Instruction Baumann 86000 Series Instructions Baumann 86000 Series Flexsleev Control Valve Instructions Contents Introduction...1 Scope...1 Safety Precautions...1 Maintenance...2 Installation...3 Air Piping...3 Disassembly of Valve...3 Reassembly of Valve...4 Changing Valve Travel...5 Parts List...7 Dimensions...8 Weights...8 INTRODUCTION The Baumann 86000 Series Flexsleev Control Valve is excellent for the precise control of acids or caustic process media. The 86000 Series Flexsleev valve incorporates the benefi ts of packless valves with the corrosion resistance of all-plastic wetted parts. Available in rated Cv s from 1 through 5.2, this valve features a ductile iron body with fl ange connections that mate with 1 class 125 Flat Face (FF) or 150 Raised Face (RF) fl anges. SCOPE OF MANUAL This instruction manual includes installation, maintenance, and parts information for the Baumann 86000 series Flexsleev sanitary control valve. No person may install, operate or maintain an 86000 series control valve without first being fully trained and qualifi ed in valve, actuator and accessory installation, operation and maintenance, and carefully reading and understanding the contents of this manual. If you have any questions about these instructions contact your Fisher sales offi ce before proceeding. NOTE Neither Emerson, Emerson Process Management, Fisher, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user. Always wear protective gloves, clothing, and eye wear when performing any installation operations to avoid personal injury. Personal injury or equipment damage caused by sudden release of pressure or bursting of pressure retaining parts might result if service conditions exceed those for which the product was intended. To avoid injury or damage, provide relief valve for over pressure protection as required by government or accepted industry codes and good engineering practices. Check with your process or safety engineer for any additional measures that must be taken to protect against process media. If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this instruction manual. 1
Baumann 86000 Series Instructions Instruction This valve is intended for a specific range of pressures, temperatures and other application specifications. Applying different pressures and temperatures to the valve could result in parts damage, malfunction of the control valve or loss of control of the process. Do not expose this product to service conditions or variables other than those for which the product was intended. If you are not sure what these conditions are you should contact your Fisher sales office for more complete specifications. Provide the product serial numbers (shown on the nameplate) and all other pertinent information. If you move or work on an actuator installed on a valve with loading pressure applied, keep your hands and tools away from the stem travel path to avoid personal injury. Be especially careful when removing the stem connector to release all loading on the actuator stem whether it be from air pressure on the diaphragm or compression in the actuator springs. Likewise take similar care when adjusting or removing any optional travel stop. Refer to the relevant actuator maintenance instructions. MAINTENANCE Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations: Always wear protective gloves, clothing, and eye wear when performing any maintenance operations to avoid injury. Disconnect any operating lines providing air pressure, electric power or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve. Use bypass valves or completely shut off the process to isolate the valve from the process pressure. Relieve the process pressure from both sides of the valve. Depending on the actuator construction, it will be necessary to manage the pneumatic actuator spring pre-compression. It is essential to refer to the relevant actuator instructions in this manual for safe removal of the actuator from the valve. Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when loosening the packing box pipe plug. 2
Instruction INSTALLATION NOTE Whenever a gasket seal is disturbed by removing or shifting gasketed parts, install a new gasket during reassembly. This provides a good gasket seal because the used gasket may not seal properly. Before attempting to do any work on a valve while the system is in operation, the valve must be isolated 100% from the active system and the isolated line voided of pressure and/or hazardous fluids. CAUTION The seating core (2) protrudes slightly beyond one side of valve body (1); to avoid equipment damage the included PTFE encapsulated line flange adapter gaskets (21) should be utilized. (Refer to Figure 1). Avoid personal injury or property damage by thoroughly cleaning the line of all dirt, welding chips, scale, oil or grease, and other foreign material. Failure to do so could result in damage to the seating and sealing surfaces of the valve and result in release of process materials. Baumann 86000 Series Instructions 1. Before installing the valve in the pipeline, thoroughly clean the line of all dirt, welding chips, scale, oil or grease, and other foreign material. A micron size filter is recommended upstream of the valve. 2. Install the valve so the controlled fl uid will fl ow through the valve body in the direction indicated by the arrow on the valve body. 3. A three-valve bypass must be used to permit removal of the control valve from the line without shutting down the system. 4. In case of a heat-insulated installation, insulate the valve body only, not the bonnet. AIR PIPING 1. For an air-to-extend actuator (air-to-close action), con nect the actuating air pressure line to the 1/4 NPT opening in the upper diaphragm case. For an air-to-retract actuator (air-to-open action) connect the actuating air pressure line to the 1/4 NPT in the lower diaphragm case. 2. Use 1/4 in. (6.4 mm) O.D. tubing or equivalent for all air lines except if air lines exceed 25 ft. (8 m) in length, then 3/8 in. (9.5 mm) tubing should be used. Air lines must not leak and air pressure should not exceed 35 psig (2.5 barg). 3. To detect a rupture of the sealing tube (5), connect vent of opening (12) to a separate vessel, vent area or to a pressure gauge. Pressure buildup indicates internal seal damage. Shut down system immediately! (Refer to Figure 1). BODY DISASSEMBLY (Refer to Figures 1, 2, and 3) 1. Mount the valve in a vise taking care not to damage the inserts, or clamp by the lip of the fl ange in a soft jaw insert in the vise (Figure 1). Caution must be taken not to damage the flange faces or seating core. 2. Unscrew yoke drive nut (9) and lift complete actuator, with amplifi cation mechanism (8) from valve body (1). Stem (3) should be at maximum upper extension (pull up). 3
Baumann 86000 Series Instructions Instruction 3. Using a small, round plastic or wooden rod, placed in Port B of seating core (2), gently tap seating core (2) together with sealing tube (5) from the body (1). 4. Slide sealing tube (5) off seating core (2) by pulling and turning (Figure 2). 5. Inspect seating surface (2A) and seating core (2) for damage and replace if necessary. NOTE: For changing fl ow capacity, you may need to use a core with a different orifi ce diameter (Parts Table 1). 6. Replace o-rings (6). 7. Inspect sealing tube (5) for wear and replace if necessary. 8. Remove plug (4) and stem (3) from body by holding plug (4) by hand and unscrewing stem (3) by using a 1/2 in. open wrench on the hex head. Inspect and replace packing follower subassembly (10) if necessary. REASSEMBLY 1. Slide sealing tube (5) over seating core (2) with o-rings (6) in place. 2. Replace plug (4) in body. Apply low strength LOCTITE no. 222MS, that can be mechanically separated, on thread of stem (3). Supporting plug (4) by hand, screw stem (3) onto plug using a 1/2 inch open wrench on the hex head. 3. Slide seating core (2) with sealing tube (5) into body (1) from "A" side of the valve body. Orifice (2A, Figure 2) must point exactly vertical up. Locate small hole in core fl ange (2B) to match center punch mark (1B) on surface of body fl ange (Figures 1 and 2). 4. When raised rim of seating core (2) enters recess of body (1), use flat smooth piece of wood or plastic to tap rim into the recess. Support spacer (120) to keep it from extending. 5. Attach a temporary pipe flange with air connection to inlet body flange and apply 10 to 50 psi air. Push down stem (3), and see if valve shuts off. If valve leaks, then core may be rotated off vertical center. Repeat step 3 and 4. 6. An Internal Seals Leak Test is very important and should be performed at this point. Attach a bolt-on blind fl ange to the "B" side of the valve. Be sure to install a line flange adapter gasket (21) between body and blind fl ange. Apply 50 lbs. of pressure on the "A" side of the valve. Remove bottom plug and either apply a bubble-tech solution or attach a small length of hose. If using the hose, insert 1/4 inch into a container of water. Initially, bubbles may appear but should slow to none. If there is a steady stream of bubbles the seals may be compromised. If this is the case, check core, o-rings and sealing tube for dents or grooves. Replace any damaged parts and proceed from step 2 above. 7. Attach temporary air line to actuator if air-to-retract (ATO) and bring actuator stem all the way up. Slide actuator with amplifi er assembly (8) half way over valve bonnet. Slip in drive nut (9) and engage bonnet thread. 8. Tighten actuator yoke with drive nut (9). 9. With air pressure in actuator (see step 7), slowly extend actuator stem down by varying the pneumatic actuator signal. Valve should shut off between 3 and 5 psig (depending on the internal pressure selected) for air-to-retract (ATO), or between 13 and 15 psig for air-to-extend (ATC). If shut-off is not obtained, loosen jam nut (27) and turn pusher pin (13) out of actuator stem in order to increase load on upper linkage (8A). If both upper link (8A) and lower link (8B) touch at lowest actuator travel and valve does not close, this indicates that the valve stem (3) is too short. Hold hex head with 1/2 inch open wrench and turn button-head screw (11) partially out of the stem (3). This may be necessary if core (2) is replaced. NOTE: If actuator travel is 1/8 inch short, this will require 1 turn of the screw (11) if linkage is 4:1 or 1/2 turn if linkage is 8:1. 4
Instruction Baumann 86000 Series Instructions CHANGING VALVE TRAVEL A change in the valve fl ow capacity may involve a different seating core (2) and a change in the valve travel. This is done by replacing the lower link (8B). Simply remove the cotter pin (8E, Table 2) to release the clevis pin (8C), slide out the lower link (8B) and add the new link. NOTE: The longer link reduces valve travel. Readjust pusher pin (13) or button head screw (11) as required for correct seating of valve. 5
Baumann 86000 Series Instructions Instruction A B Figure 1. Valve Body Assembly 8A 2A 8B 2B 6 2 6 5 8D 8C 8F Figure 2. Seating Core, Sealing Tube and O-Rings Figure 3. Mechanical Linkage Assembly, Key No. 8. 6
Instruction Baumann 86000 Series Instructions Table 1. PARTS LIST KEY NO. QTY DESCRIPTION PART NO. 1 1 Body 86201 Seating Core, Cv = 1.0 86303-701 2 1 Seating Core, Cv = 2.0 and 3.8 86302-701 Seating Core, Cv = 5.2 86301-701 3 1 Stem 86602 4 1 Plug 86501 5* 1 Sealing Tube 86401-940 6* 3 O-Ring 86704 7 1 Sleeve 86503 8 1 Mechanical Linkage Subassembly, Cv = 1.0 and 2.0 86900 Mechanical Linkage Subassembly, Cv = 3.8 and 5.2 86900-1 9 1 Drive Nut (Yoke) 011757-003-153 10* 1 Packing Follower Subassembly 86706 11 1 Button Head Cap Screw 81975 12 1 Hex Head Pipe Plug 86801 13 1 Pusher Pin 86601 14 1 Compression Spring 86800 20 1 Washer 25861 21 2 Line Flange Adapter Gaskets 86814 27 1 Locknut 971514-002-250 58 1 Travel Indicator 24299 120 1 Spacer 86511-940 * Recommended Spare Parts Table 2. MECHANICAL LINKAGE ASSEMBLY, KEY NO. 8, TABLE 1. KEY Cv = 1.0 & 2.0 Cv = 3.8 & 5.2 QTY DESCRIPTION NO. PART NO. 8A 1 Upper Link 86940 8B 1 Lower Link 86932 86931 8C 2 Clevis Pin 86802 8D 1 Support Bracket 86911 8E 2 Cotter Pin ( not visible from front) 86803 8F 2 Bushing (not shown) 81186 7
Baumann 86000 Series Instructions Instruction 3660/3661 Direct PTFE covered line fl ange adapter gaskets provided with valve. Figure 4. Dimensions; Actuator requires 4-1/2 in (115 mm) vertical clearance. (Valves rotated 90 0 for clarity.) CAUTION: The PTFE valve body insert protrudes slightly beyond both sides of valve body, it is highly recommended that the included PTFE encapsulated line fl ange adapter gaskets (21) be utilized. Table 3. VALVE AND ACTUATOR WEIGHTS DVC6010 FIELDVUE Digital Valve Controller PTFE covered line fl ange adapter gaskets provided with valve. (See CAUTION below) VALVE WEIGHT ACTUATOR WEIGHT lbs kg Type lbs kg 8 10 32 10 4.5 FIELDVUE, Flexsleev, Fisher and Baumann are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners. This product may be covered under one or more of the following patents 4,882,002, 4,953,824 or under pending patent applications. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifi cations of such products at any time without notice. Neither Emerson, Emerson Process Management, Fisher, nor any of their affi liated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user. Emerson Process Management Fisher Controls International LLC 130 International Drive Portsmouth, NH 03801 T 1 (603) 766-8500 F 1 (603) 766-8590 www.baumann.com Fisher Controls International LLC 2007; All Rights Reserved Printed in USA 8