Baker Hughes Masoneilan VariPak 28000 Series User manual

Masoneilan*
28000 Series VariPak*
Adjustable-CvControl Valves
Instruction Manual (Rev. B)
BHGE Data Classication : Public

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THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE
INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE
PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BHGE (BAKER HUGHES, A GE
COMPANY) AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT
TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY
HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN
CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR
REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO
PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION
OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE
WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD BE
REFERRED TO BHGE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO
THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL
REPRESENTATIONS OR WARRANTIES BY BHGE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY
THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION,
TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE
REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF BHGE.

Masoneilan VariPak Control Valve Instruction Manual | 3© 2018 Baker Hughes, a GE company. All Rights Reserved.
Contents
1. General .........................................................................................................4
1.1 Spare Parts................................................................................................4
1.2 After Sales Department ...................................................................................4
1.3 Training ...................................................................................................4
2. Operation .......................................................................................................5
2.1 Precise Adjustment of the Varipak 28002 Adjustable-CvValve .............................................5
2.2 Flow Coefficient of Varipak 28001 Single-Lever and 28002 Adjustable-CvValves ...........................5
2.3 Actuator ..................................................................................................7
2.4 Handwheel ................................................................................................7
2.5 Reversing the Valve Action ................................................................................8
3. Installation .....................................................................................................10
3.1 Preliminary Steps.........................................................................................10
3.2 Valve Installation .........................................................................................10
3.3 Pneumatic and Electrical Circuit ..........................................................................11
3.4 Limit Switches............................................................................................11
4. Calibration .....................................................................................................12
4.1 Piston Rod Clevis Adjustment.............................................................................12
4.2 Plug Stem Adjustment....................................................................................12
4.3 Limit Stop Adjustment....................................................................................13
4.4 Varipak 28002 CvAdjustment ............................................................................14
4.5 Positioner Start-Up Pressure Adjustment .................................................................14
5. Maintenance ...................................................................................................14
5.1 Actuator Diaphragm Removal.............................................................................14
5.2 Adding Packing Ring ......................................................................................14
5.3 Disassembly..............................................................................................15
5.4 Reassembly ..............................................................................................16
5.5 Packing Quick Change Method (Only For Valves With Max. CvOf 0.6 To 3.8) ...............................18
5.6 7700P or 7700E Positioner Maintenance..................................................................18
5.7 Maintenance Operations Specific to the 7700E Positioner.................................................19
5.8 Converting a 7700P Positioner (Pneumatic) into a 7700E Positioner (Electro-Pneumatic) ..................20

4 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
Safety Information
Important - Please Read Before Installation
Masoneilan 28000 Series instructions contain DANGER, WARNING,
and CAUTION labels, where necessary, to alert you to safety related
or other important information. Read the instructions carefully
before installing and maintaining your control valve. DANGER
and WARNING hazards are related to personal injury. CAUTION
hazards involve equipment or property damage. Operation of
damaged equipment can, under certain operational conditions,
result in degraded process system performance that can lead to
injury or death. Total compliance with all DANGER, WARNING, and
CAUTION notices is required for safe operation.
CAUTION
CAUTION
WARNING
DANGER
This is the safety alert symbol. It alerts you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
CAUTION
WARNING
DANGER
When used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, could result in
property damage.
Note: Indicates important facts and conditions.
About this Manual
• The information in this manual is subject to change without prior
notice.
• The information contained in this manual, in whole or part, shall
not be transcribed or copied without BHGE’s written permission.
• Please report any errorsorquestions about the information in this
manual to your local supplier.
• These instructions are written specifically for the 28000 Series
control valves, and do not apply for other valves outside of this
product line.
Life Period
The current estimated useful life period for the Masoneilan 28000
Series control valve is 25+ years. To maximize the useful life of
the product it is essential to conduct annual inspections, routine
maintenance and ensure proper installation to avoid any unintended
stresses on the product. The specific operating conditions will also
impact the useful life of the product. Consult the factory for guidance
on specific applications if required prior to installation.
Warranty
Items sold by BHGE are warranted to be free from defects in
materials and workmanship for a period of one year from the
date of shipment provided said items are used according to BHGE
recommended usages. BHGE reserves the right to discontinue
manufacture of any product or change product materials, design or
specifications without notice.
This instruction manual applies to the Masoneilan 28000 Series control
valves.
The Control Valve MUST BE:
• Installed, put into service and maintained by qualified
and competent professionals who have undergone
suitable training.
• Under certain operating conditions, the use of damaged
equipment could cause a degradation of the performance of
the system which may lead to personal injury or death.
• Changes to specifications, structure, and components used
may not lead to the revision of this manual unless such changes
affect the function and performance of the product.
• All surrounding pipe lines must be thoroughly flushed to ensure
all entrained debris has been removed from the system.

Masoneilan VariPak Control Valve Instruction Manual | 5© 2018 Baker Hughes, a GE company. All Rights Reserved.
1. General
These installation, operation, and maintenance instructions apply to Masoneilan VariPak 28000 series control valves. They
also include a parts reference list with recommended spare parts.
IMPORTANT REMARKS
Before installing, operating, or performing maintenance on this equipment, you should read
these instructions carefully and make sure you have understood them.
Work on this equipment should only be carried out by qualified personnel.
Failure to follow the instructions and precautions given in this document could lead to a
malfunction and seriously damage the equipment.
1.1 SPARE PARTS
For maintenance purposes, always use original
Masoneilan spare parts obtained through your local
BHGE representative or Spare Parts Department. When
ordering, always give the references of the original order
for the equipment concerned and, in particular, the number
indicated on the serial plate. (135)
1.2 AFTER SALES DEPARTMENT
BHGE has a highly skilled After Sales Department to assist
customers with start-up, maintenance, and repair of valves
and instruments. Contact your nearest BHGE Sales Office or
Representative.
1.3 TRAINING
BHGE organizes regular training courses in the operation,
maintenance and application of its Masoneilan control valves
and instruments for customer service and instrumentation
personnel. For further details, please contact your local
BHGE representative or Training Department.

6 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
2. Operation
The Masoneilan VariPak microflow control valve features a
very wide range of rated flow coefficients (Cv), from 0.004 to
3.8.
Two types of actuators are available:
- The VariPak 28001 with a single lever, designed for just one
rated Cv. This version is used when enough is known about
the operating conditions when sizing the valve.
- The VariPak 28002 with an adjustable rated Cv. This valve
uses a patented lever system to adjust the rated Cvon site
to suit the actual operating conditions, thereby avoiding
any oversizing in flow capacity. Each plug and seat ring
combination can be adjusted without changing the control
signal.
2.1 PRECISE ADJUSTMENT OF THE VARIPAK 28002
ADJUSTABLE-CvVALVE
The valve is adjusted using a simple, but robust, crossed-
lever system with an adjustable fulcrum. This can be done
easily by hand, either before installation or during operation.
For example, an application requiring a theoretical Cv
of 0.006 could be handled using a VariPak 28002 with a
maximum Cvof 0.010, that can subsequently be calibrated
on site between 0.004 and 0.010.
2.2 FLOW COEFFICIENT OF VARIPAK 28001
SINGLE-LEVER AND 28002 ADJUSTABLE-Cv
VALVES
2.2.1 Plug/seat ring combinations (trim)
Eight plugs and five seat rings are used to make up
the ten available plug and seat ring combinations,
identified by codes from 0 to 9 (see figure 2). The
shape of each plug and the port diameter of the
seat ring can be used to match parts with the table
in figure 2.
The difference between the four plugs in trim Nos.
6 to 9 lies in the angle of the flat machined on the
tip. The same seat ring (3e) and the same spacer (3f)
are used in all four cases (see figure 2).
Use the table in figure 1 to select the plug and seat
ring combination to obtain the Cvvalue or range of
Cvvalues you require.
Trim No.
FLOW COEFFICIENT Cv
VARIPAK
28001
VARIPAK 28002
MIN. RISK FREE MAX.
90.0040 0.0016 0.0020 0.0024 0.0028 0.0032 0.0036 0.0040
80.010 0.004 0.005 0.006 0.007 0.008 0.009 0.010
70.025 0.010 0.013 0.016 0.019 0.021 0.023 0.025
60.050 0.020 0.025 0.030 0.035 0.040 0.045 0.050
50.10 0.04 0.05 0.06 0.07 0.08 0.09 0.10
40.25 0.10 0.13 0.16 0.19 0.21 0.23 0.25
30.6 0.25 0.30 0.35 0.4 0.45 0.5 0.55 0.6
21.2 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
12.3 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3
03.8 1.5 1.9 2.3 2.6 2.9 3.2 3.5 3.8
Figure 1

Masoneilan VariPak Control Valve Instruction Manual | 7© 2018 Baker Hughes, a GE company. All Rights Reserved.
Plug and
seat ring
No. 9
Plug and
seat ring
No. 8
Plug and
seat ring
No. 7
Plug and
seat ring
No. 6
Plug and
seat ring
No. 5
Plug and
seat ring
No. 4
Plug and
seat ring
No. 3
Plug and
seat ring
No. 2
Plug and
seat ring
No. 1
Plug and
seat ring
No. 0
VariPak
28001 Cv0.004 Cv0.010 Cv0.010 Cv0.050 Cv0.10 Cv0.25 Cv0.60 Cv0.2 Cv2.3 Cv3.8
VariPak
28002
Cv
0.004 to
0.0016
Cv0.010
to 0.004
Cv0.010
to 0.004
Cv0.050
to 0.010
Cv0.10
to 0.04
Cv0.25
to 0.10
Cv0.60
to 0.25
Cv1.2 to
0.9
Cv2.3 to
0.9
Cv3.8 to
1.5
Orice Dia.
2 mm
3f 3d
3e Orice Dia.
1.6 mm
Orice Dia.
4.5 mm
Orice Dia.
9.5 mm
Orice Dia.
14.3 mm
3c 3b 3a
2.2.2 Changing the plug and seat ring combination
The plug and seat ring combination can be changed very
easily for trim Nos. 1 to 9 inclusive. Simply replace the
following parts:
- The plug and seat ring (see figures 1 and 2 to select the
combination required for the new Cv).
- The Cvadjustment plate (25) in the case of the VariPak
28002 adjustable-Cvvalve.
- If necessary, the actuator spring (134) (see figure 3 to check
the spring range corresponding to the new Cv.
Plug/Seat
No.
Flow
Coecient Cv
Spring Range (134)
Max. Pressure Supply
Adjustable CvSingle Lever
CI. IV CI. V CI. IV CI. V
m.bar Psi Color Code bar (Psi) bar (Psi) bar
(Psi) ATO ATC
03.8 to 1.5 414
-
1660
6-24 Red 2.1 (30) 2.1 (30) 2.1
(30)
2.8
(40)
12.3 to 0.9
21.2 to 0.5
30.6 to 0.25
40.25 to 1.10
207
-
1035
3-15 Green 1.4 (20) 1.4 (20) 1.4
(20)
1.7
(25)
50.10 to 0.04
60.050 to 0.020
70.025 to 0.010
80.010 to 0.004
90.004 to
0.0016
Figure 3 - Actuator spring ranges and supply pressures

8 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
Follow the procedure described in the "Disassembly/
Reassembly" section of the "Maintenance" chapter on
pages 14 to 18.
- Also change the serial plate (135) or correct the
information on the existing plate.
CAUTION
CAUTION
WARNING
DANGER
If the valve in question includes a 1/2" or 3/4"
NPT threaded end, the maximum capacity
of the body is respectively limited to trim
Nos. 9 to 3 inclusive or 9 to 2 inclusive. A trim
No. 9 cannot be installed in a VariPak valve
body designed for a trim No. 0. Likewise, a
trim No. 0 cannot be installed in valve bodies
designed for other trim numbers.
2.2.3 Adjusting the Cvof a Varipak 28002 valve for each
plug and seat ring combination
This is done by moving adjustment knob (24) along
adjustment plate (25) fastened to the top of lever No. 1
(21).
The adjustment plate (25) gives the range of Cvvalues
offered by the selected plug and seat ring combination.
Carry out this adjustment operation as follows:
Figure 4 - Adjusting the Cvof VariPak 28002 valve for each plug/
seat ring combination
- Loosen adjustment knob (24) and slide it along the lever
to the required value. Tighten the adjustment knob again
firmly.
Note:
- This operation entails moving lever No. 2, either
pneumatically (by allowing air into the actuator), or
manually (by pressing piston clevis (140b) with a
screwdriver or similar tool) so that the slides of the two
levers are perfectly parallel.
- It may be necessary to reset the zero to calibrate the
closure point after changing the Cv.
2.3 ACTUATOR
A single actuator allows VariPak valves to act in direct Air-
to-Close (ATC), or reverse Air-to-Open (ATO).
Valve action can be changed with no additional part by
simply shifting:
- the pivot pin and the attachment hole of the positioner
balance spring clamp for the singlelever VariPak 28001
valve,
- the two pivot pins for the adjustable-CvVariPak 28002
valve, then calibrating as required.
Follow the instructions given under "Reversing the valve
action" in paragraph 2.5.
2.4 HANDWHEEL(Figure 5)
The handwheel is an optional feature located on top of the
cover and fitted with a locking lever. Access can be gained
to it directly without removing any other parts. It consists
of a threaded rod, equipped with a handwheel (120) and
a lever arm stop (122). The threaded rod rests freely on
the actuator bracket (108) and is guided through the cover
(110) by handwheel bushing (119). The stop consists of a
block screwed onto the threaded rod. The block is guided
by the actuator bracket (108).
Figure 5

Masoneilan VariPak Control Valve Instruction Manual | 9© 2018 Baker Hughes, a GE company. All Rights Reserved.
When the handwheel (120) is turned clockwise, the stop
(122) moves up the threaded rod, compressing the spring
(134) and raising lever No. 2 (22) (VariPak 28002) or (113)
(VariPak 28001). This closes the valve if the valve is equipped
with a direct-action actuator (Air-to-Close) and opens the
valve if it is equipped with a reverse-action actuator (Air-to-
Open).
The valve can be returned to automatic mode (neutral
position), by turning the handwheel counterclockwise until
the stop (122) comes into contact with the bracket (108).
Note: During this operation, the compression is released
when the stop (122) moves away from the lever (22) (VariPak
28002) or (113) (VariPak 28001). Continue the operation until
a slight tension reappears, then tighten the handwheel lock
(121).
VariPak actuators are equipped with a limit stop. This
consists of parts (180) and (181), and is designed to prevent
damage to the plug and seat ring assembly and/or the plug
stem in the event of handwheel or actuator overstroke.
Note: The limit stop is not used with air-to-open valves fitted
with a handwheel, and must be screwed down at the bottom
of the piston.
2.5 REVERSING THE VALVE ACTION
(Figures 5, 6, 26, 27 and 29)
CAUTION
CAUTION
WARNING
DANGER
The valve must be isolated and pressure
vented before disassembly.
A. Loosen and remove cover (110). On valves equipped
with a handwheel, loosen cover screw (109), back off
handwheel lock (121), and turn handwheel (120) counter-
clockwise to release cover (110).
B. Adjust the signal so that the valve closes. Change the
signal slightly so that the plug just moves off the seat
ring. On the VariPak 28002 adjustable-Cvvalve, set the
adjustment knob (24) to the minimum Cvsetting.
C. Loosen locknut (103) and, using a screwdriver, turn the
plug stem one and three-quarter turns counter-clockwise.
Shut off the signal and the supply pressure. Slightly
tighten locknut (103) against the clevis.
D. Unlock nut (117) and completely loosen screw (116).
Unhook spring (114) from spring clamp (115).
2.5.1 VariPak 28001 single-lever valve
E. Remove retainer clips (112b) from pin (18), and remove the
pin from lever (113) and plug clevis (104a).
Note: This operation will be simplified by relieving the load
exerted on the plug clevis by the conical compression spring
(106). To do this push against the plug stem end with a
screwdriver while driving out the pins.
F. Remove the two retainer clips (112a) from the pin (105)
and disengage it to uncouple the lever (113) from the
bracket (108).
G. Refit the levers (113) making sure that the pin (105) is
fitted into the correct holes in the lever and bracket for
the new action of the actuator (see figure 6). Fit the spring
clamp (115) into the corresponding lever hole.
Note: Ensure that the clevis is correctly positioned before
fitting the lever on the bracket.
H. Couple the plug stem clevis (104a) to the lever (113)
following the normal reassembly procedure (step I. in the
"Reassembly" section). Then follow the same procedure as
for the VariPak 28002 adjustable-Cvvalve as from step L.
2.5.2 VariPak 28002 adjustable-Cvvalve (2 levers)
E. Remove retainer clips (112b) from each of the two pins
(184) and remove pins from lever (113) and plug clevis
(104a).
Note: This operation will be simplified by relieving the load
exerted on the plug clevis by the conical compression spring
(106). To do this push against the plug stem end with a
screwdriver while driving out the pins.
F. Remove the two retainer clips (112a) from pin No. 1 (105)
and disengage it to uncouple lever No. 1 from bracket
(108). Loosen adjustment knob (24) and slide it to the
maximum Cvsetting. Disengage the smooth end of the
adjustment pin (23) from the groove in lever No. 2 while
removing lever No. 1.
G. Drive out pin No. 3 (18) and remove lever No. 2 (22) from
the bracket.
H. Remove the two screws (26) and refit Cvadjustment plate
(25) after turning it round to comply with the new action.
I. Refit levers No. 1 and 2 in sequence, making sure that
pins (105) and (108) are fitted into the correct holes in the
levers and bracket for the new action of the actuator (see
figure 6).

10 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.
Note: Ensure that the clevis is correctly positioned before
tting the lever No. 1 on the bracket (108).
J. Reset adjustment knob (24) to the minimum Cvposition.
K. Couple plug stem clevis (104a) to lever No. 1 following the
normal reassembly procedure (step L. in the "Reassembly"
section).
L. Hook spring (114) in the appropriate hole in spring clamp
(115) (see gure 6).
M. Admit supply and signal pressures and complete
calibration. Ret cover (110) using the two screws (109).
If the valve is equipped with a handwheel, ret the cover
and turn the handwheel clockwise so that it engages in
lever arm stop (122). Tighten cover screws (109).
N. Put the valve back into service.
Note:
- When replacing an Air-to-Close actuator with an Air-to-
Open actuator, do not forget to neutralize the limit stop by
screwing it down at the bottom of the piston.
- When replacing an Air-to-Open actuator with an Air-to-
Close actuator, set the limit stop to the opening position.
AIR-TO-CLOSE ACTUATOR AIR-TO-OPEN ACTUATOR
VariPak 28001
with single
lever
VariPak 28002
with adjustable
Cv(2 levers)
*Only with type 7700 positioner
Figure 6 - Identication of lever pivot pin holes