping stresses, if transmitted to the valvebody, may cause plug friction, seat leakage or otheroperating : Every effort should be made to minimizeexternal stresses on the valve during VALVE MAINTENANCEAt least once every six months, check for proper op-eration by following the preventative maintenance stepsoutlined below. These steps can be performed whilethe valve is in-line and, in some cases, without inter-rupting Service . If an internal problem is suspected, re-fer to the Overhauling Look for signs of gasket leakage through the endflanges and bonnet.

6 Tighten flange and bonnetbolting (if required). (See Table II.)2. Ensure the air supply is within the specified rangeindicated on the nameplate. Insufficient orexcessive air supply can affect valve Examine the valve for damage caused by corrosivefumes or process Clean valve and repaint areas of severe Check packing box bolting for proper nuts should be slightly over finger-tight;however, tighten only as necessary to prevent : Do not overtighten packing. This cancause excessive packing wear and high stemfriction that may impede stem If possible, stroke the valve and check for smooth,full-stroke operation. Unsteady stem movementcould indicate an internal valve : Keep hands, hair, clothing, etc.

7 Awayfrom all moving parts when operating the to do so can cause serious Ensure all accessories, brackets and bolting arefastened If possible, remove air supply and observe actuatorfor correct fail-safe Check the actuator stem seal assembly (257) forwear or leakage. Apply an acceptable lubricant(such as Dow 55) to the actuator stem then retractand extend the stem to work the lubricant intothe While unpacking the valve, check the packing listagainst materials received. Lists describing thevalve and accessories are included in each When lifting the valve from the shipping container,position lifting straps to avoid damage to externaltubing and mounted Contact your shipper immediately if shippingdamage has Should any problem arise, contact your : Before installation and disassembly,ensure the actuator is secured with a suitablemethod (crane or support) and cannot This valve can be installed in alternate serviceconditions.

8 Check data on name plate and verifysizing with local Flowserve Before installing the valve, clean the line of dirt,welding chips, scale or other foreign Whenever possible, the valve should be installedin an upright position; vertical installation permitseasier valve maintenance. (See Figure 1.)4. Be sure to provide proper overhead clearance forthe actuator to allow for disassembly of the plugfrom the valve body. Refer to Table I for theclearance needed for valve I: Overhead Clearance RequirementValve SizeClearance(inches)(inches / mm)1, , 2, 3, / 1423, / 2295. Double-check flow direction to ensure the valveis installed with the flow under the plug. Flowdirection is shown by the arrow on the Connect the air supply and instrument signal Control Valves may be equipped with avalve positioner.

9 In most cases, both the actuatorand positioner are suitable for a maximum of 90 psi(6 bar) air supply. However, with tandem actuators,the air supply to the actuator assembly must belimited to 50 psi ( bar). Check the nameplate todetermine the correct air supply : Tandem actuators require a maxi-mum of 50 psi ( bar) air supply. Checknameplate to determine correct air FlowTop , 12:34 PM2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 861160-3 Mounting actuator on valve1. Determine the stroke length of the valve, (20 mm) or " (40 mm). Check thestroke plate (213) to verify if Push the plug stem down into the seat by hand tofully close the Replace the complete actuator. Clean the threadson the bonnet, using a light oil or fluid.

10 Replace thecomplete actuator onto the bonnet and install yokenut Connect an adjustable air supply to the On direct-acting actuators (air-to-close / fail-open):Apply sufficient air pressure to the actuator toextend the actuator stem (211) to 100 percent ofstroke ( or ). Using a scale,measure and verify the stroke of the actuator stem travel once full stroke has been the stem in this positioner, adjust the two stemclamp halves and connect them using the stemclamp On reverse-acting actuators (air-to-open / fail-closed): Retract the actuator stem (211) until it stopsagainst the upper diaphragm case (203). From thisposition, using an adjustable air supply and a scale,measure and verify the valve stroke.