Baker Hughes Masoneilan 41005 Series Bedienungsanleitung

Baker Hughes Data Classication : Public

41005 Series

Cage Guided Globe Valve with Lo-dB

Anti-cavitation/API 6A capabilities

Instruction Manual (Rev. G)

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC

REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND

MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BAKER HUGHES

COMPANY (AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES,

BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE

REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY

HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN

CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR

REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO

PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION

OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE

WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD

BE REFERRED TO BAKER HUGHES.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE CUSTOMER/OPERATOR ARE

STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE

EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY BAKER HUGHES REGARDING THE

EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE

INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS

DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF

BAKER HUGHES.

Masoneilan 41005 Series Globe Valves with API-6A Capabilities Instruction Manual | 3

Table of Contents

Safety Information and Warranty ...................................................6-7

1. General....................................................................... 8

1.1 Scope ......................................................................................8

1.2 Serial Plate ..................................................................................8

1.3 After Sales Service ...........................................................................8

1.4 Spare Parts .................................................................................8

1.5 Actuator and Other Accessories .................................................................8

2. Numbering System ............................................................. 9

3. Installation ....................................................................10

3.1 Cleanness of Piping ..........................................................................10

3.2 Isolating By-Pass Valve .......................................................................10

3.3 Heat Insulation ..............................................................................10

3.4 Hydraulic Test and Cleaning of Lines ............................................................10

3.5 Flow Direction ..............................................................................10

4. Disassembly ..................................................................11

4.1 Removal of Actuator ..........................................................................11

4.1.1 Disconnection of Instruments ..............................................................11

4.1.2 Plug stems screwed into the actuator stem ...................................................11

4.1.3 Stems attached with a stem connector ......................................................11

4.1.4 Removal of actuator .....................................................................11

4.2 Opening of the Pressurized Chamber .....................................................11

4.3 Disassembly of Valve Plug Stem ................................................................12

4.4 Disassembly of the Auxiliary Pilot Plug ...........................................................12

4.5. Disassembly of 41705 HTS Plug ................................................................12

5. Maintenance – Repair ...........................................................12

5.1 Packing Box ................................................................................12

5.1.1 Braided PTFE with Carbon or Aramid Core ..................................................12

5.1.2 Flexible Graphite Rings ...................................................................13

5.1.3 Low-E Packing .........................................................................13

5.1.3.1 Preparation .........................................................................13

5.1.3 .1.1 Stem ...........................................................................13

5.1.3.1.2 Packing Box .....................................................................13

5.1.3 .1.3 Pac k ing .........................................................................13

5.1.3.2 Packing Installation .................................................................13

5.1.4 Packing Box E󰀩ciency ...................................................................14

5.2 Repair of Parts ..............................................................................14

5.2.1 Guiding Surfaces .......................................................................14

5.2.2 Seating Surfaces .......................................................................14

5.2.3 Gasket seating surfaces .................................................................15

5.2.4 Seal rings and gaskets ...................................................................15

5.2.5 Valve plug, valve plug stem ...............................................................15

6. Valve Reassembly ..............................................................15

6.1 Pinning the Valve Plug Stem ...................................................................15

6.1.1 Reference Marking on the Valve Plug Stem ..................................................15

6.1.2 Tightening of the plug stem ...............................................................15

6.1.3 Drilling the pin hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1.4 Pinning ...............................................................................15

6.2 Assembly of Ring or Spring-Energized Seal Ring ...................................................16

6.2.1 41305 Valve ...........................................................................16

6.2.2 41405 and 41505 and 41705 Valves

6.2.3 41605 Valve ...........................................................................16

6.2.4 41905 Valve ...........................................................................17

6.2.5 41375 high temperature valve .............................................................17

6.3 Valve Plug and Cage Assembly ................................................................17

6.3.1 Assembly of valve plug and auxiliary pilot plug ................................................17

6.3.2 Assembly of cage .......................................................................17

6.4 Assembly of the Parts Inside the Valve Body .................................................17

6.5 Assembly of Bonnet ..........................................................................17

6.6 Tightening of Body Stud Nuts ..................................................................18

6.7 Assembly of Packing Box .....................................................................19

7. Actuation .................................................................... 24

Type 87/88 Multi-Spring Diaphragm Actuators ..........................................................24

Type 51/52/53 Cylinder Actuators ....................................................................25

Body Sub Assembly .............................................................. 34

Appendix A - 41005 API-6A Series High Pressure Valves................................ 36

1. General ...................................................................... 36

1.1 Scope ......................................................................................36

1.2 Serial Plate ..................................................................................36

1.3 After Sales Service ............................................................................36

1.4 Spare Sparts .................................................................................36

1.5 Actuator and Other Accessories .................................................................36

1.6 Warranty ....................................................................................36

2. Installation ................................................................... 37

2.1 Cleanness of Piping ..........................................................................37

2.2 Isolating By-Pass Valve .......................................................................37

2.3 Heat Insulation ..............................................................................37

2.4 Hydraulic Test and Cleaning of Lines ............................................................37

2.5 Flow Direction ..............................................................................37

3. Disassembly ................................................................. 37

3.1 Removal of Actuator ..................................................................37

3.1.1 Disconnection of instruments ..............................................................37

3.1.2 Plug stems screwed into the actuator stem ...................................................37

3.1.3 Stems attached with a stem connector ......................................................37

3.1.4 Removal of actuator .....................................................................37

3.2 Opening of the Pressurized Chamber ...........................................................37

3.3 Disassembly of Valve Plug Stem ..................................................................38

Masoneilan 41005 Series Globe Valves with API-6A Capabilities Instruction Manual | 5

4. Maintenance and Repair ........................................................ 38

4.1 Preliminary Controls .........................................................................38

4.2 Packing Box ................................................................................38

4.2.1 PTFE Based packing ...................................................................38

4.3 Repair of Parts ..............................................................................39

4.3.1 Guiding Surfaces .......................................................................39

4.3.2 Seating Surfaces .......................................................................40

4.3.3 Gasket seating surfaces .................................................................40

4.3.4 Seal Rings and gaskets ..................................................................40

4.3.5 Valve Plug and Plug Stem ................................................................40

5. Valve Reassembly ............................................................. 40

5.1 Pinning the Valve Plug Stem ...................................................................40

5.1.1 Tightening of the plug stem ...............................................................40

5.1.2 Drilling the pin hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.1.3 Pinning ..............................................................................40

5.2 Assembly of Spring-energized Seal Ring ..........................................................41

5.3 Assembly of the Parts Inside the Valve Body .......................................................44

5.4 Assembly of the Bonnet .......................................................................44

5.5 Tightening of Body Studs .......................................................................44

6. Actuation..................................................................... 46

7. API 6A Body Sub-Assembly Cross Section..........................................47

Safety Information

Important - Please Read Before Installation

Masoneilan™ 41005 Series instructions contain

DANGER, WARNING, and CAUTION labels, where

necessary, to alert you to safety related or other important

information. Read the instructions carefully before

installing and maintaining your control valve. DANGER

and WARNING hazards are related to personal injury.

CAUTION hazards involve equipment or property

damage. Operation of damaged equipment can, under

certain operational conditions, result in degraded process

system performance that can lead to injury or death. Total

compliance with all DANGER, WARNING, and CAUTION

notices is required for safe operation.

CAUTION

WARNING

DANGER

This is the safety alert symbol. It alerts you to potential

personal injury hazards. Obey all safety messages that

follow this symbol to avoid possible injury or death.

CAUTION

WARNING

DANGER

Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION

WARNING

DANGER

Indicates a potentially hazardous situation which, if not

avoided, could result in serious injury.

CAUTION

WARNING

DANGER

Indicates a potentially hazardous situation which, if not

avoided, could result in minor or moderate injury.

CAUTION

WARNING

DANGER

When used without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided, could

result in property damage.

Note: Indicates important facts and conditions.

About this Manual

• The information in this manual is subject to change without

prior notice.

• The information contained in this manual, in whole or part,

shall not be transcribed or copied without Baker Hughes

written permission.

• Please report any errors or questions about the information

in this manual to your local supplier.

• These instructions are written specifically for the 41005 Series

control valves, and do not apply for other valves outside of

this product line.

Useful Life Period

The current estimated useful life period for the Masoneilan

41005 Series control valve is 25+ years. To maximize the

useful life of the product it is essential to conduct annual

inspections, routine maintenance and ensure proper

installation to avoid any unintended stresses on the product.

The specific operating conditions will also impact the useful

life of the product. Consult the factory for guidance on

specific applications if required prior to installation.

Warranty

Items sold by Baker Hughes are warranted to be free from

defects in materials and workmanship for a period of one

year from the date of shipment provided said items are

used according to Baker Hughes recommended usages.

Baker Hughes reserves the right to discontinue manufacture

of any product or change product materials, design or

specifications without notice.

Note: Prior to installation:

• The valve must be installed, put into service and maintained by

qualified and competent professionals who have undergone

suitable training.

• Under certain operating conditions, the use of damaged

equipment could cause a degradation of the performance of

the system which may lead to personal injury or death.

• Changes to specifications, structure, and components used

may not lead to the revision of this manual unless such

changes affect the function and performance of the product.

• All surrounding pipe lines must be thoroughly flushed to

ensure all entrained debris has been removed from the

system.

Masoneilan 41005 Series Globe Valves with API-6A Capabilities Instruction Manual | 7

Safety Information (cont.)

1. It is the end user’s responsibility to ensure properly

loaded and/or supported piping to avoid undesired

stresses on the product which may result in

damage to the product, loss of containment, or

loss of functionality and resulting unsafe states or

conditions.

2. It is the end user’s responsibility to correctly

identify end locations and place product in areas

that may contain explosive atmospheres. The

failure of properly following the test, installation,

maintenance and/or disassembly/assembly

instructions may result in a compromised product

which in turn could result in an uncontrolled/

unexpected loss of containment and release of

pressure.

3. It is the end user’s responsibility to take

appropriate actions to ensure that site personnel

who are performing installation, commissioning,

and maintenance have been trained in proper site

procedures for working with and around Baker

Hughes supplied equipment, per Safe Site Work

Practices, are the end user’s responsibility.

4. The failure of properly following the test,

installation, maintenance and/or disassembly/

assembly instructions may result in a

compromised product which in turn could result in

an uncontrolled /unexpected loss of containment

and release of pressure. It is the responsibility of

the person conducting the tasks listed above to

take great care in following such procedures.

5. It is the end user’s responsibility to:

 Recognize and safely contain any leak.

 Ensure proper Personal Protective Equipment

is available and used.

 Follow Proper lifting techniques / equipment /

procedures, per Safe Site Work Practices.

6. Proper Lockout/Tagout of energy sources prior

to maintenance, per Safe Site Work Practices, is

the end user’s responsibility. This includes any

potential control signals or circuits that may have

a remote or automated control function over any

product. Instructions to properly release spring

stored energy included in IOM.

7. After installation or maintenance, it is the end

user’s responsibility to ensure the equipment has

been properly inspected and returned to proper

condition before being returned to service.

1. General

1.1 Scope

The following instructions are designed to guide the user

through the installation and maintenance of the 41005 Series

valves for all sizes and all pressure classes.

1.2 Serial Plate

The serial plate is usually fixed to the side of the actuator

yoke. It indicates, amongst other things, the type of valve,

the pressure class, the material used for the pressurized

chamber and the air supply pressure of the actuator.

1.3 After Sales Service

Baker Hughes offers it clientele an After Sales Service

comprising highly qualified technicians, for the operation,

maintenance and repair of its equipment. To benefit from this

service, contact our local representative or the After Sales

Service whose email address is given at the end of this

document.

1.4 Spare Parts

When carrying out maintenance operations, only

manufacturer’s replacement parts must be used, obtained

through our local representatives or our Spare Parts

Service.

When ordering spare parts, the model and serial numbers

indicated on the manufacturer’s serial plate must be given.

The recommended spare parts are indicated in the parts list

included in this instruction manual on page 35.

1.5 Actuator and Other Accessories

The valve is equipped with an actuator; like all the other

valve accessories, actuators are the subject of special

instructions which provide information on the electric and

pneumatic connections. The instruction manuals to be used

for standard actuators are 19530 for types 87/88 and 31188

for types 51/52/53.

Important

This document contains all the instructions required for the installation, operation and maintenance of the equipment.

Regular maintenance, strict observance of these instructions and the use of manufacturer’s replacement parts will

guarantee optimum operation and reduce maintenance costs.

Masoneilan 41005 Series Globe Valves with API-6A Capabilities Instruction Manual | 9

2. Numbering System

Note: This instruction manual describes all the standard options in the 41005 Series valve. To satisfy the particular

conditions of your application, Baker Hughes may have had to develop a special option which is the subject of an

additional clause to this instruction manual. In this case, the instructions given in the additional clause always take

precedence over the general instructions.

2nd 3rd

4th

5th

6th

2nd

1st

Actuator Type and

action on air failure

Multispring

87 Open

88 Close

Cylinder

51 Double Acting

52 Open

53 Close

Body

Series

41 Cage

Guided,

Balanced

Globe

Seal

Type

0. Undefined

3. Pressure

Energized

PTFE Seal Ring

4. Auxiliary Shut-

off Plug (Pilot)

5. Metal Seat Ring

6. PTFE Seal Ring

7. High Temp.

Seal

9. Graphite Seal

Ring

Trim Type /

Characteristic

0. Undefined

1. Standard Cage/

Linear

2. Standard Cage/

Equal %

3. Lo-dB/Anti-

Cav Single

Stage;Linear/

Equal %

4. Lo-dB/Anti-Cav

Single Stage with

Diffuser/

Linear/Equal %

5. Lo-dB Multi-

Stage/Linear

6. VRT (stack)

Type S/Linear

7. VRT (partial

stack) Type S/

Modified

8. VRT (cage)

Type C/Linear

9. Anti-Cav Multi-

Stage/ Linear

A. High Capacity

Linear

B. High Capacity

Equal %

C. High Capacity

Lo-dB/Anti-Cav

Design

Series

Optional

Config.

A. Angle Body

EB. Extension

Bonnet

C. Cryogenic

Extension

Bonnet

3. Installation

3.1 Cleanness of Piping

Before installing the valve in the line, clean piping and valve

of all foreign material such as welding chips, scale, oil,

grease or dirt. Gasket surfaces must be thoroughly cleaned

to insure leak-free joints.

3.2 Isolating By-Pass Valve

To allow for in-line inspection, maintenance and

removal of the valve without service interruption,

provide a manually operated stop valve on each side

of the control valve and a manually operated throttling valve

in the by-pass line.

3.3 Heat Insulation

In case of heat insulated installation, do not insulate the

valve bonnet and take protection measures related to

personal safety.

3.4 Hydraulic Test and Cleaning of

Lines

During this operation, the control valve must not be used as

an isolating valve.

This means that the valve must always be opened before

carrying out pressure tests in the process line, cleaning of

pipes, etc., otherwise equipment damages or destroying of

seal rings could result.

3.5 Flow Direction

The valve must be installed so that the controlled substance

will flow through the valve in the direction indicated by the

flow arrow located on the body.

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