FLOWSERVE CORPORATION NOBLE ALLOY VALVE BALL VALVE REPAIR INSTRUCTION Cookeville Valve Operation 1978 Foreman Drive Cookeville, TN 38541 PH: 800-251-6761 931-432-4021 FAX: 931-432-5518
CONTENTS FLOWSERVE/NOBLE ALLOY VALVE BALL VALVE REPAIR MANUAL 1. Disassembly 1.1 Retainer/Top Works 1.2 Body Split 1.3 Internal Parts 2. Inspection/Cleaning 2.1 Body 2.2 Ball, Seats 2.3 Stem 2.4 Top Works 2.5 Seals 3. Assembly 3.1 Internal Parts 3.2 Body and Seal 3.3 Top Works 3.4 Adjustments 4. Drawings/Specifications 4.1 Exploded View Drawings for Ball Valves 4.2 Torque Chart 4.3 2 Piece Seat Photo 4.4 Cavity Filler Drawings 4.5 Fugitive Emissions Parts Drawings 5. Special Applications 5.1 2 Piece Slurry Seats 5.2 Cavity Filler 5.3 PEEK Seats August 22, 2002, Rev. 2
1.0 DISASSEMBLY Refer to included exploded view drawings for parts identification and location 1.1 Remove the actuator from the retainer (9) if valve is automated. Mount the valve in a vice or fixture by the flange on the Body (1) if flanged or thread a piece of pipe into the Body (1) of a threaded end valve and clamp in a vice or suitable fixture. CAUTION: BE SURE THE VALVE HAS BEEN FULLY DECONTAMINATED BEFORE ATTEMPTING DISASSEMBLY. If lever operated, remove set screw (22) from the handle (21) and remove handle by lifting straight off. The handle is not press fit to the stem. Loosen and remove retainer hex nuts (17) and remove stop collars (19) from retainer (8). Lift the retainer (8) off the studs (15). Remove the four emergency packing adjusting set screws (18) from the retainer. The thrust bearing (13) may stay in the retainer or may stay on the stem. If the thrust bearing remains in the retainer, tap the retainer on the bench to dislodge the thrust bearing or use a pick to work it out, otherwise lift it off the stem. Remove the shear collars (23) from the body or retainer depending where they stay when the retainer is removed. Shear Collars are not used on valves under 1.5" conduit size. Remove the spring cap (12), packing springs (11), and packing follower (10) from the stem. The packing will be removed later when the body is apart. For valves with Fugitive Emissions package, refer to the drawings for the 2 piece ball valve with dual packing and System II valves in section 4.1, and exploded view in section 4.5 for the additional parts to be removed. These will be removed after the retainer (8) is removed. 1.2 The next step is to disassemble the body. (In the case of 3 piece valves, the valve incorporated 2 tailpieces and a body center section. The only difference would be the addition of a second body seal and a second set of nuts and studs in the center section. All other repair instructions remain the same.) Loosen and remove body nuts (16). The Tailpiece (2) can now be removed. The body seal (7) will usually stay on the tailpiece. Remove the body seal and discard. BODY SEALS SHOULD NEVER BE REUSED! The seat (4), if it came off with the tailpiece, can be removed from the seat pocket. A pick may be needed, in case of a soft seat, to get the seat from the pocket. Be careful not to scratch or damage the seat pocket. Grasp the ball (3) and pull it out of the cavity (in the case of a 2-piece valve) using a rocking action. The second seat can then be removed from the body seat cavity. Remove the stem (5) by pushing it into the body cavity and then removing it from the body cavity. Remove the stem washer (6) from the stem and discard. STEM WASHERS SHOULD NOT BE RESUSED. NOTE: Stems on valves with 1/2" and 3/4" balls and some valves with Fugitive Emissions packages will have a clip style stem collar. To remove this type of stem, push the stem part way into the body cavity, remove the retainer clip and then pull the stem out the top of the body. Remove the packing (9). The valve is now ready for cleaning. August 22, 2002, Rev. 2 1
2.0 INSPECTION AND CLEANING 2.1 Thoroughly clean the body (1) and tailpiece (2) of all residue, scale or deposits. Be very careful not to scratch or damage the body seal or seat pocket surfaces during cleaning or they may not seal properly. Visually inspect the seal areas for scoring, erosion, pitting or any other damage. Inspect the ball cavity and waterways for erosion or significant loss of material. Any damage to the seal areas or seat pockets must be repaired before the valve can be reassembled. Inspection the packing bore for damage or galling. NOTE: Nobleized parts cannot be weld repaired and must be returned to the factory for repair. Inspect the end connections for corrosion or damage. Flanged valves' composite flange cannot be removed. If there is damage to the composite flange, it must be returned to the factory for replacement. Most surfaces can be polished with scotch-bright without damage. Inspect the body studs and nuts for corrosion and galling and if damaged, they must be replaced. 2.2 Thoroughly clean the ball (3) and seats (4) (if metal) of all residue, scale or deposits. Soft seats should be discarded and not be reused. Inspect the ball for erosion on the nose and scoring or scratches on the sealing area. If the ball has been damaged, it must be discarded. Nobleized balls and seats cannot be repaired and must be replaced. Inspect the metal seats, if equipped, for erosion, scoring or scratches on the seal face. Place the seat on a flat plate. From I.D. of the seat, place a feeler gauge between the seal lip and the plate to check for yielding. The seat must be replaced in the clearance is less than.004". If the metal seats are to be reused, be sure the backseat surface is clean and in good condition as this is important to sealing on this design seat. 2.3 Thoroughly clean the stem (5) of residue, scale or deposits. Inspect the stem tang (the end that engages the ball) for corrosion, twist or bending. Inspect the packing area of the stem for scoring, corrosion or galling. Minor galling on the stem where it comes through the body below the packing or around the tang is acceptable and can be filed or polished smooth. If the packing area of the stem has any damage, it must be replaced, as it will allow the packing to leak. 2.4 Thoroughly clean the balance of the top works, including the packing follower (10), packing springs (11), spring cap (12), thrust bearing (13), shear collars (23), retainer (8), stop collars (19), emergency adjusting set screws (18) and studs/nuts. All parts should be free of corrosion, scale or residue. The packing follower (10) should fit easily over the stem. The thrust bearing (13) should fit snugly over the stem shoulder but rotate freely. It should also fit snugly into the retainer bore but rotate freely. If not, it should be replaced. Inspect the packing springs (11) for any signs of corrosion and replace if they have any indication of damage or corrosion. The set screws (18) should screw in and out of the retainer easily. An anti-seize compound should be used on these. If they are damaged or frozen in the retainer (8) replace both the retainer and the set screws. Remember, the emergency adjusting set screws (18) are your back up packing adjustment should the live loading of the packing springs fail or the packing start to leak. 2.5 All seals including the packing (9), body seals (7) and soft seats (if equipped) should never be reused and should be replaced with new factory parts. August 22, 2002, Rev. 2 2
3.0 ASSEMBLY 3.1 Fixture the body (1) so the ball cavity is facing up. (In the case of 3 piece valves, assemble one tailpiece to the body and then proceed with the standard assembly instructions.) Be sure the body studs (14) are installed and equal in length. If the stem has a "c" clip retainer, install the stem from the topside of the stem bore so it protrudes into the ball cavity, place the "c" clip in the stem groove, and pull the stem tight into the stem bore. "C" clipped stems are only found in valves with 1/2" or 3/4" bore balls and valves equipped with the Fugitive emission package. Place a seat (4) into the seat pocket in the body with the conical seal face up. Seats are not matched sets and can be installed on either side. Metal and soft seats are interchangeable with each other. Insert the ball (3) into the body with a rocking motion so the ball slot engages the stem tang. 3.2 Place a new body seal (7) onto the seal land on the face of the tailpiece (2). Install the second seat into the seat pocket of the tailpiece. Carefully slide the tailpiece onto the body studs and onto the body, making sure the seat and body seal remain in place. Once the tailpiece is in place, install the body nuts (16) and torque to the proper specification listed on the torque chart for that size nut. This will crush the body seal and pre-load the seats. The torque chart is located in the specification section at the back of this manual. Check the body joint with a feeler gauge. The joint gap must not exceed.001". If an excessive gap remains after the body nuts have been torqued, place the valve in a hydraulic press and press until the.001" feeler gauge cannot be insert in the joint. Re-torque the body nuts while still under pressure on the press. 3.3 Fixture the assembled body so the stem is facing up. Slide the new packing (9) over the stem and work into the body packing bore. In case of the fugitive package, next install the lantern ring (25), block seal (26), FEM block (if supplied on Custom Ball valve)(27), and then the second packing. The packing follower (10) can be used to help push the packing down. Install the packing follower (10) onto the stem with the relief for the springs facing up, away from the body. Place the packing springs (11) over the stem and onto the packing follower. The dished side of the springs should face up, away from the body. Place the spring cap (12) over the springs so it encapsulates the springs. Place the thrust bearing (13) over the stem until it bottoms out on the land on the stem. It will sit partially in the spring cap. Install the retainer studs (15) into the body until they bottom in the threads. Place the shear collars (23) (if equipped) over the retainer studs and engage them into the body. Apply some anti-seize compound to the emergency packing adjusting set screws (18) and screw them into the retainer (8) until the ends of the screws are flush with the inside bore on the retainer. They should not stick out into the spring cap bore. They may protrude slightly out the top of the retainer. Install the retainer (8) over the studs and drop it into place over the stem parts. Place the adjustable stop collars (19) over the retainer studs (15), install the retainer nuts (17) but do not tighten fully. Install the handle (21) over the stem and place the set screw (22) into the handle and tighten. 3.4 The only feature that requires adjustment on the Flowserve/Noble Alloy valve is the adjustable stop collar (E) feature on the handle operated valves. Actuated valves do not have stop collars. The packing does not require any further adjustment after the valve has been assemble due to the live loaded design. Rotate the handle to open the valve to the full open position and align the ball bore so that it is centered with the conduit of the valve. With the retainer nuts (17) loosened, rotate one of the stop collars (19) until it contacts the ear on the handle stop. Tighten the nut fully. Rotate the handle a few times to check the alignment and readjust if necessary. Rotate the handle to close the valve, which will position the handle 90 degrees to the bore of the valve. Rotate the other stop collar (18) until it firmly touches the handle stop and tighten the nut fully. Rotate the handle a few times open and closed and check the alignment. Readjust if necessary. The valve is now ready for testing. August 22, 2002, Rev. 2 3
4.0 DRAWINGS AND SPECIFICATIONS August 22, 2002, Rev. 2 4
FLOATING BALL VALVE, SYSTEM II August 22, 2002, Rev. 2 5
FLOATING BALL VALVE, 2-PIECE DESIGN August 22, 2002, Rev. 2 6
FLOATING BALL VALVE, 3-PIECE DESIGN August 22, 2002, Rev. 2 7
TYPICAL 2 PIECE SEAT August 22, 2002, Rev. 2 8
BODY/TAILPIECE STUD TORQUE STUD NOMINAL SIZE 1/4-20 5/16-18 3/8-16 1/2-13 5/8-11 3/4-10 7/8-9 B8M STRAIN HARDENED - (IN-LBS) B8M STRAIN HARDENED - (IN-LBS) 95-100 190-200 380-400 800-840 NA NA NA NA NA NA NA 150-160 260-280 340-360 B7/B7M - (IN-LBS) 110-120 190-200 380-400 800-840 NA NA NA B7/B7M - (FT-LBS) NA NA NA NA 150-160 260-280 380-400 STUD NOMINAL SIZE 1-8 1 1/8-7 1 1/4-7 1 3/8-6 1 1/2-6 1 5/8-6 1 3/4-5 B8M STRAIN HARDENED - (IN-LBS) B8M STRAIN HARDENED - (IN-LBS) NA NA NA NA NA NA NA 400-420 630-650 900-920 940-960 1330-1350 1610-1630 1700-1730 B7/B7M - (IN-LBS) NA NA NA NA NA NA NA B7/B7M - (FT-LBS) 580-600 940-960 1340-1360 1780-1820 2500-2540 3220-3260 3400-3460 August 22, 2002, Rev. 2 9
Figure 1-2 Piece Seat Design August 22, 2002, Rev. 2 10
Figure 2 - LOCATION OF CAVITY FILLERS August 22, 2002, Rev. 2 11
August 22, 2002, Rev. 2 12
August 22, 2002, Rev. 2 13
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Figure 3 August 22, 2002, Rev. 2 15
Figure 4 August 22, 2002, Rev. 2 16
5 SPECIAL APPLICATIONS 5.1 2 Piece Slurry Seats - Refer to section 4.0 for photographs of 2 piece seat assembly The 2-piece seat consists of a seat carrier and separate seat ring. The carrier provides the spring, in the form of a bellville machined into it, and the support for the seat ring. The separate seat ring performs the sealing against the ball and is hardened Disassembly and assembly procedures for the 2-piece slurry seat are similar to the standard seat. Once the body is apart, removal of the seat assembly from the body (1) and tailpiece (2) is the same. Typically, the seats will be locked into the seat pockets by slurry buildup and are usually damaged removing them. Soaking and scraping as much slurry from around the set assembly will aid in removal. Care should be taken not to scratch or damage the seat pocket during seat removal. Should removal be successful, thoroughly clean the parts and inspect them for erosion, corrosion and scoring. Replace if damaged. Minor erosion on the waterway area of the carrier is acceptable and the carrier can be reused as long as the sealing area where the seat ring sits is clean and undamaged. It is recommended that the seat ring be replaced during a rebuild for good valve performance. Nobleized seat rings cannot be repaired and must be replaced. On assembly of the 2 piece seats, fill the spring groove in the carrier with silicone seal or graphoil, whichever is compatible in your service, to act as an excluder to prevent slurry buildup on the groove. Install and assemble the valve as noted in section 3.2 of the assembly instructions. 5.2 Cavity Filler - Refer to section 4.0, Figures 1 and 2 of cavity filler and location Cavity fillers are utilized in slurry valve applications to prevent slurry from compacting around the ball and locking up the valve. Cavity fillers are typically made from TFE or some other resilient material and machined to fit the cavity around the ball. Cavity Fillers serve no other function than to fill the cavity around the ball. They do not provide or aid the seats in any sealing. To remove and replace cavity fillers, refer to sections 1.2 and 3.1 disassembly and assembly instructions. When the valve body is first taken apart, the "A" cavity filler will be sitting on the ball. It should lift out easily. Once the ball has been removed, the "B" cavity filler can be easily removed. If the fillers are in good condition, they can be reused. To install, place cavity filer "B" in the body before installing the ball. Once the ball is in place, install cavity filler "A", face down on the ball, and assemble the valve according to the instructions in section 3.2. August 22, 2002, Rev. 2 17
PEEK SEATS - CAUTION PEEK seats require special fitment. Should the seats be installed without checking the seat preload, the valve may lock up which could possibly over stress the valve stem and damage it. Place the seats in the valve, install the ball, and tighten the body nuts without a body seal. Try to turn the valve using a wrench or the handle on the stem. If the ball does not turn or turns with a very high effort, disassemble the valve and lap.001" off of the back side (flat side) of one seat and repeat the procedure. Repeat the process until the valve turns with moderate torque, lapping one seat and then the other. PEEK seated valves have a higher torque than TFE seated valves which is normal. Do not make the ball/seat assembly loose or the valve will not seal. Be sure to install a new body seal when the seat fitment is complete. August 22, 2002, Rev. 2 18