MODEL 5540 CONTENTS. Installation, Operation and Maintenance Instructions 1.0 GENERAL

Transcription

1 Installation, Operation and Maintenance Instructions MODEL 5540 Sep 20 CONTENTS.0 GENERAL. Model Number Specifications Parts List Model Model 5540 Actuator - Direct Model 5540 Actuator - Reverse Dimensions INSTALLATION MAINTENANCE 3. Trim Replacement Packing Replacement Actuator Diaphragm Replacement Direct (Fail Open) Actuators Reverse (Fail Closed) Actuators Preventive Maintenance Valve Body Valve Trim Packing Actuator Assembly Troubleshooting

2 Model 5540 Installation, Operation and Maintenance Instructions.0 GENERAL. Model Number Information Page 2

3 .2 Specifications Page 3

4 Model 5540 Installation, Operation and Maintenance Instructions Page 4

5 Page 5

6 Model 5540 Installation, Operation and Maintenance Instructions.3 Parts List.3. Model 5540 Page 6

7 ITEM DESCRIPTION QTY. 2" 3" 4" 6" MAT'L. 2 SEAT PLUG PH PH UPPER CAGE CS LOWER CAGE BUSHING CAGE O-RING CAGE GASKET PH TFE GRAPHITE /GRF INCONEL/GRF BUNA VITON VALVE BODY, NPT VALVE BODY, SOCKET WELD VALVE BODY, BUTTWELD, SCH VALVE BODY, 50# RF 8 VALVE BODY, 300# RF VALVE BODY, 600# RF VALVE BODY, 600# RJ WCC STL. - 9 SEAT GASKET /GRF INCONEL/GRF. 0 VALVE STEM PACKING SPRING INCONEL 2 PACKING KIT TFE/ 3 PACKING TFE GRAPHOIL 4 PACKING WASHER PACKING SPACER UPPER PACKING RETAINER PACKING STUD PACKING NUT ROLL PIN DRIVE PIN VALVE BONNET, BELOW ANSI CLASS WCC STL. VALVE BONNET, ANSI CLASS N/A WCC STL. 2 BONNET GASKET /GRF INCONEL/GRF BONNET STUD, BELOW ANSI CLASS 500 BONNET NUT, BELOW ANSI CLASS BONNET STUD, ANSI CLASS 500 BONNET NUT, ANSI CLASS (8) 5526(8) 55202(8) 55204(8) N/A N/A B7 B7 24 PACKING FLANGE WIPER TFE 26 /4" PIPE PLUG STEEL 27 NUT YOKE CS MEETS NACE SPECIFICATIONS Items 2, 26 Not Shown Page 7

8 Model 5540 Installation, Operation and Maintenance Instructions.3.2 Model 5540 Actuator - Direct Page 8

9 ITEM DESCRIPTION (TRIM SIZE) QTY. PART NUMBER MAT'L. #70 #20 #80 TRAVEL INDICATOR SCALE (.25"-") TRAVEL INDICATOR SCALE (2") TRAVEL INDICATOR SCALE (3") TRAVEL INDICATOR SCALE (4") TRAVEL INDICATOR SCALE (6") ROUND HEAD SCREW HEX JAM NUT HEX CAP SCREW LOCK NUT DUCTILE IRON 6 ACTUATOR SPRING ADJ. SCREW C. STL. 7 TRAVEL INDICATOR LOWER SPRING RETAINER SEE SPRING CHART C. STL. 9 STEM CONNECTOR C. STL. 0 ACTUATOR SPRING SEE SPRING CHART C. STL. ACTUATOR STEM ** 2 HEX JAM NUT C. STL. PLTD 3 ACTUATOR YOKE * DUCTILE IRON 4 MOLDED DIAPHRAGM NITRILE/NYLON 5 SPRING LOCK WASHER C. STL. PLTD 6 LOWER DIAPHRAGM HOUSING C. STL. 7 DIAPHRAGM HOUSING NUT (x) 536 (2) 536 (24) C. STL. PLTD 8 UPPER DIAPHRAGM HOUSING C. STL. 9 HEX CAP SCREW (x) 534 (20) 534 (24) C. STL. PLTD 20 DIAPHRAGM PLATE WCC 2 BREATHER PLUG PLASTIC 22 UPPER SPRING GUIDE, 3-5 PSI UPPER SPRING GUIDE, 6-30 PSI STEEL PLTD 23 SPRING BEARING RETAINER C.S. 24 THRUST WASHER 5540 C. STL./MOLY 25 SNAP RING 5542 STEEL PLTD 26 HEX CAP SCREW C. STL. PLTD *FOR 6 INCH BODY, USE **FOR 6 INCH BODY, USE Body Size 2" Spring Spring Retainer Plug Control Cage Control Trim Size #70 #20 #70 #20 #80 #70 (PC) #70 (CC) #20 # " -.00" " " " 4" 6" 0.250" -.00" " " " " -.00" " " 3.00" " " " Page 9

10 Model 5540 Installation, Operation and Maintenance Instructions.3.3 Model 5540 Actuator - Reverse Page 0

11 ITEM DESCRIPTION (TRIM SIZE) QTY. PART NUMBER #70 #20 #80 MAT'L. TRAVEL INDICATOR SCALE (.250"-.00") TRAVEL INDICATOR SCALE (2.00") TRAVEL INDICATOR SCALE (3.00") TRAVEL INDICATOR SCALE (4.00") TRAVEL INDICATOR SCALE (6.00") ROUND HEAD SCREW HEX JAM NUT HEX CAP SCREW HEX JAM NUT C. STL. PLTD 6 ACTUATOR SPRING ADJ. SCREW C. STL. 7 TRAVEL INDICATOR LOWER SPRING RETAINER SEE SPRING CHART C. STL. 9 STEM CONNECTOR, C. STL. 0 ACTUATOR SPRING SEE SPRING CHART C. STL. ACTUATOR STEM HEX JAM NUT C. STL. PLTD 3 ACTUATOR YOKE * DUCTILE IRON 4 MOLDED DIAPHRAGM NITRILE/NYLON 5 SPRING LOCK WASHER C. STL. PLTD 6 LOWER DIAPHRAGM HOUSING C. STL. 7 DIAPHRAGM HOUSING NUT (x) 536 (2) 536 (24) C. STL. PLTD 8 UPPER DIAPHRAGM HOUSING C. STL. 9 HEX CAP SCREW (x) 534 (2) 534 (24) C. STL. PLTD 20 DIAPHRAGM PLATE DUCTILE IRON 2 BREATHER PLUG PLASTIC 23 RETAINER BEARING SPRING C. STL. PLTD 24 WASHER THRUST 5540 C. STL./MOLY 25 RING RETAINING 5542 C. STL. PLTD 26 HEX CAP SCREW C. STL. PLTD 27 O-RING YOKE HOUSING NITRILE 28 O-RING STEM NITRILE 29 WASHER LOCK 3/4" C. STL. PLTD 30 WASHER BEARING C. STL. *FOR 6 INCH BODY, USE YOKE Body Size 2" Spring Spring Retainer Plug Control Cage Control Trim Size #70 #20 #70 #20 #80 #70 (PC) #70 (CC) #20 # " -.00" " " " 4" 6" 0.250" -.00" " " " " -.00" " " 3.00" " " " Page

12 Model 5540 Installation, Operation and Maintenance Instructions.4 Dimensions Page 2

13 2.0 INSTALLATION. 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. When installing the valve into the pipeline, consult the engineering specifications to ensure that the valve is installed according to the intended flow pattern ( above-the-seat or below-the-seat ). As a general rule of thumb, the flow pattern (direction) is below-the-seat for throttling applications, and above-the-seat for snap (on/off) applications. 3. Install valve using good piping practices. 4. Do not install the valve in a system were the working pressure might exceed the class rating marked on the nameplate. 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. 5. Connect instrument air to the actuator. 6. Valves with adjustable actuators are not shipped with actuator preset. Reverse (Fail Close) Actuators: To increase shut-off capability, increase spring pre-load by turning spring adjusting screw clockwise. To decrease spring pre-load, turn spring adjusting screw counter-clockwise. Direct (Fail Open) Actuators: To increase opening capability, increase spring pre-load by turning spring adjusting nut clockwise. To decrease spring pre-load, turn spring adjusting nut counter-clockwise. Page 3

14 Model 5540 Installation, Operation and Maintenance Instructions 3.0 MAINTENANCE 3. Trim Replacement WARNING: System pressure must be bled off to 0 psig or the valve must be isolated with the pressure bled off prior to any maintenance involving disassembly of the valve or valve actuator.. Remove air supply from actuator. 2. Remove all actuator spring pre-load on Reverse (spring closing) and Direct (spring opening) actuators prior to starting. 3. Remove the nuts from the bonnet studs. 4. Lift bonnet straight up and off valve body. Valve plug, guide and cage will be attached to the end of the valve stem. 5. Pull the seat and gasket out of seat pocket and lift out of valve body. 6. Clean seat pocket in valve body as required. 7. Insert new Seat and gasket. 8. To disassemble the plug from the stem, drive the retaining pin out of valve plug and unscrew the plug from the valve stem. 9. Slide the plug from the cage and guide. 0. Replace the Teflon O-ring and back-up Ring with new ones.. Slide new plug into the cage and guide. 2. Place new guide gasket onto the guide. 3. Screw new plug onto the valve stem until pinning holes line up and drive new retaining pin into place. 4. Install bonnet gasket on top of valve body. 5. Place bonnet assembly with new valve plug onto valve body making sure the bonnet is aligned correctly with the body. 6. Tighten bonnet nuts to recommended torque value in Table Reconnect instrument air supply to actuator. 8. Adjust actuator spring as outlined in Step 6 of Section 2.0, Installation. 3.2 Packing Replacement. Remove air supply from actuator. 2. Remove all actuator spring pre-load on Reverse (spring closing) and Direct (spring opening) actuators prior to starting. 3. Remove the nuts from the bonnet studs. 4. Lift bonnet straight up and off valve body. Valve plug, guide and cage will be attached to the end of the valve stem. 5. Assuming the actuator and stem connector have already been removed, pull the stem from the bonnet on the plug side leaving the plug, guide and cage attached. 6. Unscrew nuts from packing flange. 7. Remove upper packing retainer. 8. Remove Packing washer, spacer, load spring and packing. 9. It may be necessary to use a hook or a rod pushed through from the bottom side to the remove packing taking care not to scratch the wall in the bonnet. 0. Clean any debris from the bonnet and all metal parts.. Replace the packing spacer, the packing load spring and packing washer in that order into the bonnet. 2. Place the male V packing ring onto the packing washer. 3. Place the V packing rings onto the male packing ring. ( V downward toward the body) 4. Then place the upper packing retainer onto the packing. 5. Replace the packing flange and packing flange nuts. (Do not tighten) 6. Replace guide gasket and slide stem into the bonnet from the bottom. 7. Replace all gaskets. 8. Reinstall bonnet assembly by reversing steps 3-4 of these instructions. 9. Tighten bonnet nuts to recommended torque value in Table Tighten packing flange nuts. Page 4

15 Table 4. Torque Values (Foot Pounds) 3.3 Actuator Diaphragm Replacement 3.3. Direct (Fail Open) and Reverse (Fail Close) Actuators:. Remove air supply from actuator. 2. Remove all spring tension. 3. Remove screws and nuts around diaphragm housing. 4. Remove upper diaphragm housing. 5. If direct remove actuator diaphragm and replace with new diaphragm. 6. If reverse Remove diaphragm plate nut and/or diaphragm plate. Remove actuator diaphragm and replace with new diaphragm. 7. Reassemble actuator by reversing steps Preventive Maintenance The following preventative maintenance should be performed periodically as dictated by the severity of the application or by maintenance schedule Valve Body The internal valve body should be inspected every time trim is replaced, packing is changed, or the actuator is worked on. Under normal operating conditions the valve body should show no signs of wear. If wear is noticed within the valve body from high pressure drops, abrasive flows, or chemical corrosion, the valve body should be replaced to assure safety during valve operation Valve Trim Check the valve plug and seat for wear that might be caused by high pressure drops, abrasives in the media, or corrosion. If signs of wear are present, then trim replacement is recommended for optimum valve performance Packing Check the weep hole in the bonnet for discharge. Discharge is a sign of packing leakage. If discharge is present then packing replacement is recommended Actuator Assembly Visually inspect the actuator operation of the valve by observing the travel indicator while the valve is stoking for a smooth, consistent movement. Jerking type movements may indicate a problem within the valve. De-pressurize the valve and inspect it internally. Listen for a hissing sound during operation. This may indicate a worn seal or diaphragm. Replace any worn seal or diaphragm. Page 5

16 Model 5540 Installation, Operation and Maintenance Instructions 3.5 Troubleshooting Problem Possible Cause Fix Reverse Acting: Actuator spring load not sufficient. Valve leaks excessively when closed (Section.2 defines the Model 5500 leakage rates. Refer to ANSI / FCI for control valve allowable leakage classifications.) Direct Acting: Inadequate air supply pressure. Reverse Actuator: Increase actuator spring pre-load. Direct Acting: Increase air supply pressure but do not exceed maximum rating on nameplate. Valve will not open Discharge evident from bonnet weep hole. Supply air leaking out of breather plug during operation Debris between the plug and seat preventing tight shut-off. Plug and seat are not sealing. Plug and seat are worn out. Actuator force not enough for shut-off (actuator to small). Reverse Acting: Not receiving air supply. Reverse Acting: To much spring pre-load. Direct Acting: Inadequate spring pre-load. Debris lodged behind valve plug. Packing is worn. Diaphragm is worn out or torn. Remove debris. Re-lap trim. Replace trim. Consult factory or local representative for proper actuator sizing. Check air supply source and tubing to the actuator connection. Decrease spring pre-load by turning adjusting screw counterclockwise. Increase spring pre-load by turning adjusting nut clockwise. Remove debris. Replace packing. Replace diaphragm Page 6