Installation, Operation and Maintenance Instructions MODEL 5540 Sep 20 CONTENTS.0 GENERAL. Model Number--------------------------------------------------------------------------------------------------------------- 2.2 Specifications---------------------------------------------------------------------------------------------------------------- 3.3 Parts List---------------------------------------------------------------------------------------------------------------------- 6.3. Model 5540---------------------------------------------------------------------------------------------------------6.3.2 Model 5540 Actuator - Direct-----------------------------------------------------------------------------------8.3.3 Model 5540 Actuator - Reverse-------------------------------------------------------------------------------0.4 Dimensions-------------------------------------------------------------------------------------------------------------------2 2.0 INSTALLATION-------------------------------------------------------------------------------------------------------------------3 3.0 MAINTENANCE 3. Trim Replacement----------------------------------------------------------------------------------------------------------4 3.2 Packing Replacement------------------------------------------------------------------------------------------------------4 3.3 Actuator Diaphragm Replacement--------------------------------------------------------------------------------------5 3.3. Direct (Fail Open) Actuators-----------------------------------------------------------------------------------5 3.3.2 Reverse (Fail Closed) Actuators------------------------------------------------------------------------------5 3.4 Preventive Maintenance---------------------------------------------------------------------------------------------------5 3.4. Valve Body----------------------------------------------------------------------------------------------------------5 3.4.2 Valve Trim----------------------------------------------------------------------------------------------------------5 3.4.3 Packing--------------------------------------------------------------------------------------------------------------5 3.4.4 Actuator Assembly -----------------------------------------------------------------------------------------------5 3.5 Troubleshooting--------------------------------------------------------------------------------------------------------------6
Model 5540 Installation, Operation and Maintenance Instructions.0 GENERAL. Model Number Information Page 2
.2 Specifications Page 3
Model 5540 Installation, Operation and Maintenance Instructions Page 4
Page 5
Model 5540 Installation, Operation and Maintenance Instructions.3 Parts List.3. Model 5540 Page 6
ITEM DESCRIPTION QTY. 2" 3" 4" 6" MAT'L. 2 SEAT PLUG 55876 55892 55827 55804 7-4PH 55876-55892- 55827-55804- 36 55877 55893 55826 55803 7-4PH 55877-55893- 55826-55803- 36 3 UPPER CAGE 55878 55894 55824 55807 CS 4 5 6 7 LOWER CAGE BUSHING CAGE O-RING CAGE GASKET 55879 55895 55825 55805 7-4PH 55879-55895- 55825-55805- 36 55880 55896 5557 55809 TFE 55880-55896- 55704 55809- GRAPHITE 55882 55898 5570 5580 304/GRF. 55882-55898- 5572 5580- INCONEL/GRF. 5588 55897 53057 55358 BUNA 5588-55897- 55869 558 VITON VALVE BODY, NPT 55883 VALVE BODY, SOCKET WELD 55884 VALVE BODY, BUTTWELD, SCH. 80 55885 VALVE BODY, 50# RF 8 VALVE BODY, 300# RF VALVE BODY, 600# RF VALVE BODY, 600# RJ 55886 55886-55887 55887-55888 55888-55889 55889-55899 55829 5580 55900 55870 55873 5590 5587 55874 55902 55872 55875 -WCC STL. - 9 SEAT GASKET 55890 55903 5570 5580 304/GRF. 55890-55903- 5572 5580- INCONEL/GRF. 0 VALVE STEM 5589 55904 55828 55802 36 PACKING SPRING 5500 55544 302 5502 55538 INCONEL 2 PACKING KIT 85000 85230 TFE/ 3 PACKING 5506 55543 TFE 5572 5573 GRAPHOIL 4 PACKING WASHER 5508 55545 5 PACKING SPACER 550 55548 6 UPPER PACKING RETAINER 5504 55542 36 7 PACKING STUD 2 082 083 8 PACKING NUT 2 084 9 20 ROLL PIN 554 55550 DRIVE PIN 556 557 36 VALVE BONNET, BELOW ANSI CLASS 500 558 5594 55284 55558 WCC STL. VALVE BONNET, ANSI CLASS 500 558 5596 55286 N/A WCC STL. 2 BONNET GASKET 5520 5598 55288 55552 304/GRF. 5522 55200 55290 55552- INCONEL/GRF. 22 23 BONNET STUD, BELOW ANSI CLASS 500 BONNET NUT, BELOW ANSI CLASS 500 8 8 5524 5526 5524 5526 55292 55296 55292 55296 BONNET STUD, ANSI CLASS 500 BONNET NUT, ANSI CLASS 500 2 2 5524(8) 5526(8) 55202(8) 55204(8) 55202 55204 N/A N/A B7 B7 24 PACKING FLANGE 5528 5554 36 25 WIPER 5530 55575 TFE 26 /4" PIPE PLUG 55432 STEEL 27 NUT YOKE 5532 55547 CS MEETS NACE SPECIFICATIONS Items 2, 26 Not Shown Page 7
Model 5540 Installation, Operation and Maintenance Instructions.3.2 Model 5540 Actuator - Direct Page 8
ITEM DESCRIPTION (TRIM SIZE) QTY. PART NUMBER MAT'L. #70 #20 #80 TRAVEL INDICATOR SCALE (.25"-") 55305 TRAVEL INDICATOR SCALE (2") TRAVEL INDICATOR SCALE (3") 55300 55302 TRAVEL INDICATOR SCALE (4") 55304 TRAVEL INDICATOR SCALE (6") 55540 2 ROUND HEAD SCREW 2 33070 3 HEX JAM NUT 2 55306 4 HEX CAP SCREW 2 5532 5 LOCK NUT 55308 55364 DUCTILE IRON 6 ACTUATOR SPRING ADJ. SCREW 5530 55366 C. STL. 7 TRAVEL INDICATOR 5532 55368 55570 8 LOWER SPRING RETAINER SEE SPRING CHART C. STL. 9 STEM CONNECTOR 55320 55374 C. STL. 0 ACTUATOR SPRING SEE SPRING CHART C. STL. ACTUATOR STEM 55334 55388** 2 HEX JAM NUT 55336 55390 C. STL. PLTD 3 ACTUATOR YOKE 55338 55392 * 55554 DUCTILE IRON 4 MOLDED DIAPHRAGM 55340 55394 55574 NITRILE/NYLON 5 SPRING LOCK WASHER 8 5322 C. STL. PLTD 6 LOWER DIAPHRAGM HOUSING 55342 55396 55563 C. STL. 7 DIAPHRAGM HOUSING NUT (x) 536 (2) 536 (24) C. STL. PLTD 8 UPPER DIAPHRAGM HOUSING 55344 55398 55564 C. STL. 9 HEX CAP SCREW (x) 534 (20) 534 (24) C. STL. PLTD 20 DIAPHRAGM PLATE 55346 55400 55566 WCC 2 BREATHER PLUG 002 55599 PLASTIC 22 UPPER SPRING GUIDE, 3-5 PSI 55404 UPPER SPRING GUIDE, 6-30 PSI 55406 STEEL PLTD 23 SPRING BEARING RETAINER 55408 C.S. 24 THRUST WASHER 5540 C. STL./MOLY 25 SNAP RING 5542 STEEL PLTD 26 HEX CAP SCREW 8 534 7088 C. STL. PLTD *FOR 6 INCH BODY, USE 55554 **FOR 6 INCH BODY, USE 55389 Body Size 2" Spring Spring Retainer Plug Control Cage Control Trim Size #70 #20 #70 #20 #80 #70 (PC) #70 (CC) #20 #80 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 0.250" -.00" 55324 55376 5538.50" 55332 5578 55386 5579 5538 55322 55324 55376 55378 5534 5538 5538 55370 2.00" 55322 55324 55376 55378 5534 3" 4" 6" 0.250" -.00" 55324 55376 5538.50" 55322 55324 55376 55378 5534 5538 2.00" 55322 55324 55376 55378 5534 5538 55326 55328 55380 55382 5534 5538 3.00" 55326 55328 55380 55382 5534 5534 0.250" -.00" 55324 55376 5538.50" 55322 55324 55376 55378 5534 5538 2.00" 3.00" 55326 55328 55380 55382 5534 5534 55330 55332 55384 55386 5534 5538 4.00" 55330 55332 55384 55386 5534 5538 4.00" 55384 55386 5576 5577 6.00" 5574 5575 55567 55568 55370 55370 55370 Page 9
Model 5540 Installation, Operation and Maintenance Instructions.3.3 Model 5540 Actuator - Reverse Page 0
ITEM DESCRIPTION (TRIM SIZE) QTY. PART NUMBER #70 #20 #80 MAT'L. TRAVEL INDICATOR SCALE (.250"-.00") 55305 TRAVEL INDICATOR SCALE (2.00") 55300 TRAVEL INDICATOR SCALE (3.00") 55302 TRAVEL INDICATOR SCALE (4.00") 55304 TRAVEL INDICATOR SCALE (6.00") 55540 2 ROUND HEAD SCREW 2 33070 3 HEX JAM NUT 2 55306 4 HEX CAP SCREW 2 5532 5 HEX JAM NUT 55348 5544 C. STL. PLTD 6 ACTUATOR SPRING ADJ. SCREW 55350 5546 C. STL. 7 TRAVEL INDICATOR 5532 55368 55570 8 LOWER SPRING RETAINER SEE SPRING CHART C. STL. 9 STEM CONNECTOR, 55320 55374 C. STL. 0 ACTUATOR SPRING SEE SPRING CHART C. STL. ACTUATOR STEM 55352 5548 55606 2 HEX JAM NUT 55336 C. STL. PLTD 3 ACTUATOR YOKE 55354 *55420 55598 DUCTILE IRON 4 MOLDED DIAPHRAGM 55360 55428 55573 NITRILE/NYLON 5 SPRING LOCK WASHER 8 5322 C. STL. PLTD 6 LOWER DIAPHRAGM HOUSING 55342 55396 55563 C. STL. 7 DIAPHRAGM HOUSING NUT (x) 536 (2) 536 (24) C. STL. PLTD 8 UPPER DIAPHRAGM HOUSING 55344 55398 55564 C. STL. 9 HEX CAP SCREW (x) 534 (2) 534 (24) C. STL. PLTD 20 DIAPHRAGM PLATE 55362 55400 55566 DUCTILE IRON 2 BREATHER PLUG 002 55599 PLASTIC 23 RETAINER BEARING SPRING 55408 C. STL. PLTD 24 WASHER THRUST 5540 C. STL./MOLY 25 RING RETAINING 5542 C. STL. PLTD 26 HEX CAP SCREW 8 534 7088 C. STL. PLTD 27 O-RING YOKE HOUSING 55358 55424 NITRILE 28 O-RING STEM 60078 55426 NITRILE 29 WASHER LOCK 3/4" 55430 C. STL. PLTD 30 WASHER BEARING 55356 C. STL. *FOR 6 INCH BODY, USE 55598 YOKE Body Size 2" Spring Spring Retainer Plug Control Cage Control Trim Size #70 #20 #70 #20 #80 #70 (PC) #70 (CC) #20 #80 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 3-5 6-30 0.250" -.00" 55324 55376 5538.50" 55332 5578 55386 5579 5538 55322 55324 55376 55378 5534 5538 5538 55370 2.00" 55322 55324 55376 55378 5534 3" 4" 6" 0.250" -.00" 55324 55376 5538.50" 55322 55324 55376 55378 5534 5538 2.00" 55322 55324 55376 55378 5534 5538 55326 55328 55380 55382 5534 5534 3.00" 55326 55328 55380 55382 5534 5534 0.250" -.00" 55324 55376 5538.50" 55322 55324 55376 55378 5534 5538 2.00" 3.00" 55326 55328 55380 55382 5534 5534 55330 55332 55384 55386 5534 5538 4.00" 55330 55332 55384 55386 5534 5538 4.00" 55384 55386 5576 5577 6.00" 5574 5575 55567 55568 55370 55370 55370 Page
Model 5540 Installation, Operation and Maintenance Instructions.4 Dimensions Page 2
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
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 4. 7. 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 4. 9. Tighten packing flange nuts. Page 4
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 -4. 3.4 Preventive Maintenance The following preventative maintenance should be performed periodically as dictated by the severity of the application or by maintenance schedule. 3.4. 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. 3.4.2 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. 3.4.3 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. 3.4.4 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
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 70-2-976 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