Flowserve ColdFlow 341000 Bedienungsanleitung

Kämmer Series 341000 FCD KMENIM4104-01 03/18

Experience In Motion

Maintenance

USER INSTRUCTIONS

ColdFlow - 341000

Cryogenic Control Valves 4K

FCD KMENIM4104-01 03/18

Kämmer Series 341000 FCD KMENIM4104-01 03/18

1 USING KÄMMER VALVES AND ACTUATORS CORRECTLY

1.1 General

The following instructions are designed to assist in installing and performing maintenance as required on FLOWSERVE

Kämmer products. Product users and maintenance personnel should Thoroughly review this maintenance instruction prior

to installing and prior to performing any maintenance on the product.

DANGER: Please review also the general Installation and Operational Manual (IOM) for general safety instructions.

1.2 Terms concerning safety

The safety terms DANGER, WARNING, CAUTION and NOTE are used 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.

STOP!

WARNING: indicates that death, severe 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.

Compliance with other, not particularly emphasized notes, with regard to transport, assembly, operation and maintenance

and with regard to technical documentation (e.g. in the operating instruction, product documentation or on the product

itself) is essential, in order to avoid faults, which in themselves might directly or indirectly cause severe personal injury or

property damage.

STOP!

Contents

1 Using Kämmer Valves And Actuators Correctly

2 Initial Installation

3. Trim Parts

4 Actuator

5 Identiﬁcation

6 Spare Parts

7 Technical Tables

8 Trouble Shooting

Kämmer Series 341000 FCD KMENIM4104-01 03/18

2 INITIAL INSTALLATION

2.1 Unpacking

2.1.1 Valve and Actuator are delivered separately. This

allows for more compact transport boxes and easier

installation. After unpacking the valve and actuator,

clearly mark the parts for proper assembly. The trim is

installed inside the valve body to avoid damage during

transport. To remove the trim assembly from the valve

please refer to section 3.1

2.1.2 Marking (ﬁgure 1)

Valve components have been marked with the serial

number in order to allow a proper disassembly and

assembly. The valve body is marked on top of the

cover plate (1.1), trim kit at the upper part of the

extension(1.2) and the bonnet on the side (1.3). All

relevant technical data is shown on a stainless steel

nameplate attached to the actuator. See also section 5

Identiﬁcation.

2.2 Preparation for vacuum box installation (ﬁgure 2)

2.2.1 After trim has been removed from the valve body (see

chapter 3.1) mount the installation ﬂange (2:1) on the

bonnet ﬂange thread of the valve.

CAUTION: Please ensure that the mounting ﬂange has

been tightened with the correct torque (see table 7.3).

2.2.2 Attach hoisting equipment of adequate lifting capacity

to the hoisting lug (3:1) and lower the valve body into

the vacuum box. See also table 7.2 for approximate

maximum weights of this subassembly.

CAUTION: take care when lowering the valve

subassembly into the vacuum box.

Mounting (ﬁgure 3)

Insert the mounting Tool (3.1) between the valve

cover plate (3.2) and the mounting ﬂange (3.3) before

reaching the ﬁnal position inside the box.

Figure 1: Marking

Figure 2: Mounting Preparation

Figure 3: Mounting

1.2

1.3

2.1

3.1

3.2 3.3

1.1

Kämmer Series 341000 FCD KMENIM4104-01 03/18

2.3 Welding

2.3.1 Pipe connections

Position the valve inside the vacuum box and secure it

with the mounting tool. The pipe connections for inlet

and outlet can now be welded.

NOTE: Ensure that the trim internals are removed and

that the mounting ﬂange is the correct size.

For the standard pipe sizes refer to table 7.2 BW (mm).

2.3.2 Welding cover plate (ﬁgure 4)

With the mounting tool (4.1) in position tack weld the

cover plate to the vacuum box to secure it‘s position.

Rotating the mounting tool will provide space for the

tack welding.

NOTE: ensure the valve can move freely and is not

under tension while welding it to the vacuum box.

Damage to trim and trim guiding may occur.

Remove the mounting tool (4:1)and weld the entire

circumference of the cover plate to the vacuum tank.

2.4 Pressure testing

After welding all the valves into the vacuum tank

perform a pressure test with all valves. For this all

valves must be ﬁtted with mounting ﬂanges. This

mounting ﬂange has a dual purpose: ﬁrstly it assists

in mounting the valves into the vacuum tank and

secondly to seal the valve at the bonnet connection in

order to pressurize the piping system without the trim

assemblies and actuators mounted.

CAUTION: Ensure all mounting ﬂanges are in place and

properly tightened. A loose mounting ﬂange cannot

sustain the pressure and will result in unwanted or

unsecure leakage.

2.5 Cleaning

With the mounting ﬂanges in place, clean and purge the

entire piping system with a cleaning media to remove

dirt and welding residues from the system.

2.6 Remove mounting ﬂanges (Figure 5)

After completing all tests, cleaning and mounting

procedures, remove all mounting ﬂanges (5.1) and

spacer plates (5.2) from the valves. Flowserve Essen

offers a refund system for returning the mounting

ﬂanges and mounting tools after use. For further details

please contact Flowserve Essen Order administration.

Figure 4: Cover Plate Welding

4.1

Figure 5: Remove Mounting Flange

5.1

5.2

Kämmer Series 341000 FCD KMENIM4104-01 03/18

3. TRIM PARTS

3.1 Remove Trim assembly

3.1.1 Remove actuator (See section 4)

3.1.2 Remove bonnet (ﬁgure 6)

3.1.3 Unscrew the bonnet (6.1) counter clockwise with a

suitable tool and carefully remove the bonnet from

the stem.

CAUTION: do not rotate the stem in any direction.

Severe damage to the bellows seal and/or the trim

assembly may occur.

3.1.4 Carefully remove the trim assembly (7.1) - consisting

of bellows seal, extension and plug - from the valve

housing (Figure 7)

CAUTION: do not rotate the trim assembly within the

valve body. Remove the trim assembly in an upright

position avoiding any contact of the trim assembly with

the valve housing. Severe damage of the bellows seal

and/or the trim assembly may occur.

3.2 Install Trim assembly (Figure 8)

3.2.1 Insert body O-Ring seal (8.1)

3.2.2 Carefully insert trim assembly (8.2) into valve housing.

CAUTION: do not rotate the trim assembly within the

valve body in any direction. Insert the trim assembly

in an upright position. Avoid any contact of the trim

assembly with the valve housing. Severe damage of

the bellows seal and/or the trim assembly may occur.

3.2.3 Bonnet assembly

(Figure 9)

Carefully place the bonnet (9.1) over the stem (9.2)

and tighten the bonnet clockwise with the suitable tool

to the correct torque (see table 7.3). Ensure that

the

wiper ring (9.3) seats correctly on the stem

Figure 6: Bonnet

6.1

7.1

Figure 7: Trim Assembly

Figure 8: Body O-Ring

8.1

8.2

Figure: 9 Bonnet assembly

9.1

9.2

9.3

Kämmer Series 341000 FCD KMENIM4104-01 03/18

3.3 Disassemble trim assembly (ﬁgure 11)

3.3.1 The trim assembly consists out of 3 parts: the stem

with bellows (11.1), the extension (11.2) and the plug

(11.3). All three components can be disassembled and

replaced individually. These parts are secured with pins

(11.4). To remove the pins carefully drive them out by

a suitable tool. When replacing one or more parts of

the assembly always use new pins (see spare parts

table) and make sure that they are in place and secure.

Figure 10: Trim Assembly

Figure 11: Trim Parts

11.1

11.2

11.3

11.4

Kämmer Series 341000 FCD KMENIM4104-01 03/18

4 ACTUATOR

4.1 KP Diaphragm Actuator

4.1.1 First Installation after unpacking (ﬁgure 12)

ColdFlow Series 341000 will be delivered in two parts:

valve subassembly and actuator. Especially for small

sizes the mounted actuator might cause damage to

the valve. Also for welding the valve into the vacuum

cold box actuator and trim must be removed from the

valve body.

Remove the locknut (12.1) from the valve bonnet.

Place the actuator with the installed yoke plate (12.2 )

onto the valve bonnet. Before connecting the coupling

(12.3) slip the locknut over the valve stem (12.4)

and screw the locknut onto the bonnet thread. For

tightening torques please refer to chapter 7.3

CAUTION: Be careful while placing the yoke plate over

the stem. Damage of the stem and/or the entire trim

assembly may occur.

NOTE: Make sure that the Serial Number of the valve

(engraved at the bonnet) and of the actuator (Tag plate)

correspond to each other.

4.1.2 Removing for repair or maintenance (ﬁgure 13)

We recommend separating the actuator from the valve

during all repair work. However, many maintenance

and adjusting operations can be carried out in an

installed condition.

4.1.2.1 Shut off air supply

4.1.2.2 Disconnect all air tubing from the actuator

4.1.2.3 Remove and install actuator (ﬁgure 14)

Typically for a quick removal of the actuator the 2 yoke

nut screws (14.1) are removed. After this remove the

coupling screws (14.2) from the coupling and take off

both coupling parts.

NOTE: If there are accessories such as positioners and/

or limit switches connected to the coupling, please

carefully disconnect the lever or if necessary the entire

accessory.

NOTE: Ensure that the plug assembly is not rotated

with the plug seated. This may cause irreparable

damage to the seating faces.

Figure 12: Actuator Mounting

12.1

12.2

12.3

12.4

Figure 13: Actuator Assembly

Figure 14: Remove and install actuator

14.1

14.2

Kämmer Series 341000 FCD KMENIM4104-01 03/18

4.1.3 Install Actuator (ﬁgure 15)

The actuator stem must be fully extended:

Actuators with air-to-open action must be fully vented.

Actuators with air-to close action apply pressure.

Manually depress the plug stem to ensure the plug is

fully seated.

4.1.3.1 Screw coupling insert locknut (15.1) and coupling

insert (15.2) as far as possible onto plug stem (15.3)

4.1.3.2 Place the actuator assembly on the valve engaging the

yoke rod threads in the lower yoke plate (15.4) and

ensuring the actuator faces in the right direction.

4.1.3.3 Unscrew the coupling insert until the lower yoke rods

are raised from the lower yoke plate by around 2 mm.

NOTE: Ensure that the plug assembly is not rotated with

the plug seated. This may cause irreparable damage to

the seating faces.

4.1.3.4 Reﬁt the coupling (ﬁgure 16)

Reﬁt the coupling (16.1), ensuring that the arrows

(16.2 ), embossed on the coupling halves, point upward

towards the actuator, and secure with 2 coupling

screws (16.3).

4.1.3.5 Apply supply pressure respectively vent actuator to

50% stroke and reﬁt and tighten yoke nuts.

4.1.3.6 Connect all tubing.

Figure 15: Install Actuator

15.115.2

15.3

15.4

16.1 16.2

16.3

Figure 16: Reﬁt the Coupling

Kämmer Series 341000 FCD KMENIM4104-01 03/18

4.2 FlowAct Actuator

4.2.1 First Installation (ﬁgure 17)

The FlowAct actuator is equipped with a casted yoke,

for all assembly and disassemble the entire actuator

including the yoke must be installed or removed.

Remove the locknut (17.1) from the valve bonnet. Place

the actuator and yoke assembly (17.2 ) onto the valve

bonnet. Before connecting the coupling (17.3 ) slip

the locknut over the valve stem (17.4 ) and screw the

locknut onto the bonnet thread. For tightening torques

please refer to chapter 7.3

CAUTION: Be careful while putting the yoke plate

through the stem. Damage of the stem and/or the

entire trim assembly may occur.

NOTE: Ensure that the serial sumber of the valve

(engraved at the bonnet) and actuator (Tag plate)

correspond to each other.

4.2.2 Removing for repair or maintenance

We recommend separating the actuator from the valve

during all repair work. However, many maintenance and

adjusting operations can be carried out in an installed

condition.

4.2.2.1 Shut off air supply

4.2.2.2 Disconnect all air tubing from the actuator

4.2.2.3 Remove actuator coupling (ﬁgure 18)

NOTE: If there are accessories such as positioners and/

or limit switches connected to the coupling, please

carefully disconnect the lever or if necessary the entire

accessory. Remove four screws (18.1) from the upper

coupling half.

4.2.2.4 Remove locknut (18.2)

NOTE: The lower coupling half is still connected to the

stem and can’t be removed from the actuator at this

stage.

4.2.2.5 Carefully raise the actuator assembly vertically around

40 mm. Be aware that most of the FlowAct actuators

are heavy, please use suitable lifting equipment.

4.2.2.6 Remove the lower coupling half (18.3) counter

clockwise from the stem.

NOTE: Ensure that the plug assembly is not rotated with

the plug seated. This may cause irreparable damage

to the seating faces and/or the bellows seal.

Figure 17: Actuator Mounting

Figure 18: Remove and install actuator

17.2

17.1

17.4

17.3

18.2

18.1

18.3

Kämmer Series 341000 FCD KMENIM4104-01 03/18

4.2.3 Installation

The actuator stem must be fully extended. Actuators

with air-to-open action must be fully vented. Actuators

with air-to close action apply pressure. Manually

depress the plug stem to ensure the plug is fully

seated.

4.2.3.1 Using suitable lifting equipement, carefully place the

actuator onto the valve assembly. Before the actuator

is fully lowered slip the locknut onto the bonnet and

thread on the lower coupling half onto the stem.

4.2.3.2 Tighten the locknut. For tightening torques please refer

to chapter 7.3

4.2.3.3 Reinstall the coupling

4.2.3.4 Connect all tubing

Figure 19: Actuator Assembly

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