MASCOT DiskFlo Leitfaden

CAUTION :

1. Use pressure relief valves for high pressure

piping.

2. Use explosion proof valves/accessories for

dangerous media piping.

3. Use ﬁre safe valves for piping where chances of

ﬁre by external means.

4. Use seismic proof valves where chances of

earthquake are frequent.

5. Check whether locaon of the valve mounng is

of the same service/applicaon as speciﬁed on

the marking plate.

Installation, Operation,

Maintenance Instructions

DiskFlo

Control Valves

GENERAL INFORMATION

The guidelines below will help you in un-packing, installing and

doing maintenance of DiskFlo rotary valves. It is advised that the

relevant personnel should review this bulletin thoroughly before

proceeding to install, operate, or perform maintenance on the

DiskFlo rotary valves. Instructions for maintenance of

accessories, fail-safe systems, etc. are given separately.

Installing, maintaining, troubleshooting, calibrating, and

operating Mascot actuators or positioners is not covered in this

publication. You need to refer the right Mascot Installation,

Operation, Maintenance guidelines when the information is

needed.

It is strongly advised to stick to the WARNING and CAUTION

notes for preventing any possible injury or damage to personnel

or valve parts. Modifying, substituting nonfactory parts, or using

maintenance procedures other than mentioned in this manual

not only will adversely affect performance and can be dangerous

to the operators and equipment but also will void the warranties.

WARNING : Please follow the standard industry safety practices

when working on every process control product. Use of personal

protection and proper lifting is advised.

Note : The onus of selecting the right fastener material is on the

customer. The supplier cannot know about the valve service

conditions or environment that may be existing. The standard

body bolting material of Mascot's is B7/2H. There is an option

for B8 (stainless steel) when temperatures are above 800 °F and

with alloy body or stainless steel valves. The onus of considering

material's re-sistance to stress corrosion cracking in addition to

general corrosion lies on the customer. Periodic inspection and

maintenance is required, as with all the mechanical equipments.

In case more details are needed about fastener materials, please

contact the local Mascot factory, office or representative.

Unpacking :

During the unpacking of valve, the packing list received with

the materials needs to be checked. Detailed description of the

valve and accessories are included in the lists in each

shipping container.

Proper attention is to be paid during the positioning of lifting

straps. This will avoid damage to tubing and mounted

accessories while lifting the valve from the shipping container.

The actuator lifting ring is advised to be used for lifting

Valves up through 14-inch. Use lifting straps or hook through

the yoke legs and outer end of the body for lifting the larger

valves.

The shipper should be contacted immediately in case of an

unfortunate event of damage caused due to negligence while

shipping.

Mascot representative is always at your service in case any

problems.

Installation :

The first step is to do basic cleaning for the line of dirt, scale, welding

chips, and other possible foreign material. The surfaces of gasket

should be cleaned thoroughly thus ensuring that the joints are leak-

proof

The direction of the flow should be checked for ensuring that the

installation of valve is right. In case of Fail-closed valves,installation

should be done only on gas service with the shaft upstream. In case

of liquid service valves, installation is preferred with the shaft

downstream, irrespective of the air failure action. Under certain flow

conditions, however, the valve can flow shaft upstream. In case of

Fail-open valves, installation should be done with the shaft

down-stream.If the mounting of valve must be with the shaft upstream

in liquid service,

please consult our representative or contact our factory.

WARNING : It has to be made sure that the flange face gasket

covers the seat retainer and body and surface when installing the

valve in line between flanges. There is a possibility of excessive

leakage downstream in case this is not done. Figure 1 can be

referred to for "Seat Insert/Snap-ring Configuration"

Before and during the installation process, the valve needs to

be fully closed.

WARNING : Keeping clothing and body parts away from the

rotating disc and the seat when operating the valve can avoid any

possible serious injuries.

CAUTION : DiskFlo has a self-centering seat and therefore the

valve should not be opened at any time during installation

process, keeping it closed until the complete installation of the

valve.

Air supply and instrument signal needs to be connected. Valve

positioners are usually present in Throttling valves. Separate two

connections are given for instrument signal and air supply. 150

psi air supply is suited for both cylinder and positioner. No need

for an air regulator is there till the supply pressure is 150 psi.

Unless the supply air is unusually clean and dry, an air filter is

recommended. There should be no leaks in connections.

CAUTION : For valves with air filters, the air filter will not

perform properly if the air filter bowl is not pointing down.

NOTE : There are certain cases wherein the air supply needs to

limited to 100 psi rather than 150 psi. The sticker pasted near the

upper air port on the cylinder indicates the same. An air regulator

must be installed to Ensure that the supply pressure is not exceeding

the desired 100 psi.

For proper disc rotation, it is necessary to have proper clearance

internally in the mating piping.

For proper sealing, the torque values as recommended should be

applied to line flange bolting for proper sealing - Refer Table 1

Table 1 : Flange Bolting Torques

 Valve Rating Torques

 Size (In.)  (ft.Lbs.)

  150 118

 2 300 118

  600 118

  150 118

 3 300 209

  600 209

  150 118

 4 300 209

  600 505

  150 209

 6 300 209

  600 505

  150 209

 8 300 337

  600 728

 10 150 337

  300 728

 12 150 337

  300 728

 14 150 505

 16 150 505

 18 150 728

 20 150 728

 24 150 1009

 30 150 1009

DiskFlo Control Valves

Quick Check:

Before starting, the control valve should be checked as per the

these steps given below :

Full stroke needs to be checked by making the appropriate

instrument signal change. The disc position indicator plate

mounted which is mounted on the transfer case should be

observed for this. The change in the position of the disc must

be in a rotary fashion and smooth.

All the air connections should be checked for leaks and in

case of leaking lines, tighten or replace.

The packing nuts are to be tightened evenly by little over

finger-tight force.

CAUTION : The packing should not be over tightened. The

over tightening may cause excessive packing wear and

high shaft friction, that can adversely affect the rotation of

the shaft.

The packing nuts need to be inspected after some time of

operation of the valve to make sure that they are just over

finger-tight and not more. Readjustment should be done if

needed. The packing nuts should be tightened just enough to

stop leakage in case of the leaking in the packing box.

For observing the valve failure mode when air failure occurs,

the valve needs to be positioned to mid-stroke and the air

supply needs to be shut off or the instrument signal needs to

be disconnected. On observation of the indicator plate, the

disc should either fail open or closed. Please refer "Reversing

the Actuator" section in the appropriate Actuator Maintenance

Instructions if incorrect.

PREVENTIVE MAINTENANCE

The preventive maintenance steps presented below need to be

followed and at least once every six months, proper operation

should be checked. These steps are easy and can be performed

while the valve is in line and, in some cases, without interrupting

service. Refer to the "Dis-assembly and Reassembly" section if an

internal problem is suspected.

Check for any signs of gasket leakage through body and line

flanges. Tightening of flange bolting should be done if

needed.

Pay attention to any corrosive fumes or process drippings that

are likely to cause damage to the valve.

For any areas of severe oxidation, cleaning of the valve needs

to be done, followed by painting.

For proper tightness, inspect the packing box bolting. The

tightness of the Packing nuts should be slightly over finger-

tight. To prevent stem leakage, tighten as necessary.

CAUTION : Never overtighten the packing.

In case of valve supplied with a lubricator, lubricant supply

needs to be checked and adding of lubricant if necessary

should be done.

When possible, stroke valve and verify functioning for

smooth, full-stroke operation by seeing the disc position

indicator plate that is on the transfer case. An internal valve

problem is indicated by unsteady movement of the disc (In

case when Grafoil packing is used, jerky motion is normal).

By observing the gauges and the disc position indicator plate,

check the positioner calibration. Ensuring calibration of the

positioner to the correct range is important.

Ensure that the positioner linkage and internal actuator parts

are securely fastened by removing transfer case cover plate.

Using a soap solution, check for air leaks through actuator

stem seal.

CAUTION : Without the cover plate installed, air should

not be applied to the actuator because there is a possibility

of the unsup-ported shaft getting damaged.

Ensure secure fastening of all accessories, brackets and

bolting.

For correct fail-safe action, remove air supply and observe

stroke plate if possible.

To check for air leaks through the O-rings, spray soap

solution around the cylinder retaining ring and the adjusting

screw.

The ex-posed portion of the shaft should be free from dirt or

other foreign material.

In the air filter, check and replace cartridge if needed.

DISASSEMBLY AND REASSEMBLY

Removal of Valve from Line

When disassembly is required on a suspected internal

problem with the valve, the valve needs to be removed from

the line. The procedure for the same is as follows:

WARNING : Bring the line to atmospheric pres-sure and

drain all process fluids. In case of presence of caustic or

hazardous materials, decontaminate the valve. Possibility

of injur is eliminated by decontamination.

10.

11.

12.

13.

Figure 1: Seat Retainer Configurations

A Dual Seat B Metal Seat C Soft Seat D Seat Insert /

Snap-ring

DiskFlo Control Valves

Ensure complete closure of the valve.

Note : For valves with fail-open action, supply air pressure

under the actuator piston for closing the valve. The handwheel

can be used to close the valve, in case provided.

The valve needs to be supported for which, attach a hoist or

by some suitable means.

The line bolting should be removed. Pushing or pulling on

valve actuator should not be attempted to pry line flanges

apart.

The valve needs to be Slided carefully from the line. The valve

should not be twisted as this might cause damage to gasket

surfaces.

On complete removal of the valve from the line, the air

pressure from the actuator should be slowly relieved.

Removing Actuator From Body

With the actuator removed from the body, it is easy to dissemble

the body assembly and the actuator.The procedure for the same

is as follows To do so, proceed as follows:

Before disconnecting the actuator, from the body assembly,

support the actuator assembly by the lifting ring.

The transfer case cover bolts need to be removed. With care,

pry or slide the cover plate from the end of the shaft.

Loosen the linkage bolt on Mascot actuators.

To release spring pressure, loosen the actuator adjusting

screw.

The bolts connecting yoke to the actuator subassembly need

to be removed.

The entire actuator assembly needs to be slide off the shaft.

To loosen it from the shaft splines, it might be necessary to

wedge the halves of splined lever arm apart.

Disassembling the Body

Refer to Figures 1, 2 and 5 to disassemble the body and

proceed as instructed below :

For DiskFlo valves with seat retainer screws, the seat retainer

screws and retainer clips need to be removed. The seat

retainer needs to be lifted out of the valve body. (Presented in

Figures 1A, B, C).

For valves supplied with retainer snap-ring configu-ration,

insert a screwdriver carefully in the key slot provided in the

retainer; pry the retainer and snap ring out of the valve body.

(Presented in Figure 1D).

Remove both packing nuts to remove the gland flange. The

studs need not be removed.

By tapping on the small end of the pins using a punch and

hammer, drive the taper pins out of the disc.

Remove the end plug (optional bolted flange and seal if

applicable).

By inserting a press or a nylon rod (or identical material) into

body's blind end, and using a hammer, carefully tap the shaft

through the body and remove.

CAUTION : Utmost care should be taken during disassembly so

that the splined end of the shaft is not damaged.

Supports underneath the disc are needed to avoid scratching

the sealing surface of the disc while removing the shaft. As

the shaft comes off the bearing surfaces, the binding of shaft

in the body is prevented.

Using a dowel of appropriate diameter, push the packing and

bearings out of the body. Packing needs to be pushed from

the center of the valve.

Reassembling the Body

To reassemble the body sub-assembly, refer Figures 1, 2, 3, and

5 and proceed as mentioned below :

All parts should be cleaned.

The disc seating surface should be checked to make sure it is

smooth and free of scratches and scoring.

CAUTION : Damaged discs should be promptly replaced as

damaged or dirty seat surfaces can cause excessive seat wear and

high torque requirements.

Figure 2: Body Assembly

Note : Item numbers correspond to bill of material of Valve. Please refer to it for specific part numbers.

(Item No. 123)

Seat Retainer ClipSeat Retainer Bolt

(Item No. 124)

Body

(Item No. 1)

Taper Pins

(Item No. 52)

Shaft Bearing

(Item No. 83)

Shaft

(Item No. 51)

Inner Packing

(Item No. 88)

Outer Packing

(Item No. 88)

Packing Follower

(Item No. 87)

Packing Spacer(s)

(Item No. 93 - 95)

Packing Retainer

(Item No. 85)

Shaft

Plug

(Item No. 122)

Disc

(Item No. 50)

O-ring

(Item No. 61)

Seat

Shaft

Bearing

(Item No. 83)

Disc Stop

1. 1.

DiskFlo Control Valves

Shaft needs to be inspected for galled surfaces or scratches.

The very smooth finish of the DiskFlo shafts give maximum

performance. In case of any damage, replace the shaft or

contact our factory representative.

NOTE : In recent designs, Disc and shaft are interchangeable.

Replacing the disc does not require replacing the shaft. Older

designs needed that the disc and shaft be machined together.

For matched disc and shaft, contact the factory.

New sliding stem shaft bearings should be inserted into the

body. (With some designs, a press may be required.)

NOTE : Previous DiskFlo designs need the disc to be aligned

in the body in such a way that it can properly rotate. After

aligning the shaft bearings on either side of the disc, insert the

shaft through the body, disc and bearings.

Making sure it will rotate in the proper direction with respect

to the body's internal disc stop, position the disc in the body.

insert the shaft through the body, disc and bearings.

CAUTION : To avoid damage to both the shaft and

bearings, care needs to be taken while sliding the shaft

into the sliding stem shaft bearings.

New taper pins need to be inserted and driven firmly into

place in the side opposite the stop.

Over splined end of the shaft and into the body, slide the

packing retainer, lower packing, packing spacer, upper

packing, and packing follower. The typical packing

configurations are as in Figure 3.

NOTE : Whenever rebuilding the packing box, use new

packing.

CAUTION : As the sealing on V-ring packing is at the

feather edge, it is necessary to avoid damage to that edge.

Install the end plug again (alternatively replace the end seal

and again install the bolted flange).

The gland flange and packing nuts should be Reinstalled.

Packing to be tightened evenly to slightly over finger-tight

strength.

CAUTION : Over tightening of packing should be avoided. This

causes excessive packing wear and high shaft friction, which may

hamper rotation of the shaft.

NOTE : Orientation 1 is standard. Orientation positions 2 and 4 are

not available in some actuator sizes. Contact factory.

A gasket is required in all seat configurations with screw/clip

retainers (item #55) installed in the appropriate groove. This

is done by pressing the gasket into the appropriate groove.

In case the seat retainer is the screw/clip type and possesses

a soft or dual seat, press the soft seat into the soft seat

retainer or metal seat. (An interference between the soft seat

and the retainer is necessary.) Secure the retainer or metal

seat in place by tightening the retainer clips and screws, with

the valve in the closed position. This helps the seat to align

with the disc, making tight shutoff possible.

In case the seat retainer is the screw/clip type with a metal

seat design, a gasket needs to be installed in the metal seat

before clipping the seat in place with the screws and seat

clips.

NOTE : DiskFlo valves of earlier design may require the disc to be

open while installing the soft seat into the body.

In case an early design DiskFlo seat retainer has an indexing

groove to accept a soft seat, press the corresponding seat

into the retainer groove. Install the seat retainer subassembly

into the body.

For valves supplied with the retainer snapring configuration,

the snapring needs to be installed into the groove around the

retainer (or metal seat). With the open ends of the snap-ring

in the body groove, start the retainer into the body. Lightly

press the snap-ring into the retainer until both the retainer

and snap-ring slide into the body.

For early design DiskFlo valves supplied with seat retainer

screws, the insert and retainer need to be installed into the

body with the disc open. The retainer screws need to be

loosely installed, then the disc is to be closed. After the closed

disc has centered the seat, tighten the screws. This permits a

tight shutoff as it allows the seat to align with the disc.

10.

11.

12.

13.

14.

15.

Figure 3: Typical Packing Configurations

SafeGuard / SureGuard

Fire-safe Option

(live-loading omitted)

SureGuard

Standard Square Standard Single "V" Twin "V"

SafeGuard

(packing studs rotated 45 degrees)

Twin "V" with Lubricator

DiskFlo Control Valves

Remounting Actuator to Valve

It needs to be verified that the disc rotation matches the actuator

rotation and complies with the air failure requirements, before

mounting a Valflo actuator on the valve body.

For mounting the actuator, the procedure is as follows:

The entire actuator assembly needs to Slide onto the shaft. If

needed on Valflo actuator designs wedge the splined lever

arm apart to loosen it on the shaft splines. Marks provided on

the end of the shaft and on the lever arm should be aligned

for full rotation of the disc.

The actuator yoke needs to be bolted to the valve body.

Ensure that the stroke indicator plate is positioned properly

for accurately indicating the rotation of the valve.

Align the actuator lever arm on the shaft so the actuator stem

is centered in the transfer case. The linkage bolt needs to be

firmly tightened.

CAUTION : Applying air to the actuator without the cover

plate installed; may cause damage to the unsupported

shaft.

Until the disc is parallel to the seat surface, but not resting on

body disk stop, adjust the actuator stroke stop bolts.

CAUTION : To prevent the valve disc from overstroking,

the actuator stroke stop bolts must be properly adjusted.

The valve shaft may be twisted or sheared off if incorrectly

adjusted.

The valve in line needs to be installed as mentioned in

"Installation" section.

Style E

Air-to-close

Fail- open

Air-to-close

Fail- open

Air-to-open

Fail-close

Air-to-open

Fail-close

Shaft Downstream

Style F

Shaft Downstream

Style G

Shaft Downstream

Style H

Shaft Upstream

NOTE: Styles F and H may

require a heavy-duty spring

to achieve failure.

Right-hand Mounting

Facing Downstream

Left-hand Mounting

Facing Downstream

FLOW

Style G Style H Style F Style E

Left-hand

Mounting

Right-hand

Mounting

NOTE: Orientation 1 is standard. Orientation positions

2 and 4 are not available in some actuator sizes.

Figure 4 : Transfer Case Mounting

DiskFlo Control Valves

Failure Probable Cause Corrective Action

Valve moves to failure position, excessive air  1. Failure of actuator O-ring 1.Replace actuator stem O-ring

bleeding from transfer case 2. Failure of sliding seal assembly 2.Repair or replace stem adapter / linkage assembly

Jerky shaft rotation 1. Overtightened packing 1.Retighten packing box nuts to slightly over finger-tight

 2. Improper adjustment of lever arm on shaft causing arm  2. Readjust lever arm (see step 1 in the

  to contact transfer case thus failing to convert torque.  “Remounting Actuator” section)

 3. Cylinder wall not lubricated 3.Lubricate cylinder wall with silicone lubricant

 4. Worn piston O-ring allowing piston to gall on cylinder wall 4. Replace O-ring; if galling has occurred replace all damaged parts

 5. Worn actuator stem O-ring causing ctuator stem to gall on stem collar  5. Replace O-ring; if actuator stem is galled replace it

 6. Worn (or damaged) shaft bearings, shaft bearings or packing followers  6. Disassemble and inspect parts; replace any worn or damaged parts

Excessive leakage through seal 1. Improper adjustment of external stroke stops  1. See “Adjusting External Stroke Stops” section

 2. Worn or damaged seat  2. Replace seat

 3. Damaged ball seating surface  3. Replace disc and shaft

 4. Improper handwheel adjustment acting as limitstop  4. Adjust handwheel until disc seats properly

 5. Ball not centered in body I.D.  5. Center ball; replace damaged seals.

Leakage through line flanges 1. Dirty line gasket surfaces  1. Clean gasket surfaces and reinstall valve

 2. Improper torque on line flanges  2. Tighten line flanges evenly and completely (see Table 1 for proper torque)

 3. Flange or pipe misalignment  3.Realign flanged ends with piping.

 4. Warn Gaskets  4.Replace Gaskets

Leakage through packing box  1. Loose packing box nuts  1. Tighten packing box nuts to slightly over finger-tight

 2. Worn or damaged packing  2. Replace packing

 3. Dirty or corroded packing  3. Clean body bore and stem, replace packing

Valve slams, won’t open, or  1. Improper valve installation  1. See step 2 in “Installation” section and

causes severe water hammer     correct flow direction

Shaft rotates, ball remains open or closed 1. Broken shaft 1.Replace shaft

Actuator operates, shaft does not rotate  1. Broken internal actuator parts  1. Refer to appropriate actuator Maintenance Instructions

Trouble shooting DiskFlo Valve

Figure 5: Exploded Body Sub-Assembly

Note : Item numbers correspond to bill of material of Valve. Please refer to it for specific part numbers.

Item No. Description

1body

20 hard seat

21 seat insert

22 seat retainer

50 disk

51 shaft

52 taper pins

55 seat gasket

61 O-ring

80 gland flange

83 shaft bearing

85 packing retainer

87 packing follower

88 packing

93 packing spacer

109 packing box stud

117 packing box nut

122 shaft plug

123 clip

124 screw

109

117

122 61

20/22

123

124

MASCOT VALVES PVT. LTD.

166 / 167, G I D C, Naroda, Ahmedabad : 382330. India

Phone : +91 79 22821619/22823369, Fax : +91 79 22822430

Email : info@mascotvalves.com / web : www.mascotvalves.com

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