RK ‘SINGLE SEATED GLOBE VALVE - series 10 ANGLE VALVE - Series 70 INSTRUCTION MANUAL STORAGE When a vaive is to be put into storage betore instalation, remove Fzrngaton protection covers and spay a fm of machin al on 6 internals, Replace the covers. Exposed parts should also be ‘prayed with a protective fim of oll. le ‘A packing lst, containing a complete description ofthe valve and ‘accessories (such as a valve positioner, etc) accompanies each valve when shipped. This list should be checked soon alter the ‘shipment has been received, ‘When holsting the vaive, make sure that ropes or cables are Positioned so that any tubing or accessories willnot be damaged. INSTALLATION Position ‘The valve should be installed preferably In straight run of pipe ‘away from bends or section of abnormal veloclty. The preferred osttion is with the actuator vertically above or below the valve body, but it may be installed in horizontal or angled position rovided the targest diaphragm actuator (Ax-300) is supported. Correct direction at flow must be observed. Araised metal pattern ‘cast on the body indicates the location ofthe seat ring bridge and ‘connections are marked ‘IN’ and ‘OUT’. ‘Qlearance should be provided above the actuator to permit ts ‘moval for servicing, or for inepection of the valve internals, By-Pass ‘The conventional three valve by-pass should be installed if tis Necessary to continue operation during periods of control valve seivicing. Connections Pipe threads should be clean and sharp. Use pipe compound on the male threads only, ‘When making flanged connections. tighten the’ bolts evenly to ‘avoid placing strain on the body or cracking a flange. Inetrumente ‘An ait supply pressure regulator with fier should be installed in the alr ine ahead of any valve-mounted instruments. Mounted Positioners are piped and adjusted atthe factory. tightened at ‘Alltypes of packing -The gland nuts wil have been the factory but shoul there be any gland leakage ater installation, further tightening is indicated. Slightly more than hand tightening should be adequate to stop any stem leakage, Oversightening ‘wil restrict stem movement. ‘See Pages 3/8 for further instruction on packing. For packiaes Balows Seal construction - See Instruction Manual {or Bolows Seal Valve. ‘Special Bonnets ‘The normalising bonnet is similar tothe standard bonnet but has ‘extended length to protect the stem packing from extremes of the temperature. It ust not be wrapped with any form of insulating material. Final Check Attar the valve has been installed, make a final check of the following : Valve travel - vary alr supply tothe actuator to ascertain ‘that actual travel corresponds with the nameplate Indloation. Alr {ines to the actuator - check for leaks. Control instruments/valve ‘action ~ check to be sure that the combined actions (direct or reverse) of controller, positioner (if any) and valve will provide the desired drection of valve movement and will ensure the, required valve position in the event of air failure. \Variationsin pressure drop across single seated valves fay result ina ahi in spring range. This can be corrected by adjusting the actuator spring. See Actuator Instruction Manual for this procedure.aaeeerenen cna nREDMDNUNNNNDUNNENOUMNCNNINUUUNNnNrrrt ern rr reer rer rer reper ree prer ere reese rarer eerreereeeine MAINTENANCE Genera ‘A Maintenance such as diaphragm, packing or trim replace- ‘ment can be done without removing the vaive from the line, ‘but removal of the actuator is 60 simple that Itis usual to ‘work on this lem In the workshop. Itwil algo be found more ‘convenient to work on the valve In the workshop whenever possible, For special instructions relating to valves with Bellows Seal ‘construction, see instruction Manuel. © For instructions relating to Actuator Maintenance, 660 ‘Actuator Instruction Manual Removal of Actuator from Valve 4. NOTE: The valve plug must be off the seat ring while the ‘ster coupling is being separated - apply air to the actuator Mnecessary. 2 Remove any existing checknut or other attachment from the end of the ster coupling screw - actuator yoke will pass: over the packing flange.. ‘3. Unscrew and remove the coupling screw and remove the coupling halves. 4, Disconnect the air supply and/or any electrical connections: ‘to the actuator. ‘5. Unscrew the locking ring from the bonnet threads and itt it ‘over the plug stem. 6. Ut or holstthe actuator unit off the valve, taking care to ‘avoid damaging the plug stem, instruments or tubing, NOTE: The locking ring and yoke will pass over gland flange without dismanting the gland assembly. Disassembly of Valve 1. Unscrew the gland nuts and remove gland flange and gland. 2. Remove the bonnetvbody stud nuts and tthe bonnet, white holding the plug stem (to prevent the plug from dropping out), careful off the valve body. Discard the body gasket. 3. Withdraw the plug and stem out of the body, through the ‘cage guide (if present). CAUTION : Spline Plugs are seat guided, so that a straight ‘upward pul is required unti the plug clears the seat 4 Using @ narrow hook or ent wire, pull the packing rings” and lantem ring oUt ofthe packing box, Plugs, Seat and Guide New plugs are usually supplied complete with a new stem, ‘80 detachment ofthe plug from the etem is seldom required. ‘To remove the plug from the atem, drive out the plug stem pln (parallel) and unscrew the stem from the plug. ‘Unscrew and remove the seat ring. NOTE: The seat ring should be removed ony for remachining ‘or replacement. It should nat be removed for cleaning purposes. Special wrenches are available for seat removal, ‘A lathe or boring mill can be used for unscrewing stubborn ‘seat rings. Heating the valve body or chiling the seat may be required to loosen an extremely tight seat. ‘The prossed:in guide bushing, which ig usually in a hard material, will require replacement. The guide Is a drive fit in the bonnet and when necessary should be removed in & machine. ‘Assembly of Valve [Now plugs are usually supplied complete with new stems. I only one ofthese parts isto be replaced, the old plug stem pin’ must be driven out and the stem unscrewed. After Sorewing together the new combination, dil through the plug and stem, countersink, insert the 1/8" pin, then machine the pin tush withthe plug shank surface. ‘Apply pipe compound to the seat ring threads, then Install the seat rng in the body. CAUTION : Each Microspline Plug and seat is @ matched set, precision ground to a selective ft. Extreme care should a taken with Splines to avoid chipping or breakage. Lower the plug and stem assembly into the body. With Micro spline Plugs be extremely cereful when inserting the plug into the seat ring, to avoid damaging the plug tip. Piace anew bonnet gasket onthe body, and lower the bonnet ‘carefully over the plug stem and body studs, tots place on tho body. Centre the bonnet go that the plug moves freely. Install the Stud nuts and tighten them evenly.- Packing (Clean the packing box thoroughly. Sip two or three packing rings over the stern to the Bottom ‘of the packing box. Pace the lantern ring on top of two rings, then place four oF five rings on the top of the lantern ring. \NOTE:Check to be sure that the channel in the lantem ring 4s opposite the lubricator hole in the vaive bonnet. Slip the gland over the s tem to rest on the packing and ‘check to see that It enters the packing box at least 1/8", Place the gland flange fat side up aver the stem and gland ‘studs to rest on the gland. ‘Screw the giand nuts onto the studs and tighten them eveniy to avoid cocking the flange. Just over hand tight should be sufficient. Mounting Actuator on Valve. 2 Assomble and adjust the actuator as instructed in the ‘Actuator Instruction Manual Lower the actuator over the plug stem and gland flange to ‘seat squarely on the bonnet shoulder. Rotate the actuator to a convenient position, then screw the locking ring onto the valve bonnet threads and tighten it “The vaive plug must be on its seat while the actuator stem is being connected and the actuator stem must be at its lowest position of travel (apply air pressure if necessary) Press the half of the stem coupling which is threaded for ‘the coupling screw against the actuator stem and valve plug 10. n ‘tem po that: (@) The ends ofthe stems are equidistant from the tapped coupling sorew hole, and ‘The tapped coupling screw hole is on the samo side © line aouator ea De ‘or other accessories ‘thich may require attachment tothe coupling screw, 77: may be necessary to move the valve lug ofits Mra wight stance n order to mesh the valve pug sim threads with the lower coupling treads. Apply te other hal of the coupling. cahily enganing threads, then inser the coupling screw and Ughten it by hand. ‘Maintaining the actuator stem as its lowest position of travel slacken off the coupling sorew slightly and, preventing the ‘stem coupling from rotating, unscrew the valve plug stem from the coupling untl the plug isfy seated. Move the plug off the seat by changing the alr pressure. thon unscrew the valve plug stem an additonal turn out of the coupling to ensure poaive seating Tighten the coupling screw securely. ‘Seat the vaive plug firmly by means of the actuator. ‘Adjust the travel indicator scale eo that the” Shut mark ‘opposite the travel indicator ring. Disconnect the airline used for assembly procedure, thon ‘apply the check nut or attachments (if any) to the coupling screw.LAPPING SEAT AND PLUG Genera Lapping should be carried out with the valve fully assembied (minus actuator to ensure correct contact between the surfaces to be lapped. Lapping can correct emall Imperfections inthe ‘seating surfaces but deep voratches can only be removed by machining. Excessive lapping produce a groove inthe plug whieh ta dettmertal to efficient operation. tug contoure should not be eiturbed by machining ork tn his wil change the cheracerato and rangeabg "7 Lapping Procedure 1. Produce a lapping tool, This can be made by welding a nut {with threading to maich the lug tem) tothe centre of a ‘ectangular section bar about 8* long. Screw and lock th ‘ool 10 the end ofthe plug stem. 2 Apply Grade’ compound (or finer othe seating surface ‘ofthe seat ng only. Lubvcate the plug stom whereit enters ‘the packing box, wih alight el. 3. Lapwith short oscilating strokes. The welght ofthe plug ‘Stem and lapping tool provides ample pressure for apping 60 not boar down ‘4. Rio the plug occasional, owe ito another postion and Feeume the oscillating strokes. This ensures an even lap ‘ver the entre seating surfaces of plug and seat. 5. Approximately § to 10 minutes lapping time, wih Grade ‘A Compound, 18 usually required to obtain a satstactory ft between a new plug and saat 8. Gleanthe plug and seat, then, holding the plug on the seat bby hand, apply compressed alr tothe init sie ofthe valve to check the tightness &f the lapped parts. Repeat the lapping procedure If necessary 7. Disassemble the vaive and clean all parts thoroughly. Remove all traces of grinding compound. 'NOTE : Do not laosen or remove the seat ring tor cleaning Purposes. PACKING INSTRUCTIONS ‘The instructions for valve packings described in the section headed * Maintenance" are appicabe to all ypes of packing in the form of ings of rectangular or square sacton. (Chevron PTFE Packing ‘The procedure to be adopted for Chevron rings genealyimtar but the arrangement is diferent (se0 Fig.) ‘Assembly 1. Clean the valve packing box thoroughly and check thatthe ‘stem and packing box surtaces are not damaged. 2 Lubricate the tive PTFE rings lightly with slicone Worieant {or ease n assembly one mele adaptor, one female adaptor ‘and three chevron rings.) 3. Slide the packing spacer aver the vaive plug stem tothe bottom ofthe packing box. Drop the packing washer over tha stem to rest on the spacer. Placa the PTFE male adaptor fet elde down, against the packing washer then ft the three chevron rings into the packing box, with grooved sides down. Seat he female ‘Adaptor fat side up on the topmost chevron ring. NOTE :Avold damage tothe PTFE rings when sipping them ‘ver the stem threads, and be sure each ring ls pushed firmty into the packing Dox. Slide the gland over the stem to reston the female adaptor 7. Slide the gland flange ft side up over the stem and studs to reat on the gland. 8. Screw the gland nuts onto the studs and tighten them evenly to avoid cocking the ange. Finger tightening is suticent. ‘NOTE : To tun the Plug Stem In the above instructions, frequent reference is made to tuning ‘he plug stem, to sight raise Ro ower tn relation tothe actuator stem. Betore carrying out this operation always check that the lug face Is nt in contact withthe seat and the coupling sorew is loosened sufclenty to allow the plug stem threads to rotate in the coupling, Fats fora spanner are not provided onthe atom as these cause local weak spot, but the stem cen be turned quite cell after above precautions have been taken by wrapping & ‘tip (about 1/2" wide) of emery cloth around the stem {rough surface in contact with the stem) just below the coupling, and thon gripping tle wth pliers having recessed jaws. Ifthe stem is aff to turn by this method the plug face Is probably in contact With the seat of the coupling screw has not been sufficiently loosened. NOTE : WHEN ORDERING SPARES, THE SERIAL NUMBER ‘OF THE VALVE MUST BE QUOTED.TTEMS MARKED* ‘ARE RECOMMENDED SPARES Fig. 2 Lubricator with isolating Vaive (fitted when required) Fig. 1 Chevron Packing *TTEMS MARKE ‘ARE RECOMMENDED SPARES Fig. 3 Plug and Guide Arrangement as for 1/2 - 94-1 Valves ‘Fg.5 Tim Arangement fo Mcrospiine Plug in Globe & Angie Vales Fig. 4 Phg and Guide Arargment sf 3. 2"- 16" abe Vas only| NAME OF PART 203 Body 208 Bonnet s217 Seat “ Spline Plug om pug “237 Plug Stem 243 Body Stud 4 Body Stud Nut +248 Body Joint Ring 250 Lubricator Plug +251 Packing Washer #282 Packing Ring +256 Lantern Ring +258 Gland 202 Gland Flange 265 Plug Guide #270 Plug Stem Pir 260 Gland Stud 283 Gland Stud Locknut 207 Locking Ring TTEMS MARKED" ‘ARE RECOMMENDED SPARES Fig, 7 Angle Vaive (Cast Body) Sizes 172°- /4°- 1".‘SAFETY MEASURES WARNING IN ORDER TO ENSURE OPERATOR SAFETY AND PLANT SAFETY IT |S IMPORTANT THAT : Installation and maintenance of this equipment is carried out by suitably trained personnel. Before selecting a location and installing the valve all the relevant sections of this manual must be read, and the requirements of associated equipment considered. Recommended pressures are not exceeded, all piping and pressure connections are adequate for the duty and are fitted correctly to give reliable pressure tight joints. This Is important where compressible fluids (gases, etc.) are concerned, since for these applications a fallure under pressure can result in an explosive release of energy. Where equipment such as solenoid valves and limit switches are fitted to the control valve, normal safety precautions must be taken to avoid the possibility of electrical shock. ‘The Company's poly is one of continuous product improvement andthe right is reserve to modity the spectations contained herehn without notice. Bd R. K. CONTROL INSTRUMENTS PVT. LTD. PLOT NO. 4.250, OPP. POLICE STATION, WAGLE INDUSTRIAL ESTATE, THANE 400 604. TEL : 532.0049, 892 2991, 832 1082. FAX : 022) 692 0801,