Flowserve Valtek CavControl Trim Leitfaden

Valtek No. 10003460 15-1

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Valtek CavControl Trim

GENERAL INFORMATION

The following instructions are designed to assist in

assembling, disassembling and troubleshooting

Valtek® globe valves equipped with CavControl™ trim.

Product users should thoroughly review this bulletin in

conjunction with Installation, Operation, Maintenance

Instruction 1 (Mark One and Mark Two Control Valves)

and Installation, Operation, Maintenance Instruction 24

(Valtek Beta Positioner) before installing, operating or

performing any maintenance on the valve.

To avoid possible injury to personnel or dam-

age to valve parts, WARNING and CAUTION

notes must be strictly followed. Modifying this

product, substituting non-factory or inferior

parts, or using maintenance procedures other

than outlined could drastically affect perfor-

mance and be hazardous to personnel and

equipment.

Installation

Standard unpacking and installation instructions are

outlined in Installation, Operation, Maintenance Instruc-

tion 1. Regardless of the air-action, valves equipped

with CavControl trim must be installed in the line with the

flow direction over the plug.

CAUTION: Improper installation will result in severe

cavitation damage to the valve.

NOTE: Flowserve recommends a strainer be installed

upstream of the valve prior to start-up. This will help

prevent debris build-up and trim fouling.

DISASSEMBLY AND REASSEMBLY

Disassembling CavControl Trim

When disassembling valves with CavControl trim, refer

to either figure 1 or 2 and proceed as follows:

WARNING: Depressurize line to atmospheric pres-

sure or remove valve from line and drain all process

fluids and decontaminate the valve (if caustic or

hazardous materials are present). Failure to follow

this warning can cause serious injury.

1. Stroke the valve to the full open position by applying

air to the lower cylinder port.

2. Remove the bonnet flange bolting and lift the ac-

tuator/plug assembly out of the valve body.

CAUTION: Lift the actuator/plug assembly

straight out of the valve body to avoid damage

to the plug head, seat ring or trim. If the actuator

is not provided with a lifting ring, use lifting

straps around the yoke legs.

WARNING: With pressure-balanced trim,

danger exists in removing the actuator/plug

assembly out of the valve body, especially if

PTFE pressure seals are used on the plug. The

pressure-balanced sleeve could bind on the

plug, allowing the sleeve to be lifted out of the

body along with the actuator/plug assembly. If

the sleeve should loosen and fall, it could cause

personal injury and damage valve parts or

nearby equipment. Step 3 outlines the correct

procedure for removing the sleeve from the

plug.

15-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

3. If the pressure-balanced sleeve binds with the plug,

carefully lift the sleeve out with the actuator/plug

assembly. Place several sturdy, soft supports (pref-

erably wood) underneath the sleeve after it clears

the body. Lower the actuator/plug assembly until

the sleeve and the supports are resting on top of the

body.

NOTE: The above procedure is designed to prevent

damage to the body should the sleeve fall during

disassembly.

To free the sleeve from the plug, apply air above the

actuator piston, extending the plug. This creates a

gap between the bonnet and sleeve. Insert wood

blocks of equal thickness in at least three positions

in this gap. Blocks should be at least 1-inch thick and

should be positioned so as to not interfere with the

plug head. Finally, retract the plug until the sleeve is

free of the plug.

4. If the sleeve has not been removed with the plug, lift

it out of the valve body.

5. Remove the seat ring and gaskets from the valve

body.

6. If the plug is pressure-balanced, remove the plug

seals.

7. If necessary, the plug may be removed from the

actuator and bonnet in accordance with the basic

valve instructions.

Reassembling CavControl Trim

When reassembling valves with CavControl trim, refer

to either Figure 1 or 2 and proceed as follows:

1. Install new bonnet and seat ring gaskets.

2. Reinstall seat ring and sleeve.

3. For pressure-balanced trim, install a new sleeve

gasket on sleeve and new plug seals on plug head.

Figure 1: Unbalanced CavControl Trim

NOTE: Item numbers correspond directly to the item numbers on the bill of material; refer to it for specific part numbers.

Bonnet Flange Bolting

(Item No. 108/114)

Bonnet Gasket

(Item No. 58)

Sleeve

(Item No. 30)

Seat Ring

(Item No. 20)

Seat Gasket

(Item No. 55)

Body

(Item No. 1)

Bonnet

(Item No. 40)

Bonnet Flange

(Item No. 70)

Plug

(Item No. 50)

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 15-3

4. Retract plug to the full-open position by applying air

to the lower cylinder port.

5. Lower the actuator/plug assembly squarely into

the valve body.

CAUTION: Lower plug squarely into sleeve to

prevent galling and scoring of trim parts. Plug

seals must be compressed, using an appropri-

ate ring compressor, until they enter the

pressure-balanced sleeve. Stagger the cuts on

the PTFE seals or the gaps on the piston ring

seals 180O(for 2 rings) or 120O(for 3 rings) to

minimize leakage.

6. Hand-tighten the bonnet flange bolting.

7. For pressure-balanced trim with PTFE seals, drive

the plug into the sleeve by applying air to the

actuator until the plug seats. Repeat operation, if

necessary, to bring the bonnet fully down into the

body.

8. Stroke the valve two or three times to ensure that

the plug and seat ring are concentrically aligned for

proper seating.

9. Apply air pressure above the actuator piston (or to

the top port) to seat the plug. This ensures that the

plug and seat ring remain concentrically aligned

during the tightening of the bonnet flange bolting.

Tighten two opposing bonnet flange bolts or nuts

1/6of a turn (one flat). Tighten all bolting in this

manner evenly and completely. Proper bonnet

gasket compression occurs when the bonnet is

seated metal-to-metal in the body. This requires

considerable force; however, the bottoming of the

bonnet metal-to-metal in the body can easily be felt

through the wrench.

CAUTION: Insufficient tightening will result in

improper seat ring gasket compression.

10. If the valve has been removed from the line, make

sure flow direction is correct upon reinstallation.

Figure 2: Pressure-balanced CavControl Trim

NOTE: Item numbers correspond directly to the item numbers on the bill of material; refer to it for specific part numbers.

Bonnet Flange Bolting

(Item No. 108/114)

Sleeve Gasket

(Item No. 56)

Bonnet Gasket

(Item No. 58)

Seat Ring

(Item No. 20)

Seat Gasket

(Item No. 55)

Body

(Item No. 1)

Plug Seal

(Item No. 65)

Pressure-balancing

Vent

Bonnet

(Item No. 40)

Bonnet Flange

(Item No. 70)

Pressure-balanced Sleeve

(Item No. 30)

Plug

(Item No. 50)

FCD VLAIM015-07

Troubleshooting Chart

Failure Probable Cause Corrective Action

Jerky stem 1. Overtightened graphite packing 1. Graphite packing is often associated with jerky

movement stem movement

2. Galling or scoring between plug 2. Superficial scoring or galling may be removed

andsleeve with a light application of emery cloth; if more

serious damage exists, contact factory

CAUTION: Trim parts are machined to close

tolerances, which are essential for correct

functioning of the valve. Attempting to remove

deep scratches could result in high leakage

rates or improper functioning of the valve

3. Overtightened packing 3. Adjust the packing box nuts to just slightly over

finger-tight (over-tightening will also cause

excessive packing wear and high stem friction)

4. Service temperature is beyond 4. Reconfirm service conditions and contact factory

operating parameter of trim design

5. Inadequate air supply 5. Check for leaks in air supply or instrument

signal system; tighten any loose connections

and replace any leaking lines

6. Malfunctioning positioner 6. Refer to positioner maintenance instruction

Excessive 1. Loose bonnet flange bolting 1. Refer to step 9 of “Reassembly”section for

leakage correct tightening procedure

2. Worn or damaged seat ring 2. Disassemble and replace or repair seat ring

(for correct procedure on remachining seat

surfaces, see Maintenance Instruction 1)

3. Worn or damaged pressure- 3. Disassemble and replace plug seals

balanced plug seals

4. Worn or damaged seat, 4. Disassemble and replace gaskets

bonnet or sleeve gaskets

5. Inadequate actuator thrust 5. Check for adequate air supply to the actuator; if

supply is OK, reconfirm service conditions and

contact factory

6. Incorrectly adjusted plug 6. Refer to Installation, Operation, Maintenance,

Instruction 1 for correct plug adjustment

7. Improper flow direction 7. Confirm flow direction is always over the plug

Excessive 1. Worn or damaged plug seals 1. Disassemble and replace plug seals

cavitation causing excessive trim vibration

damage 2. Misapplication of trim design 2. Reconfirm service conditions and contact factory

3. Improper flow direction 3. Reinstall with flow direction over the plug

4. Severe corrosive service 4. Reconfirm service conditions and contact factory

exceeds trim material limitations

Inadequate 1. Improper plug adjustment 1. Refer to Installation, Operation, Maintenance

flow limiting stroke Instruction 1 for correct plug adjustment

2. Malfunctioning positioner 2. Refer to positioner maintenance instruction

3. Blocked pressure-balanced plug 3. Eliminate matter from line, disassemble and

vents or sleeve holes clean plug vents and sleeve

4. Service conditions exceeding 4. Verify service conditions and consult factory

trim design capacity

Plugslams 1. Incorrect plug adjustment allowing 1. Refer to Maintenance Instruction 1 for correct

improper cushion of air between plug adjustment

actuator piston and yoke

2. Inadequate air supply 2. Check air supply to actuator; repair leaks and

remove any restrictions in the supply line

3. Trim sized too large for flow rate 3. Install reduced trim to provide greater plug-to-seat

clearance

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