W-K-M Model MA-1 DynaCentric Butterfly Valve

Transcription

1 Page 1 of 16 R E P A I R M A N U A L W-K-M Model MA-1 DynaCentric Butterfly Valve

2 Page 2 of 16 Published October 2001 W-K-M and DynaCentric are trademarks of Cooper Cameron Corporation Cooper Cameron Corporation, Cooper Cameron Valves Division, All rights reserved.

3 Page 3 of 16 Table of Contents Bill of Materials... 4 Catalog Number... 5 Nameplate Information... 6 Scope... 6 Field Repair... 6 To Replace Stem Packing... 6 To Replace Valve Seat "- 12" Class 150, 3"- 10" Class 300, and 3"- 8" Class 600 Disassembly... 7 Bearing Drive Tools... 9 Assembly "- 30" Class 150, 12"- 24" Class 300, and 10"- 12" Class 600 Disassembly Bearing Drive Tools Assembly... 13

4 Page 4 of 16 Bill of Materials Figures 1 and 2 show a part-by-part breakdown of the DynaCentric butterfly valve. The name of each part is cross-referenced to a number for easy identification when ordering replacement parts. When ordering parts, make sure that the valve catalog number is included along with a description and reference number for the part. The catalog number is listed on the nameplate of each valve. (Figure 3) The catalog number code is defined on page 5. Seal kits are available, which include seat inserts (with inboard and outboard rings for metal seats), stem packing set and gaskets as applicable (Wafer body shown, lug body available) Figure 1 - Cooper Cameron Valves' W-K-M 3"-12" Class 150, 3"-10" Class 300, 3"-8" Class 600 DynaCentric Valve Components. ITEM DESCRIPTION ITEM DESCRIPTION 1. Body Screw 4. Stem/Disc Spring 5. Stop Pin 6. Stop Pin Plug 7. Stem Bearing 8. Nameplate 9. Gland Retainer 10. Gland Retainer Stud 11. Gland Retainer Nut 12. Body Gasket 13. Stem 14. Disc 15. Lower Stem 16. Stem Pins 17. Disc Spacer 18. Key 19. Stem Retainer Pins 20. Packing Spacer 21. Gland Ring 22. Seat 23. Packing Set 25. Bottom Cover 26. Bottom Cover Gasket 27. Bottom Cover Screw

5 Page 5 of (Lug body shown, wafer body available) Figure 2 - Cooper Cameron Valves' W-K-M 14"-24" Class 150, 12"-24" Class 300, 10"-12" Class 600 DynaCentric Butterfly Valve Components. Catalog Number Information X X - A5 X X X - X X - X X X - X X - X X Size Body Trim Seal Packing Actuation Inches Group Group Group Group 4 3" 03 4" 04 6" 06 8" 08 10" 10 12" 12 14" 14 16" 16 18" 18 20" 20 24" 24 Class Material Style 1=150 1=CS 0=Wafer 3=300 2=SS 1=Lug 6=600 3=CS2 1 4=CS/ENC 5=LCC Note: Valves with optional materials of construction are available on application. 1 Controlled hardness carbon steel (H 2 S Service). 2 Valves equipped with 316 SS stems may require derating depending on size and class. 3 Standard seat for class 600 valves. 4 SS packing adjustment studs and nuts are standard. * Cabon steel discs (14" and larger consult factory). 5 Ref. "inconel" CS Disc* 17-4 Stem SS Disc 17-4 Stem SS Disc Ni-Cr 5 Stem Ni-Cu 6 Disc & Stem SS Disc 316SS Stem 2 SS Disc HF-6 O/L Stem SS Disc HF-6 O/L 7 Ni-Cr Stem TFE RTFE SS/RTFE Ni-Cr 5 Alloy (UNS No. 6625)/RTFE 316SS Ni-Cr 5 Alloy (UNS No. 6625) S01 S02 F02 3 F03 M01 M03 TFE VEE High Temp Graphitized Grafoil 14 Bare Stem Handle Handwheel Worm Gear 00 HL WG Chainwheel CH Worm Gear 6 Ref. "monel" 7 Ref. "Stellite" overlay

6 Page 6 of 16 Nameplate Information ITEM STAMP 1 Valve Size. 2 Model Number 3 Optional Information 4 Bill of Material Number 5 Stem Material 6 Disc Material 7 Seat Material 8 Packing Material 9 Maximum CWP 10 Seat Ratings Scope This manual details repair procedures for the DynaCentric Model MA-1 high performance butterfly valve. Under no circumstances should Figure 3 - Typical Dynacentric Nameplate. repairs be attempted with pressure on the valve. Disassembly and parts replacement is easily accomplished as outlined in this manual. Field Repair To replace stem packing: 1. De-pressurize the system, and place the valve in full open or closed position. Remove handle, worm gear operator or power actuator from top of valve. Note: It is not necessary to remove these components to add split ring packing. 2. Remove hex nuts from gland retainer and remove gland retainer and gland ring from valve stem. 3. Remove packing from stuffing box using a packing auger. (Figure 4) 4. Install new packing set. Split ring packing must be installed with seams staggered every 90. Vee packing is continuous and except for valves in vacuum service is installed with the pressure lips directed toward the bottom of the stuffing box. (For vacuum service, Vee packing is installed with the pressure lips directed away from the bottom of the stuffing box.) 5. Replace the gland ring, gland retainer and hex nuts. Tighten the nuts alternately until resistance is encountered. Tighten the nuts an Hex Nuts Gland Retainer Gland Ring Packing Set Figure 4 additional half turn to energize the packing. Do not over tighten the gland retainer nuts. Excessive tightening can cause extreme valve torque and premature packing wear. 6. Replace handle or actuator. Bring system back on-stream. 7. Inspect valve for stem leakage. Should leakage occur, tighten gland retainer nuts evenly until leakage stops.

7 Page 7 of 16 To replace valve seat: 1. De-pressurize system and place valve in closed position. 2. Remove valve from line. 3. Remove seat retainer capscrews and seat retainer. (Figure 5) 4. Remove seat from body or seat retainer. Carefully clean residue from seat pocket in body and seat retainer. 5. Install new seat into seat retainer. Nonmetallic seats are simply laid into the seat pocket taking care to match seat profile with the contour of the pocket. Metallic seats require the application of sealant to both the seat retainer and the valve body seat pockets. PTFE base pipe thread sealant such as Permatex Seals Pipe, Loctite PST or the equivalent is recommended for temperatures less than 500 F. Key Red-D-Mix TM, a graphite paste and sealant, should be used for high temperature applications. 6. Replace seat retainer and capscrews. Tighten capscrews evenly using a star or crossover pattern to the following torque values: 1/4" Screws ft.lb. 5/16" Screws ft.lb. 3/8" Screws ft.lb. Check that heads of capscrews are below the surface of the seat retainer. 7. Hydro-test and return valve to the line. Disassembly 3 12 Class Class Class 600 DynaCentric butterfly Valves 1. De-pressurize system and place valve in closed position. 2. Remove valve from line. 3. Position the valve horizontally on wooden support blocks with the seat retainer facing upward. (Figure 6) 4. Remove the handle, the worm gear or the power actuator from the top of the valve. Valves 8 and larger have a stem key, which should be retained for reassembly. 5. Using a hex key, remove the socket head capscrews that attach the seat retainer. 6. Remove the seat retainer, seat and body gasket (if applicable) from the valve body. 7. Remove two hex nuts from the gland retainer. Seat Pocket Figure 5 Seat Cap Screws Teflon is a registered trademark of DuPont. Permatex Seals Pipe and PST are registered trademarks of Loctite Corporation. Cap Screws Support Block Body Gasket Seat Body Gasket Figure 6 8. Remove the gland retainer and the gland ring from the valve stem. 9. Using a packing removal tool such as a packing

8 Page 8 of 16 auger, remove the stem packing and the packing spacer from around the stem (Figure 7) Packing Spacer Packing Gland Ring Gland Retainer Hex Nuts Suggested drill sizes are: Stem Size 1/2 Drill Size 3/32 5/8 5/32 7/8 3/16 1-1/8 9/32 1-3/8 11/32 1-3/4 3/8 2 3/8 2-1/4 1/2 2-1/2 1/2 3-1/2 9/ Remove the stem from the top of the valve body. If necessary, grip the stem top with a vice or locking pliers and pull the body off the stem. (Figure 10) Figure Rotate the disc to the open position. 11. Using a punch against the small end of the groove pins, drive the pins from the disc/stem assembly. (Figure 8) Figure 10 Stem Disc Spacer Disc Figure If the pins cannot be driven out of the disc with a punch, they can be drilled and then punched out. Take care to keep the drill exactly in the middle of the groove pin to preserve the disc and stem integrity. (Figure 9) Figure 9 Stop Pin Stop Pin Plug 14. Remove the disc and disc spacer from the valve. 15. Remove the upper bearing from the valve body by driving it downward into the valve bore. It is recommended that a bearing removal tool be constructed to facilitate bearing removal. (Figure 11). 16. If necessary to remove the lower bearing, pack the bearing with grease and drive it out with sharp hammer raps on the bearing removal tool or use a commercial bearing extractor. 17. If necessary to replace the stop pin, remove the stop pin plug with a hex key. Using a punch, drive the stop pin outward from the valve body.

9 Page 9 of 16 Bearing Drive Tools Table 1. Bearing Drive Tool Dimensions Valve Size A(dia) B(dia) C(dia) D E in. in. in. in. in. 3" 150/300/ " 150/300 4" " 150/300 6" 600 8" 150/ " 150 8" " " 150 Construction of two simple bearing drive tools is recommended to facilitate the removal and installation of the stem bearings. Refer to Table 1 and Figure 11 for bearing drive tool dimensions for each valve size. Assembly 1. Clean and inspect all parts, and replace or repair any parts that are damaged or worn. Do not use preventatives or cleaning solutions on non-metallic parts. 2. Stand the valve body vertically on a work surface with the valve top down. 3. Position a stem bearing into the upper stem hole with the vertical seam in the bearing 90 from the valve through-bore. 4. Using a bearing installation tool, drive the bearing into the stem hole until it is flush with the upper stem counterbore. (Figure 12) Bearing Installation Tool Bearing Bearing Seam Bearing Removal Tool Ø C Bearing Installation Tool Ø B Figure Turn the valve body on the work surface so the valve top is up. (Figure 13) E D E Bearing Installation Tool Ø A Ø A D Bearing Bearing Seam Stem/Disc Springs (3) Figure 11 Figure Insert three (3) stem/disc springs in series, with the top spring s cone side up, into the lower stem bore. 7. Position a stem bearing into the lower stem hole with the vertical seam in the bearing oriented 90 from the valve through-bore. Use care to avoid dislodging the springs from their series stack when driving the bearing into position. 8. Using a bearing installation tool, drive the bearing into the stem hole until it is flush

10 Page 10 of 16 with the inside of the body through bore. 9. Remove any burrs caused by driving the stem bearings into position. 10. If the stop pin was removed during assembly, use a punch to drive the pin into the body until it bottoms out in the pin hole counterbore. 11. Using a punch, flatten or stake the head of the stop pin to tighten it in the body. (Figure 14) 17. Using a punch, drive the groove pins through the disc and stem until securely seated. (Figure 16) Always use new groove pins for reassembly. Body Plug Stop Pin Figure 16 Punch Figure Wrap the stop pin plug with Teflon tape and install in the body with a hex key. 13. Install the stem retainer pins into the blind holes in the stem. Mushroom the pins with a blow from a hammer to tighten them in the stem. 14. Lay the valve body flat on the work surface with the seat side up. Slip the stem into the upper stem bearing until it protrudes through into the body bore approximately 1/8". Install the disc spacer on the end of the stem. (Figure 15) Stem Disc 18. Slide the packing spacer over the stem and into the packing box. 19. Install new packing set. Split ring packing must be installed with seams staggered every 90. Vee packing is continuous and except for valves in vacuum service is installed with the pressure lips directed toward the bottom of the stuffing box. (For vacuum service, Vee packing is installed with the pressure lips directed away from the botom of the stuffing box. Figure 17) Packing Spacer Packing Gland Ring Gland Retainer Hex Nuts Figure 17 Figure 15 Disc Spacer 15. Position the disc with the groove pin holes toward the top of the valve, position the disc in the body bore and slide the stem through the disc into the lower stem bearing. 16. Rotate the stem to align the groove pin holes in the stem with those in the disc. 20. Slip the gland ring over the stem. 21. Install the gland retainer studs if they have been removed. Install the gland retainer over the stem and gland retainer studs. 22. Install the gland retainer nuts on the gland retainer studs. Tighten the nuts alternately until resistance is encountered. Tighten the nuts an additional half turn to energize the packing. Do not over tighten the gland retainer nuts. Excessive tightening can cause extreme valve torque and premature packing wear.

11 Page 11 of Inspect the seat pockets in both the body and the seat retainer to ensure that they are clear of contaminants. 24. Move the disc to the closed position. 25. Install new seat into seat retainer. Non-metallic seats are simply laid into the seat pocket taking care to match seat profile with the contour of the pocket. Metallic seats require the application of sealant to both the seat retainer and the valve body seat pockets. PTFE base pipe thread sealant such as Permatex Seals Pipe, Loctite PST or the equivalent is recommended for temperatures less than 500 F. Key Red-D-Mix TM, a graphite paste and sealant, should be used for high temperature applications. (Figure 18) 26. For metal seated valves, install the body gasket into the gasket groove in the body. 27. Install the seat retainer screws, and tighten them evenly in a crossover or star pattern to the following torque values: 1/4" Screws ft.lb. 5/16" Screws ft.lb. 3/8" Screws ft.lb. Support Block Cap Screws Body Gasket Seat Figure 18 Ensure that the heads of the screws do not protrude above the surface of the seat retainer. 28. Hydro-test the valve to assure no leakage through or out of the valve. Disassembly 14" - 30" Class " - 24" Class " and 12" Class 600 DynaCentric Valves 1. De-pressurize system and place valve in closed position. 2. Remove valve from the line. 3. Position the valve horizontally on wooden support blocks with the seat retainer facing upward. (Figure 19) 4. Remove the worm gear operator or the power actuator from the top of the valve. Retain the stem key for re-assembly. 5. Using a hex key, remove the socket head capscrews that attach the seat retainer. 6. Remove the seat retainer, seat and body gasket (if applicable) from the valve body. (Figure 19) 7. Remove the two hex nuts from the gland retainer. 8. Remove the gland retainer and the gland ring from the valve stem. 9. Using a packing removal tool such as a packing auger, remove the stem packing and the packing spacer from around the stem. (Figure 20) Seat Stem Key Cap Screws Body Gasket Support Block Figure 19

12 Page 12 of 16 Hex Nuts Packing Spacer Packing Gland Ring Gland Retainer 10. Remove the four bolts from the bottom cover plate. (Figure 21) Springs Gasket Bottom Cover Plate Cover Plate Screws Figure 20 Figure Remove the bottom cover plate, gasket and the stem/disc springs. 12. Rotate the disc to the open position. 13. Using a punch against the small end of the groove pins, drive the two upper pins and one lower pin from the disc/stem assembly. (Figure 22) Figure Install a bolt in the internally threaded end of the lower stem and pull the stem out of the valve body. (Figure 24) 16. Remove the upper stem from the top of the valve. If necessary, install a bolt in the threaded hole in the end of the stem to facilitate removal. 17. Remove the disc and disc spacer from the valve. Note: The back of the disc has a tapped hole for installation of an eyebolt to allow easier handling of the disc. Bolt Upper Stem Eyebolt Lower Stem Bolt Figure 24 Figure If the pins cannot be driven out of the disc with a punch, they can be drilled and then punched out. Take care to keep the drill exactly in the middle of the groove pin to preserve the disc and stem integrity. (Figure 23) Suggested drill sizes are: Stem Size: 1-3/8" Drill Size: 11/32" 1-3/4" 3/8" 2" 3/8" 2-1/4" 1/2" 2-1/2" 1/2" 3-1/2" 9/16" 18. Remove the upper and lower bearings from the valve body by driving them inward toward the valve bore. It is recommended that a bearing removal tool be constructed to facilitate bearing removal. (Figure 25) Bearing Removal Tool Bearings Bearing Removal Tool Figure 25

13 Page 13 of 16 Bearing Drive Tools Table 2. Bearing Drive Tool Dimensions Valve Size A(dia) B(dia) C(dia) D E in. in. in. in. in. 14" " " " " " " " " " " " " " 150 Construction of two simple bearing drive tools is recommended to facilitate removal and installation of the stem bearings. Refer to Table 2 and Figure 26 for dimensions for each valve size. Bearing Removal Tool Ø C Ø A D E Bearing Installation Tool Ø B Ø A D E Figure 26 Assembly 1. Clean and inspect all parts, and replace or repair any parts that are damaged or worn. Do not use preventatives or cleaning solutions on non-metallic parts. 2. Place the valve body horizontally on wooden support blocks with the seat counterbore facing downward. 3. Position a stem bearing in the upper stem hole (Figure 27) with the vertical seam of the bushing 90 from the valve through bore. Bearing Seam Bearing Installation Tool Bearing Support Blocks Bearing Figure Using a bearing installation tool, drive the bearing in until it is flush with the upper stem counterbore. 5. Place a stem bearing in the lower stem bore with the vertical seam 90 from the valve through bore. 6. Using a bearing installation tool, drive the bearing in until it is flush with the body bore. 7. Remove any burrs caused by driving the stem bearings into place. 8. Position the disc so that the end with two groove pin holes is toward the top of the valve body and the flat disc face is down. Lower the disc through the valve bore and onto the work surface below. Note: The back of the disc has a tapped hole for installation of an eyebolt to allow easier handling of the disc. 9. Install the stem retainer pins into the blind holes in the stem. Mushroom the pins with a blow from a hammer to tighten them in the stem. 10. Slide the upper stem through the bore in the top of the valve body until it protrudes approximately 1/2" past the upper stem bearing. (Figure 28)

14 Page 14 of 16 Upper Stem Retainer Pins Disc Spacer Eyebolt Lower Stem Figure 28 Springs Gasket Bottom Cover Plate Cover Plate Screws Figure Slide the disc spacer over the protruding stem. 12. Slide the lower stem through the bore in the bottom of the body until the stem is flush with the body bore. 13. Lift the disc into position between the disc spacer on the upper stem and the lower stem. 14. Slide the upper and lower stems through the disc until the groove pin holes are aligned. If necessary, use a soft mallet to tap the stems into place in the disc. 15. Rotate the upper and lower stems as required to align the groove pin holes 16. Install the groove pins through the disc and into the stem. Rotate the disc to open the valve. 17. Using a punch, drive the groove pins flush with the disc hubs. (Figure 29) 20. Install the bottom cover gasket around the lower stem bore. 21. Install the bottom cover plate over the lower stem bore with the four bottom cover screws. 22. Slide the packing spacer over the top of the upper stem and into the packing box. (Figure 31) Packing Spacer Packing Gland Ring Gland Retainer Hex Nuts Figure 31 Figure Move the valve to the horizontal position on the wooden support blocks with the seat counterbore facing up. 19. Insert three (3) stem/disc springs in series, with the top spring s cone side up, into the lower stem bore. (Figure 30) 23. Install the packing set over the stem and into the packing box. The splits in split-ring packing must be alternated at 90 intervals. Vee packing must be positioned so that the seal lips face down toward the pressure. In vacuum applications, however, the seal lips should face up toward the top of the valve. 24. Slip the gland ring over the stem. 25. Install the gland retainer studs if they have been removed. Install the gland retainer over the stem and gland retainer studs. 26. Install the gland retainer nuts on the gland retainer studs. Tighten the nuts alternately until resistance is encountered. Tighten the nuts an additional half turn to energize the packing. Do not over tighten the gland retainer nuts. Excessive tightening can cause extreme valve torques and premature packing wear. 27. Inspect the seat pockets in both the body and

15 Page 15 of 16 the seat retainer to ensure that they are clear of contaminants. 28. For non-metallic seats, place the seat into the body over the disc. When installing metallic seats, apply a PTFE based sealant to the seat pocket of both the body and the seat retainer for F0 or M0 seats. A graphite based sealant is recommended for high temperature metal seats. Install the metal seat into the seat retainer. (Figure 32) Cap Screws Seat Body Gasket 29. For metal seated valves, install the body gasket into the gasket groove in the body. 30. Move the disc to the closed position, and install the seat and seat retainer into the body counterbore so that the holes in the seat retainer are aligned with the holes in the body counterbore. 31. Install the seat retainer screws, and tighten them evenly in a star or cross-over pattern to the following torque values: 5/16" ft.lb. 3/8" ft.lb. Ensure that the heads of the screws do not protrude above the surface of the seat retainer. 32. Hydro-test the valve to assure no leakage through or out of the valve. 33. Reinstall actuator or gear to the valve top. Stem Key Support Block Figure 32

16 Headquarters Cooper Cameron Valves South Main Street, Missouri City, TX Phone: , , Fax: Manufacturing Cooper Cameron Valves W-K-M Products P.O. Box Oklahoma City, OK Phone: , Fax: c Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / / W-K-M and DynaCentric are trademarks of Cooper Cameron Corporation