Flowserve Valtek Mark 100 Bedienungsanleitung

Experience In Motion

Valtek®Control Products

Mark 100™and Mark 100SC™

Control Valves

USER INSTRUCTIONS

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

Sections

1General information ........................... 3

2Terms concerning safety ...................4

3Unpacking .........................................5

4Installation..........................................6

5Valve maintenance ............................8

6Valve disassembly

and reassembly ...............................10

7Severe service trim options .............14

Tables

1 Valve disassembly clearance.............6

2 Recommended body

bolt torque values...............................7

3 Common packing lubricants..............7

4 Troubleshooting chart.......................17

Figures

1 Exploded drawing..............................9

2 Cutaway drawing .............................10

3 Seal designs.....................................12

4 PTFE seal cutting detail ...................12

5 Actuator stem / stem

clamp alignment...............................12

6 Bolt patterns .....................................13

7 Mark One with CavControl

trim body assembly..........................14

8 Mark One with ChannelStream

trim body assembly..........................15

9 DiamondBack trim body

assembly ..........................................15

10 Mark One with MegaStream

trim body assembly..........................16

11 Mark One with Stealth trim

body assembly.................................16

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

The following instructions are designed to assist in unpacking,

installing and performing maintenance as required on Valtek

Mark 100 and Mark 100SC control valves. Product users and

maintenance personnel should thoroughly review this bulletin

prior to installing, operating or performing any maintenance on

the valves. Separate Installation, Operation and Maintenance

instructions cover additional features (such as actuators,

handwheels, packing and positioners).

To avoid possible injury to personnel or damage to valve parts,

WARNING and CAUTION notes must be strictly followed.

Modifying this product, substituting non-factory parts, or using

maintenance procedures other than outlined could drastically

affect performance, be hazardous to personnel and equipment,

and may void existing warranties.

cWARNING: Standard industry safety practices must be

adhered to when working on this or any other process

control product. Speciﬁcally, personal protective and

lifting devices must be used as warranted.

NOTE ON FASTENERS: Selecting the proper fastener material is

the responsibility of the customer. Typically, the supplier does

not know what the valve service conditions or environment may

be. Flowserve’s standard body bolting material is B7/2H. B8

(stainless steel) is optional for applications more than 425°C

(800°F) and with stainless steel or alloy-body valves. The

customer, therefore, must consider the material’s resistance

to stress corrosion cracking in addition to general corrosion.

As with any mechanical equipment, periodic inspection and

maintenance are required. For more information about fastener

materials, contact your Flowserve representative.

General

information

1.2 Applicability

The following instructions are applicable to the maintenance

and installation of Valtek Mark 100 and Mark 100SC globe

and angle body design control valves. These instructions

cannot claim to cover all details of all possible product

variations, nor can they provide information for every possible

example of installation, operation or maintenance. This means

that the instructions normally include only the directions to

be followed by qualiﬁed personnel using the product for its

deﬁned purpose. If there are any uncertainties in this respect,

particularly in the event of missing product-related information,

clariﬁcation must be obtained via the appropriate Flowserve

sales ofﬁce. All Flowserve User Manuals are available at

www.ﬂowserve.com.

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

Terms concerning

safety

The safety terms DANGER,WARNING, CAUTION and NOTE

are used in these instructions to highlight particular dangers

and/or provide additional information on aspects that may

not be readily apparent.

bDANGER: indicates that death, severe personal injury

and/or substantial property damage will occur if proper

precautions are not taken.

cWARNING: indicates that death, severe personal injury

and/or substantial property damage can occur if proper

precautions are not taken.

a 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

instructions, 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.

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

1. While unpacking the valve, check the packing list against

materials received. Lists describing valve and accessories

are in each shipping container.

2. When lifting the valve from shipping container, use the lifting

lugs attached to the bonnet bolting. Take care to position

lifting straps to avoid damage to the tubing and mounted

accessories.

cWARNING: When lifting a valve using the lifting lugs,

be aware that the center of gravity may be above the

lifting point. Therefore, support must be given to prevent

the valve assembly from rotating. Failure to do so can

cause serious injury to personnel, damage to the valve

or nearby equipment.

3. Contact your shipper immediately if there is shipping

damage.

4. Should any problem arise, call your Flowserve

representative.

Unpacking

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

Installation

1. Before installing the valve, clean the line of dirt, welding

chips, scale or other foreign material.

2. Whenever possible, the valve should be installed in an

upright position. Vertical installation permits easier valve

maintenance.

a CAUTION: Do not insulate extension bonnets that are

provided for hot or cold services.

3. Be sure to provide proper overhead clearance for the

actuator to allow for disassembly of the plug from the valve

body. Refer to Table 1 for the necessary clearance needed

for valve disassembly.

Table 1: Valve disassembly clearance

Valve Size

(in)

Clearance

in mm

610 254

813 330

10 14 356

12 16 406

14 18 457

16 20 508

18 23 584

20 25 635

24 31 787

30 37 940

4. Double-check ﬂow direction to be sure the valve is installed

correctly. Flow direction is indicated by the arrow attached

to the body.

5. If welding the valve into the line, use extreme care to avoid

excess heat buildup in the valve.

6. Connect the air supply and instrument signal lines.

Throttling control valves are equipped with a valve

positioner. Refer to the appropriate positioner bulletin for

connections, maximum air supplies and maintenance

instructions.

a CAUTION: On valves equipped with air ﬁlters, the air

ﬁlter drain must point down to perform properly.

NOTE: In some rare cases, the air supply must be limited

to less than 150 psi (10.3 bar). This is indicated on a sticker

found near the upper air port on the actuator cylinder. An air

pressure regulator should be installed to ensure the supply

pressure does not exceed the line pressure indicated on

the sticker.

4.1 Quick-check

Prior to start-up, check the control valve by following these

steps:

1. Stroke the valve and observe the plug position indicator on

the stem clamp compared to the stroke indicator plate. The

plug should change position in a smooth, linear fashion.

NOTE: Due to excessive friction, graphite packing can

cause the plug stem to move in a slip/stick fashion.

2. Check for full stroke by making appropriate instrument

signal change.

3. Check all air connections for leaks.

4. Check packing box bolting for the correct adjustment. Refer

to the packing installation manual for speciﬁc details on

maintaining the style of packing supplied.

a CAUTION: Do not overtighten packing. This can cause

excessive packing wear and high stem friction that may

impede plug movement.

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

5. Make sure the valve fails in the correct direction in case

of air failure. This is done by turning off the air supply and

observing the failure direction.

6. After a temperature excursion has occurred, bonnet ﬂange

bolting should be retorqued to ensure bonnet gaskets do

not leak. See Table 2.

Table 3: Common packing lubricants

Lubricant Manufacturer Temperature Range Applications, Description

Krytox 206 E.I. DuPont -20°C to 285°C

(-5°F to 550°F) Fluorinated general purpose grease; handles common liquids and

gases; good lubricity in harsh mediums; nonﬂammable, chemically

inert; will not harm plastic or metal parts

GP 460 Graphite Products Co. 0°C to 540°C

(32°F to 1,000°F) Graphite in petrolatum; high pressures; anti-galling, graphite remains

above 316°C (600°F)

Aeroshell Grease 7 Shell Oil Co. -75°C to 150°C

(-100°F to 300°F) Synthetic oil-based; low-temperature applications

Garlock Luball Garlock Inc. 0°C to 260°C

(32°F to 500°F) General purpose molybdenum disulﬁde lubricant economical; good

in water, steam and common chemicals; not good in harsh mediums

where Krytox 206 is recommended

Table 2: Recommended body bolt torque values

Bolt Size Bolt/Stud Material

B7 Studs, 2H Nuts B8 Studs and Nuts

(in) ft-lb N m ft-lb N m

7⁄8230 312 150 203

1350 474 220 298

11⁄8510 691 330 447

1¼ 730 990 460 624

13⁄81,000 1,356 630 854

1½ 1,320 1,790 840 1,139

15⁄81,710 2,318 1,080 1,464

13⁄42,170 2,942 1,400 1,898

17⁄82,700 3,660 1,700 2,305

23,350 4,542 2,100 2,847

21⁄44,050 5,491 2,530 3,430

21⁄24,850 6,575 3,010 4,081

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

Valve

maintenance

At least once every six months, check for proper operation by

following the preventative maintenance steps outlined below.

These steps can be performed while the valve is in-line and in

some cases without interrupting service. If an internal problem

is suspected, refer to the “Valve disassembly and reassembly”

section.

1. Look for signs of gasket leakage through the end ﬂanges

and bonnet. Retorque ﬂange and bonnet bolting (if

required). See Table 2.

2. Check for ﬂuid leakage to the atmosphere through the body

drain plug, if applicable.

3. Examine the valve for damage caused by corrosive fumes

or process drippings.

4. Clean valve and repaint areas of severe oxidation.

5. Check packing box bolting for proper tightness. Refer to the

packing installation manual for speciﬁc details on main-

taining the style of packing supplied.

a CAUTION: Do not overtighten packing. This can cause

excessive packing wear and high stem friction that may

impede stem movement.

6. If the valve is supplied with a lubricator ﬁtting, check

lubricant supply and add lubricant if necessary. See Table 3

for common lubricants.

7. If possible, stroke the valve and check for smooth, full-

stroke operation. Unsteady stem movement could indicate

an internal valve problem.

NOTE: Due to excessive friction, graphite packing can

cause the plug stem to move in a slip/stick fashion.

cWARNING: Keep hands, hair and clothing away from all

moving parts when operating the valve. Failure to do so

can cause serious injury.

8. Make sure positioner linkage and stem clamp are securely

fastened. If the stem clamp is loose, check plug thread

engagement (refer to the “Reassembling the actuator”

section for the correct procedure on aligning the plug with

the seat.) Tighten stem clamp nut.

9. Ensure all accessories, brackets and bolting are securely

fastened.

10. If possible, remove air supply and observe actuator for

correct fail-safe action.

11. Check rubber actuator bellows for splits, cuts or wear.

12. Spray a soap solution around the cylinder actuator retaining

ring, adjusting screw and actuator stem guide to check

for air leaks through the O-rings.

13. Clean any dirt and other foreign material from the plug stem.

14. If an air ﬁlter is supplied, check and replace cartridge

if necessary.

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

Parts list

Part Item

Body 1

Seat Ring* 20

Plug* 50

Plug Stem* 51

Cage 30

Pressure-Balanced Sleeve 31

Bonnet 40

Seat Gasket* 55

Sleeve Gasket* 56

Bonnet Gasket* 58

Seal Types*

O-ring Seal 65

PTFE Seal 65

Metal Multi-Seal 65

Carbon Single Seal 65

Carbon Triple Seal 65

Gland Flange 80

Gland Flange Bolting 109, 117

Lower Guide* 83

Upper Guide* 87

Packing* 88

Anti-Extrusion Spacer* 93

Body Bolting 108, 114

Packing Spacers 94 to 99

(1) Body

(55) Seat Gasket

(20) Seat Ring

(30) Cage

(31) Pressure-Balanced Sleeve

(50) Plug

(65, 66) Pressure-Balancing Seals

(58) Bonnet and (56) Sleeve Gasket

(40) Bonnet

(108, 114) Body Bolting

(83, 87, 88, 93, 94 to 99)

Packing, Guides and Spacers

(80) Gland Flange

(109,117) Gland Flange Bolting

Figure 1: Exploded drawing

* Recommended spare parts

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves

Valve disassembly

and reassembly

6.1 Disassembling the body

To disassemble the valve body, refer to Figures 1 and 2, then

proceed as follows:

cWARNING: Depressurize line to atmospheric pressure

and drain all ﬂuids before working on the valve. Failure

to do so can cause serious injury.

1. Fully retract the plug until the stem clamp indicator points to

the open position.

2. Remove the bonnet ﬂange bolting and lift the actuator,

bonnet and plug out of the valve body.

cWARNING: Danger exists in removing the actuator,

bonnet and plug, especially if PTFE plug seals are used.

The sleeve may stick to the plug and fall during disas-

sembly, causing possible serious injury and damage

to the valve or nearby equipment. If sleeve is observed

sticking to the plug, steps 3 to 5 should be consulted.

aCAUTION: Heavy actuators may require a hoist. Lift the

actuator with the yoke legs using a lifting strap and a

hoist. Great care should be taken to lift the actuator and

plug straight out of the body to avoid damage to the

plug and seat.

3. If the sleeve is observed sticking to the plug during

removal, fully extend the plug by applying air above the

piston, allowing the sleeve to remain in the body and the

bonnet to rise above the body.

4. In the gap between the top of the sleeve and the bottom of

the bonnet, place wooden blocking of equal thickness in at

least three places. The wooden blocks must not extend in

far enough that they interfere with plug movement. The plug

must be allowed to stroke up to the bonnet.

5. By applying air below the piston, retract the plug until the

plug head is freed from the sleeve. Once the plug is free

from the sleeve, remove the plug and bonnet assembly from

the body.

6. Lift the sleeve out of the valve body using lifting points on

the top of the sleeve.

7. Remove cage, seat ring and gaskets from the valve body.

Figure 2: Cutaway drawing

8. Remove the pressure-balancing seals from the plug head.

9. Check to see the seating surfaces on both the seat ring

and plug are free of damage to ensure tight shutoff. Make

sure the gasket surfaces on the seat ring, bonnet and body

are clean and undamaged. Inspect the pressure-balanced

sleeve for scratches, wear or other damage.

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