MARC Certified

Technician Training

Section
Three
Page 1
 Learning Objectives

• What a 21000 with standard actuator

and instrument is?
• Why it exists?
• How it works
• How to disassemble, inspect, repair,
assemble, calibrate and test

Page 2
 Reciprocating Control Valves
Globe Design
• Post (Shank) Top Guided
• Unbalanced Packing Follower

• Single Seated
Packing Ring (S)
• Captured Seat Ring (QC)
• Top Entry Stem

• Crane 285K / Grafoil Packing Plug Guide

Bushing
• General Service
Bonnet Gasket
• ¾” thru 6” ANSI 150—2500
Cage
• Raised Face End Connection
Plug Head

Seat Ring

Seat Ring
Gasket

Page 3
 Reciprocating Control Valves
Globe Design
• Post (Shank) Top Guided
• Unbalanced Packing Follower

• Single Seated Packing Ring (S)

• Captured Seat Ring (QC) Bonnet

• Top Entry
• Bellows
Bellows
• Special Service
• 1” thru 6” ANSI 150—300
Bonnet Extension
Masoneilan 21000
2” Cv = 46

Plug Guide
Bushing

Plug Head

Cage

Seat Ring

Page 4
 Reciprocating Control Valves
•
Angle Design
Post (Shank) Top Guided
• Unbalanced
• Single Seated
Packing Follower
• Captured Seat Ring (QC)
Packing Ring (S)
• Top Entry
• Wide Trim Selection Stem

• General Service Plug Guide

Bushing
• ¾” thru 6” ANSI 150—2500
Cage

Masoneilan 21000 2” Cv = 25 Plug Head

Seat Ring

Lo-db/Anti-Cavitation Trim

Page 5
 Reciprocating Control Valves
•
Globe Design
Post (Shank) Top Guided
• Unbalanced Packing Follower

• Single Seated Packing Ring (S)

• Threaded Seat Ring

• Top Entry Bonnet

• Bellows
Bellows
• Special Service
• 1” thru 6” ANSI 150—300
Bonnet Extension
Masoneilan 21000
1” Cv = 12

Plug Guide
Bushing
Body

Plug Head

Seat Ring

Page 6
 Reciprocating Control Valves
•
Globe Design
Heavy Plug Guided
• Unbalanced
• Single Seated Packing Follower
• Threaded Seat Ring Packing Ring (S)
• Top Entry
Lantern Ring
• Live-Loaded Seat Plug Stem
• Chemical Service Disc Springs
• 1” thru 2” ANSI 300
Plug Shank

Bonnet

Masoneilan 215X1 2” Cv = 45 Plug Guide

Bushing

Soft Seat Insert

Plug Tip

Seat Ring

Body

Page 7
21000A SERIES
TOP GUIDED ANGLE Follower

21000A Series Cast Angle

Lantern Ring
Grafoil Packing
Ring

1 -6 ANSI 150-2500 Class Stem

Carbon Steel & Alloy Extended Bonnet

Plug Bushing
Extended Bonnet
Bonnet Gasket

End Connections - SW,BW,RF,RTJ Plug

Reduced Trim Seat Ring

Retainer

ANSI Class IV & V Shutoff Seat Ring Gasket

Stellite Venturi Outlet

Stellite Venturi
Seat

Angle Body
Spring Diaphragm & Piston Actuation
Stellite Venturi Outlet
Page 8
 Disassembly
21000 Series Valve Body SA

Page 9
 Disassembly
21000 Series Valve Body SA
Bonnet Gasket Seat Ring

Packing Rings

Seat Ring Gasket

Cage

Plug Guide Bushing

Plug & Stem

Gland Flange Studs

Packing Follower Bonnet

Gland Flange

Gland Flange Hex Nuts Body Bolting Hex Nuts

Page 10
Instructor Guided Demo
Components

Page 11
 Disassembly
21000 Series Valve Body SA
Instructor Guided Demo

Page 12
 Disassembly - Review
21000 Series Valve Body SA

Page 13
 Inspection - Review
21000 Series Valve Body SA
• Wall thickness
in wear areas. Gasket Surface

ANSI B16.34
• Flange Bonnet Locating
Register

thickness ANSI
B16.5
Gasket Surface

• Gasket Surfaces
(125/250 RMS
Typical) Wall Thickness

• Guides

Page 14
ANSI B16.34 and B16.5

Page 15
 Body Wall

see tab 8
Page 16
 ANSI B16.5

Flange Dimensions

B Y

• Class 150 and 300

Page 17
 Flange Thickness
X
A

B Y
O
C
C
O

Blind Welding Neck

See tab 8
Page 18
 Inspection - Review
21000 Series Valve Bonnet
• Gasket Surfaces
Gland Flange
Studs
• Packing Box
• Stud
• Threads
Packing Box
Surface Finish &
• Bent
Inside Diameter

• Bushing
Gasket Surface
• Guide Surfaces
Plug Guide
Bushing

Page 19
 Inspection - Review
21000 Series Valve Trim

• Stem
• Pin
• Plug
• Seat Ring
• Sometimes:
• Cage
• Bushing

Page 20
Seat Re-Machining
0.015’’ max.
30º

28º

Stellite
Page 21
 Inspection - Review
21000 Series Valve Body SA
Common Types of Damage

• Cavitation
• Flashing
• Wire Drawing
• Erosion
• Chemical Corrosion
• Fretting

Page 22
 Cavitation & Flashing

Flow Direction

Vena Contracta
Inlet
P1
P2 Outlet
Dynamic Pressure
Profile
Pvc
Letdown Path

Control Valves Convert

Static Pressure to Kinetic Energy


Page 23
Cavitation & Flashing

Hydrodynamic Flow Regimes

Page 24
 Cavitation Phenomena

Vvc

Pressure  Downstream Pressure

P1 Recovery Above Vapor
Pressure

 Formation of
Vapor Bubbles
Velocity V2
V1
P2  Bubbles
Collapse
Pvapor
Flashpoint Pvc Cavitation
 Local Fluid Pressure Drops Below Fluid Vapor
Pressure

Page 25
Cavitation

o Localized
o Rough pock
marked
o Sounds like rocks
o Will attack any
material
o Worse with high
pressure

Page 26
 Flashing

• Erosion
• Mechanical
solutions
• Material
solutions

Page 27
Wire Drawing

• Erosion
• Seat leakage at
high pressure
• Cavitation
secondary

Page 28
Erosion

Page 29
Corrosion

• Chemical induces
• All wetted parts are
affected
• Material

Page 30
 Fretting

• Vibration induced
• Hardened
materials

Page 31
 Review
21000 Series Valve Body SA
Threaded Trim
• Post (Shank) Top Guided Packing Follower
Packing Ring (S)
• Unbalanced
Packing Spacer
• Single Seated Stem
Plug Guide
• Threaded Seat Ring Bushing

• Top Entry Bonnet Gasket

• Crane 285K / Grafoil Packing

• General Service Plug Head

• ¾” thru 6” ANSI 150—2500

• Race Face End Connection Seat Ring
(Threaded)

Body

Page 32
 Review
21000 Series Valve Body SA
Lo-dB® - Anti-Cavitation Trim

Page 33
 21000 Series Valves
Lo-dB® Noise Attenuation
• Drilled Hole Technology
• Flow-to-Open (FTO)
• Single Stage Trim
– 20 dBA Reduction

• Compressibles only
– Including Steam

• Application Dependent
– Pressure Ratio (P1/P2)

Page 34
 21000 Series Valves
Anti-Cavitation Trim
• Drilled Hole Technology
• Flow-to-Close (FTC)
• Single Stage Trim
– 20 dBA Reduction

• Incompressibles only
– Clean Service

• Application Dependent
– Pressure Ratio (P1/P2)

Page 35
 21000 Series Valves
Anti-Cavitation
Single Stage Trim
Fluid enters through the drilled cage.
Bubbles form and collide into each
other. As the bubbles collide they
implode against each other instead of
the valve trim.

Page 36
 21000 Series Valves
Anti-Cavitation
Two Stage Trim
Fluid enters through the drilled cage.
Bubbles form and collide into each
other. As the bubbles collide they
implode against each other instead of
the valve trim. Turn
Recombine

Split

Two stage cavitation control

works on the same principle
as the single stage. However
a second stage or cage is
added to take an initial
pressure drop.

Page 37
Instructor Guided Demo

Page 38
 Assembly Review
21000 Series Valve Body SA
Bonnet Gasket

Cage

Packing Rings
Body Bolting Studs Seat Ring

Plug Guide Bushing

Bonnet

Plug & Stem

Gland Flange Studs

Packing Follower

Seat Ring Gasket

Gland Flange

Gland Flange Hex Nuts Body Bolting Hex Nuts

Page 39
 Torque Procedures
• Reference
• Bulletins
• Instructions

Page 40
 21000 Series Control Valve
Model Number Identification
1st 2nd - 1st 2nd 3rd 4th 5th

Actuator Body Plug Control Seat

Type Series Type Characteristics Type
37 Air-to-Close 21 0 - Undefined 0 - Undefined 0 - Undefined
38 Air-to-Open 1 - Unbalanced 1 - Linear 4 - Quick
47 Air-to-Close contoured 2 - Equal % Change
48 Air-to-Open 5 - Threaded
7 - LO-DB
87 Spring Diaphragm
6 - Soft Seat
Air-to-Close
88 Spring Diaphragm
Air-to-Open
Page 41
 Part Numbers
• Trim Components
• 12 Digits
• Non Significant Except Material Code

Base Dash Material Code

xxxxxx - xxx - xxx (Alpha)

Location
Page 42
 • Typical Material Call-Outs

Material Code Description ASTM Application

010 Chrome-Moly Alloy Hex Nuts per ASTM A194 Gr 2H Nuts
066 Chrome-Moly Alloy Bolting per ASTM A193 Gr B7 Bolting
030 Carbon Steel Forge per ASTM A105 Body/Bonnet
104 Carbon Steel Cast per ASTM A216 Gr WCC Body/Bonnet
153 304 Stainless Steel Body/Bonnet/Trim
158 Austenitic stainless steel 304 per ASTM A194 Gr 8 Nuts
163 316 Stainless Steel Cast/Forge Body/Bonnet/Trim
177 304 Stainless Steel Bolting per ASTM A193 B8 Bolting
173 316 Stainless Steel Bolting per ASTM A193 B8M Bolting
174 316 Stainless Steel Hex Nuts per ASTM A194 Gr 8M Nuts
193 Martensitic Stainless Steel Cast per ASTM A487 Gr CA6NM Trim
210 17-4ph per ASTM A564 Gr 630 Trim
220 Martensitic SS per ASTM A276 Gr 440C Guide Bushings
244 Chrome-Moly casting per ASTM A217 Gr WC9 CL 3 Body/Bonnet
246 Chrome-Moly Casting per ASTM A217 Gr WC6 Body/Bonnet
250 Stainless Steel any 300 Series General
254 High-Strenght Bolting up to 1000F per A453 Gr 660 Bolting/Nuts
300 Casting Gray Iron Per ASTM A126 Class B General
322 Casting Ferritic Ductile Iron per ASTM A395 General
537 Inconel X-750 Per ASTM B637 GR 688 Trim
567 Stellite 6B Bar Trim
587 Hardface Stellite 6b on 316 SS Trim W/Over-Lay

Page 43
 Actuators
Model 37
• Air To Extend
• Air is supplied to top
side of the diaphragm
which opposes a
spring on the opposite
side
• Different Spring
Ranges are available
• Spring is adjustable

Page 44
 Actuators
Model 37
• Air Inlet
• Diaphragm
• Actuator Case
• Diaphragm Plate
• Stem
• Spring
• Spring Seat
• Yoke
• Spring load Adjustment
• Guide Bushing
• Travel Scale

Page 45
 Actuators
Model 38
• Air To Retract
• Air is supplied to
bottom side of the
diaphragm which
opposes a spring on
the opposite side
• Different Spring
Ranges are available
• Spring is adjustable

Page 46
 Model 38
Actuators
• Spring Load Adjustment
• Spring Seat
• Spring Barrel
• Spring
• Actuator Case
• Diaphragm
• Diaphragm Plate
• Stem
• Travel Stop
• Yoke
• Packing
• Guide Bushing
• Travel Scale

Page 47
Actuator Force Calculations
• F= Actuator Force (Lbs. Thrust )
• Pi = Actuator spring initial pressure
• Ai = Diaphragm initial effective area
• Dc = Diaphragm (Piston) Diameter (Inch)
• Ps = Actuator supply pressure
• Pf = Actuator spring final pressure
• Af = Diaphragm final effective area
• Y1 = Valve stroke

Air To Extend/Retract
F = (Ps - Pf ) x Af
Spring to Extend/Retract
F = Pi x Ai
Diameter of an Area
D c  1.128 * A i
Area of a Diameter
Dc 2 * 
Ai 
4
Page 48
 Actuator Force Calculations
Exercise
Air to Open / Fail Close
Actuator Selected
– #10 Actuator = 100 sq. inch area
• 6 Psi - 30 Psi spring range Air to Open
• 45 psi Supply 1-1/2” Stroke
Air To Retract F = (Ps - Pf ) x Af
• Available thrust to Open Valve=
Supply Pressure (Pi) – Spring Final (Pf) x Area of Diaphragm (Ai)
• Available Thrust (Factuator) = 45 Psi – 30 psi x 100 sq. inch
• Available Thrust (Factuator) = 15 x 100= 1500 Pounds
Spring to Extend F = Pi x Ai
• Available thrust to Close Valve=
Spring Initial (Pi) x Area of Diaphragm (Ai)
• Available Thrust (Factuator) = 6 psi x 100 sq. inch
• Available Thrust (Factuator) = 6 x 100= 600 Pounds
Page 49
 Actuators
Model 87
• Air to Extend
• Rolling elastomer diaphragm
for constant area.
• Multi-spring arrangement
allows for 4 standard spring
ranges.
– 3 - 15 PSI
– 6 - 30 PSI
– 11 - 23 PSI
– 21 - 45 PSI
• Changes are made by varying
the spring quantity (3 or 6),
type and placement.
• Field reversible with no
additional parts.
Page 50
 Actuators
Model 87
• Air Inlet
• Upper Diaphragm Case
• Rolling Diaphragm
• Diaphragm Plate
• Spring (s)
• Stem Bushing with Wiper Seal
• O’ring
• Actuator Stem
• Travel Scale
• Stem Connector (Top & Bottom)
• Short Yoke

Page 51
 Actuators
Model 88
• Air to Retract
• Rolling elastomer diaphragm
for constant area.
• Multi-spring arrangement
allows for 4 standard spring
ranges.
– 3 - 15 PSI
– 6 - 30 PSI
– 11 - 23 PSI
– 21 - 45 PSI
• Changes are made by varying
the spring quantity (3 or 6),
type and placement.
• Field reversible with no
additional parts.
Page 52
 Actuators
Model 88
• Spring (s)
• Upper Diaphragm Case
• Rolling Diaphragm
• Diaphragm Plate
• Stem Bushing with Wiper Seal
• O’ring
• Actuator Stem
• Travel Scale
• Stem Connector (Top & Bottom)
• Short Yoke

Page 53
 87/88 Spring Diaphragm
Actuators
Actuator Travel Spring Color Code Spring Range Number of Springs Spring Spacer
.8" Red 3-15 psi 3 No
1.5" Blue 6-30 psi 6 No
2.0" Green 11-23 psi 3 Yes
2.5" Yellow 21-45 psi 6 Yes
Spacers required on size (10) 1-1/2" stroke
Spacers required on size (16 & 23) 1-1/2" thru 2-1/2" stroke

Spring Selection and

Location

Lower Pedestal Upper Pedestal

Page 54
 87/88 Actuators
Instructor Guided Demonstration
Disassemble Inspect and
Assemble
Model 87
Model 88

Page 55
Diaphragm Plate
88 Actuators Disassembly

Jam Nut
Washer

Spring (s)

Upper Diaphragm Case

Capscrew Head Hex

Compression Nuts

Diaphragm
Hex Nuts
Page 56
 88 Actuators Assembly

Jam Nut
Washer Diaphragm Plate

Diaphragm
Spacer

Actuator Stem

Diaphragm

Page 57
 87/88 Actuators
Instructor Guided
Demonstration
Disassemble Inspect and
Assemble

Page 58
Type 87/88 Actuators
Handwheels

Page 59
21000A SERIES
TOP GUIDED ANGLE
• Post (Shank) Top Guided
• Unbalanced
• Single Seated Signal to Close
• Captured Seat Ring
Fail Open
• Extended Bonnet
• Top Entry
• Wide Trim Selection
• General Service
• ¾” thru 6” ANSI 150—2500

Page 60
 Type 37/38 Actuators
Handwheels
• 6A1-6A2-6A3
– Side Mounted H/W

Page 61
Bench Set and Test

• Spring Initial
• Spring Final
• Travel
• Operation
• Leakage

Page 62
Instructor Guided Demo
Assemble

Page 63
21000 Body SA and 87/88 Actuator
Assembly Review

SVI-II

Page 64
 Right-Hand ¼”-28

D C B A

Left-Hand ¼”-28
Valve Stroke Lever Arm Hole
Turnbuckle Length
1/4" - 3/4" A
1.25"
3/4" - 1-1/2" B
2.25"
1-1/2" - 2-1/2" C
2.90"
2-1/2" - 4" D
4.25"
7.25"

Page 65
 Turnbuckle Assembly

Jam Nut

Jam Nut

Right-Hand ¼”-28
Left-Hand ¼”-28
Rod-End Bearing
Rod-End Bearing
Page 66
 Mounting Bracket
Assembly

Take-Off Arm

5/16”-18 X ¾” Capscrew (2)

1-4”-20 Capscrew & Hex Nut

Turnbuckle Assembly
Right-Hand Rod End Bearing
Left-Hand Rod End Bearing
Turnbuckle
Jam Nuts

Page 67
Typical Reciprocating Alignment

Magnet Array is part of the bracket assembly and supported with roller bearings

Page 68
 Alignment of Lever Arm
Apply or Exhaust Instrument Air to the Actuator
Closing the Valve

Align Bracket so that Turnbuckle

assembly is parallel to actuator stem

Adjust Turnbuckle so that “Alignment”

Witness Mark is in “Line of Sight” with
Lever Arm

Page 69
 Mounting MNI 37/38
Mounting Sub-Plate
5/16”-18 X ¾” Capscrew (3)

Mounting Bracket
Assembly

Half-Shell Stem Clamps

Fillister Head Machine Screws

Take-Off Rod (5/16-18 X ¼-20”)

1-4”-20 Capscrew & Hex Nut

Turnbuckle Assembly
Right-Hand Rod End Bearing
Left-Hand Rod End Bearing
Turnbuckle
Jam Nuts

Page 70
 Alignment of Lever Arm
Apply or Exhaust Instrument Air to the Actuator
Closing the Valve

Align Bracket so that Turnbuckle

assembly is parallel to actuator stem

Adjust Turnbuckle so that “Alignment”

Witness Mark is in “Line of Sight” with
Lever Arm

Page 71
SVI-IIAP Keypad Flowchart

Page 72
SVI-IIAP Keypad Flowchart

Page 73
SVI-IIAP 375HHC Flowchart

Page 74
 4700 Series Positioner
Model Numbering
1st 2nd 3rd 4th 5th
4 E&P

P = Pneumatic
E = Electro/pneumatic

Page 75
 Positioners
Instructor Guided Demo
• Input • Output
• Pneumatic • Pneumatic

Page 76
Pneumatic Force Balanced Direct
Feedback Positioner

Actuator

Cam Differential Diaphragm

Pilot Assembly

Instrument Instrument Exhaust Output

Signal Supply

Page 77
 4700E Positioner
Pneumatic
• Input • Output
• Analog • Pneumatic

Page 78
 4700E Positioner
Electro-pneumatic

• Replace gauges
• Replace all O-Rings
• Replace Diaphragm
• Check Pilot Spool !!!!!
• Don’t over tighten

Page 79
 7400 Positioner
Bellcrank
Leaf Bearing Force Balance Spring

Index Lock screw

Index
Bypass Plug

Stroke Lever
1

3/8 3/4 1/2 1 1-1/2 2 3 Stroke Scale

Manifold
Pinion

Bellows
Spring Lever
Pilot

• Pneumatic Adjusting Screw

• Not Cam Characterized

Turnbuckle

• Linear Only
Page 80
 Valve Assembly Testing
Completing the MARC
Class “A” Repair

 Calibration
 Seat Test
 Hydro Test
 Performance Signature
 Tagged

Page 81
Masoneilan Global Standards

CES 1001 Hydrostatic Testing

CES 1002 Seat Leakage Testing
CES 1003 Minimum Quality Requirements for
Pressure Retaining Parts
CES 1004 General Requirements - Welding
CES 1006 Materials for H2S - Nace Service

CES 1007 Packing Leakage

CES 1008 Performance Testing
Page 82
 Masoneilan Standards

CES 1009 Hysteresis & Deadband

CES 1011 Procedure to Rate Valves Other
than ANSI B16.34 Code Material
CES 1013 Part Marking
CES 1014 Product Painting - Refer to ES 407
CES 1015 Product Cleaning - Refer to ES 392
CES 1016 Packaging - Refer to ES 256-1, -2
CES 1017 Stroke Time Test - Refer to ES 345

Page 83
 Masoneilan Standards

CES 1018 Actuator Sizing - Unbalanced Valves

CES 1019 Actuator Sizing - Balanced Valves

CES 1021 Maximum Tightening Torque Table

for Studs & Bolts in Pressure Retaining Service

& Other Product Specific Global Standards

Page 84
 20000 Series Valve Body SA
Compare and Contrast to 21000
 Older Style Version of 21000
 Never Stopped Making For Nuclear Industry
 Equipped With 37/38 Actuator
o Stem Diameter was 3/8” (21000 Min. ½”)
o Body & Bonnets not interchangeable
o Stem projection changes due to 87/88 implementation
o Cage design changed to “Bar-Stock”
o Body Bolt pattern 4-Bolt & 8-Bolt
o Some trim components are interchangeable

Page 85
 MARC Certified
Technician Training
Section
Three

Page 86