Installation Operation and Maintenance Instructions Model Contents

Transcription

1 Contents 1.0 General 1.1 Model Number Specifications Dimensions Repair Kit Materials & Part Numbers Valve Materials & Part Numbers Installation Maintenance 3.1 Preventive Maintenance Troubleshooting Mallard Control 1500 S.E. 89th Street Oklahoma City, OK USA Phone: (405) Fax: (405) sales@circorenergy.com Mallard-5127IOM-Nov-11-2up-HP 2011 CIRCOR Energy Mallard Control is a Brand of CIRCOR Energy Litho USA Mallard reserves the right to change designs, materials or specifications without notice or without obligation to furnish or install such changes on products previously or subsequently sold. Viton is a registered trademark of DuPont Dow Elastomers. Inconel is a registered trademark of Special Metals Corporation, USA

2 1.0 General 1.1 Model Number Information 1.2 Specifications Body Style Angle Process Connections 2" MNPT x 1" FNPT Pressure Rating 3000 psig (200 bar) Assembled Valve Temperature Limits -50 to 200 F (-46 to 93 C) ANSI Leakage Rating Class IV Materials of Construction Description Material Valve Body LCC Bonnet 1018 Steel, Electroless-Nickel Coated Hammer Nut Carbon Steel Trim 17-4Ph Stainless Steel,Tungsten Carbide (Optional) Valve Stem 303 Stainless Steel, 316 Stainless Steel (Optional) Packing PTFE V-Ring Seals Buna, Viton (Optional) Diaphragm Housings Steel Diaphragm Buna Reinforced with Nylon Fabric Actuator Spring Steel Approximate Weight with Actuator / Pressure Ratings Actuator Weight (lbs., kg) Max. Differential Pressure Size lbs. kg (psig) (bar) No No Page 2

3 1.3 Dimensions Repair Kit Materials & Part Numbers 316SS Trim Repair Kits 0.25 QO Buna-N QO Buna-N QO Buna-N QO Viton QO Viton QO Viton Meets NACE MR0175 Specifications Carbide Trim Repair Kits 0.25 QO Buna-N QO Buna-N QO Buna-N QO Viton QO Viton QO Viton Carbide / 316SS Trim Repair Kits 0.25 QO Buna-N QO Buna-N QO Buna-N QO Viton QO Viton QO Viton Valve Repair Kits (Less Trim) #35 Buna-N #35 Viton Complete Valve Topworks (Less Trim) Description Part No. #35 Fail Open #35 Fail Close Replacement Hardware Materials & Part Numbers Qty. 1 Adjusting Screw 316SS Jam Nut SS Diaphragm Housing Screw 316SS Diaphragm Housing Nut 316SS Qty. 2 Hex Nut SS Lock Washer SS Packing Plug 316SS Snap Ring SS Page 3

4 Valve Materials & Part Numbers Item Qty. 1 1 Adjusting Screw CS Jam Nut CS Upper Spring Retainer CS Spring OTMB Diaphragm Plate CS Upper Diaphragm Housing CS Lower Spring Retainer CS *8 1 Diaphragm Neoprene Lower Diaphragm Housing CS Diaphragm O-Ring Buna Viton Washer Bearing Steel Diaphragm Housing Screw CS Diaphragm Housing Nut CS Hex Jam Nut CS Hex Jam Nut CS Position Indicator Assembly CS Lock Washer CS *18 1 Stem O-Ring Buna Viton Packing Plug CS Snap Ring CS Hammer Nut CS Travel Stop CS Stem 303SS SS *24 1 Lower Housing O-Ring Buna Viton *25 B Packing Kit Includes: B1 1 Upper Packing Retainer Brass B2 1 Packing TFE B3 1 Lower Packing Retainer SS *25 SS Packing Kit Includes: SS1 1 Upper Packing Retainer SS SS2 1 Packing TFE SS3 1 Lower Packing Retainer SS Packing Spring *27 1 Packing Plug O-Ring SS Inconel Buna Viton Plug Guide SS 29 1 Cage CS *30 1 Seat O-Ring Buna Viton Valve Plug, QO 316SS Carbide Valve Plug,.5 QO 316SS Carbide Item Qty. 1 Seat, SS Carbide Seat, SS Carbide Seat, SS Carbide Body CS Seat / Cage O-Ring Buna Viton Lock Washer CS *Recommended Spare Parts Meets NACE MR0175 Specifications Page 4

5 2.0 Installation 1. Prior to valve installation, inspect the unit for damages which might have occurred during shipment and handling. Remove any items covering the process connections of the valve. Inspect the inlet and outlet connections to assure that no debris has become lodged inside the valve. 2. Install valve using good piping practices. 3. Connect instrument air to the actuator. WARNING: Working pressure of control valve body does not necessarily reflect the shut-off pressure of which the actuator is capable. Check actuator shut-off charts or call the factory. 3.0 Maintenance WARNING: System pressure must be bled off to 0 psig prior to any maintenance involving disassembly of the valve or valve actuator. 3.1 Preventive Maintenance 1. Seat and Valve Plug Normal Service: Check for wear or damage every six months. Severe Service: Check for wear or damage every sixty days. 2. Valve Stem O-Ring Inspect once a year. 3. Actuator Diaphragm Inspect once a year. 4. Body Check for wear or damage every time the actuator is removed. 3.2 Troubleshooting Problem Possible Cause Fix Debris between the plug and seat preventing tight shut-off. Remove debris. Valve leaks when closed. Plug and seat are worn out. Replace trim. Increase actuating air pressure to 20 psig. Valve will not open. Pressure drop across valve seat is too great. If this does not solve the problem, then the orifice is too large. Contact factory. Supply air leaking out of Diaphragm is worn or torn. Remove pressure and disassemble. diaphragm housing breather Diaphragm plates have worked loose If diaphragm is damaged, replace. plug during operation. and need to be tightened. If nuts that hold diaphragm are loose, tighten. Page 5